CONTENTS

1. INTRODUCTION OF MLSM
1.1 Mill Layout
1.2 Supplier & Technology
1.3 Salient Features of Mill
1.4 Raw Materials
1.5 Sections of Mill
1.5.1 Raw material Yard
1.5.2 Reheating Furnace
1.5.3 Descaler
1.5.4 Roughing Mill
1.5.5 Finishing Mill
1.5.6 Technogamma
1.5.7 Profile
1.5.8 Cooling Bed
1.5.9 Straightening Machine
1.5.10Cold Saws
1.5.11Stacker
1.5.12Typing Machine
1.5.13Collecting Bay
1.6

Products

1.7

Application/End Use

1.8

Standards followed for rolling of structurals in MLSM

2. Definition of the problem

3. Literature Survey
4. Present Status/ Current Scenario of the problem by Pareto analysis
5. Root Cause analysis by Fish-bone diagram
6. Data compilation & Analysis
6.1

Raw material: Study with regard to the LRF & Casting Parameters.

6.2

Study pertaining to the Reheating furnace parameters.

6.3

Study of the Roll Pass Design.

6.4

Metallography: Inclusion Ratings & Micro examination.

7. Results & Observations

8. Conclusions & Recommendations
9. References

LIST OF TABLES

LIST OF FIGURES

ABSTRACT
Hot rolling operation is one in which plastic deformation essentially has to take
place above the recrystallisation temperature. In hot rolling the grain first deforms
in the rolling direction, the deformed grains further recrystallise into a new set of
smaller grains as the rolling proceeds. Prior to the start of hot rolling the steel
micro structure consists of coarse equiaxed grains of austenite [of the order of
ASTM 3 to 4]. During passing though the rolls, the austenite grains get flattened
and elongated on the average, each austenite grain undergoes a dimensional change
corresponding to that of the work piece as a whole.
The present project report is mainly aimed at the understanding of the possible
reasons / or root causes for the generation of the crack at the junction of the web &
either of the flange. Junction crack has been the severe defect arising in the rolling
of structural especially in channels at MLSM. Junction cracks accounts for the
organizational losses; to name few, loss to the market reputation, customer
dissatisfaction, delayed delivery of products, delay in projects at the customer end
and last but not the least; it will add to the extra cost by way of salvaging.
Henceforth, in this view, an action plan was made to systematize the project work
which can be seen in the contents of the report.

1. INTRODUCTION
MLSM Plant Layout

Supplier & Technology

MILL

Danieli

REHEATING FURNACE

Tenova

HI-PROFILE

Technogamma

MILL AUTOMATION

ABB (Asea Brown Baveri)

CRANES (EOT)

Jindal Steel & Power Limited

ENGG. CONSULTANTS

Korus Engg. Solutions

Salient Features of the Medium & Light Structural Mill

1.Continuous Structural Rolling Mill 8.Online Bundling & Strapping of
Products
2.High Production Capacity
9.Rolling of Beams & Channels on

Universal Stands
3.Superior Quality Products
4.Automatic Minimum tension Control
5.Optimum Roll Pass Design
6.Cartridge type Stands
7.Wide range of Products
Raw Materials
The finished products are of three different grades i.e.
1

C-18

C-18MMn and

HT

And the main raw materials used in MLSM are given in table below:
Table: 1 Types of Raw Material Used & All Finished Sections produced

RAW MATERIAL

SIZE

FINISHED PRODUCT
ANGLE 100 TO 130mm

BILLET

150x150mm
CHANNEL 125, 150 mm
ANGLE 150 TO 200mm

BLOOM

250x250mm

CHANNEL 175mm, 200mm

BEAM (NPB)180mm,200mm

Sections of the Mill

1.5.1 Raw Material Yard:
The raw material yard is the area where generally all the input materials are
kept / or stored for converting them into suitable products according to the end
applications/ uses so that it can then be used in future as per the requirement of

the customers. The basic raw materials used in MLSM are described above in
table1
Reheating Furnace:
This is the heart of any hot rolling mill where in the charge is heated to rolling
temperature. Hence, the first and the vital step of hot rolling includes heating
the raw material to sufficiently high temperature in order to minimize the flow
stresses during subsequent rolling and ease the process of plastic deformation
through rolling operation. The charge might be either in the form of billets or
blooms. The type of furnace could be pusher type (where the raw materials are
forced or pushed by subsequent material), walking hearth or walking beam
either top fired or top and bottom fired. The fuel used could be either oil or gas.
The burners are located in a manner so as to achieve uniform heat distribution.
The radiation heat energy is efficiently transferred through the useful heat
transfer area created by the charge bed. The reheating furnace at MLSM-JSPL
is a walking beam type furnace with a capacity of 200 ton/hour being installed
by Tenova (Italy). The pushing mechanism of Pusher Type Furnace owes to the
disadvantage of maintaining the sufficient gap between two adjacent charge
materials. As the name suggest, in this type of furnace the raw material are
loaded on heavy beams that move in manner resembling a step.
This movement is often referred to as a stroke. During the material movement
inside the furnace the material first moves 100mm upwards, then 500mm
forward followed by 200mm downward movement and then finally 500mm
backward. This stroke tends to move the material into the furnace.
1.5.1.1

Construction of Reheating furnace:

The total length (refractory to refractory) of RHF is 28mt 800mm with a width
of 12mt
800mm. The furnace is constructed with steel having a refractory
lining of high alumina. Further some clearance is provided at each side of
furnace so as to compensate for the expansion of raw material.
For charging higher thickness raw material as in case of blooms and slabs,
burners are provided below and above the skids as against conventional
furnaces where burners are provided only on the top. Hence it is known as top
and bottom fired Reheating Furnace. There are total 58 burners utilized in the

furnace for the purpose of heating the raw input material. The steps of heating
the raw material are:
Yard: All the input materials of all types & all grades from SMS are stored here
for further processing in the Mill
Storage Table: The Raw material from the yard are then stored at storage table
prior to charging.
Roller Table: The Raw material moves from storage table to loading table
through roller assembly.
Loading Table: The raw material then passes through a small door by Pusher
type mechanism as shown in the figure below which is then loaded on loading
table one by one inside the furnace. It allows uniform heating of raw material
with an added advantage of uniform load distribution on skids. The materials
are generally charged in one/single row pattern. This type of charging or rather
the type of door functioning has an advantage of the less drop in temperature as
while charging the opening of the door is less.
Main Furnace: From the loading table the raw material is transferred to main
furnace where they are heated up to the desired rolling temperature.
Discharging Roller Table: After the raw materials are heated up to the desired
temperature, they are then ejected out of the furnace by the same kick-off
mechanism. The Exit Raw material then moves to the De-scaler.
1.5.1.2

Zones of furnace

The furnace is basically divided into three zones namely preheating, heating
and soaking zones. Manually, there are in total 4 zones where in the 4 th zone is
Recuperative Zone. Our furnaces are highly fuel efficient due to proper roof
profile / zonal distribution, optimum preheating / recuperative zone lengths,
proper burner / flue port locations and good instrumentation including furnace
chamber pressure control eliminating atmosphere air ingress, which also
reduces the scale loss and decarburization of the charge.
Preheating zone

 Heating zone
Soaking zone
Recuperative zone
In preheating zone the raw material are heated to certain predetermined
temperature,
however the actual heating takes place in the heating zone.
However to ensure the uniformity of temperature up to the desired limits
between the surface and core of raw material the material is kept hold in the
soaking zone for a specified limit of time.
The waste/flue gases generated and have attained a sufficient temperature of
nearly 900C move in a direction opposite to that of the charge thereby ensuring
considerable amount of waste heat recovery by convection in the preheating
zone, which is also termed as the recuperative zone. It is also called as Nonburner zone. It is rather getting heated up by the flue gases returning back by
other three zones through ID Fan. The recuperator generally utilizes its sensible
heat for the purpose of heating the incoming cold gas utilized in the furnace.

1250
C

10501150C

9501050C

Schematic Representation of the MLSM-Reheating furnace

Recuperative
/ Non-burner
zone

1.5.2.3 Zone wise distribution of burner

Zone
Preheating zone
Heating zone
Soaking zone

Top side
5
8
24

Bottom side
5
8
8

Total
10
16
32

The total number of skids on which the raw material is charged is 25 out of
which up to Preheating zone 4 are moveable and 4 are fixed where as in
soaking zone 4 are moveable and 5 are fixed. This is because the materials
temperature is high and it needs certain support for not getting bend or to
avoid between fsna skids k beech me disturbance in the movement of the
materialskids These skids are water circulated in order of avoid overheating.
1.5.1.3

Type of charging

The raw material can be charged in furnace either in hot condition or in a cold
condition Depending on this the furnace charging system can be categorized as
Cold charging
Hot charging
But in the reheating furnace of MLSM generally Cold charging is done.

1.5.2.5 Raw Materials and Zone wise temperature

Ideal Temperatures
Soaking zone
Heating zone
Preheating zone
Retention Time

Parameter
s

Inle

Cold Charging
Bloom (150x150)

Upper Soaking
Lower Soaking
Upper Heating
Lower Heating

Water
Outle
Flow

Bloom (250x250)

113020
113020
110020
110020
103020

122020
122020
118020
118020
108015

1 hour 30 minutes

2 hour 30 minutes

Compresse
d air

Instrument air
Pressur Flow

Fuel
oil

Combustio
n Air

LPG

t
Values

5 bar

t
2 bar

e
500m/h
r

7 bar

5 bar

300
Nm/h
r

7 bar

950
dapa(mmwc)

2000
dapa

1.5.2.6 Firing System of RHF

In order to attain the desired temperature inside the furnace dual firing system is
used in which a mixture of mixed gas (mixture of producer gas and LPG), heavy
furnace oil & Light Diesel Oil are used. With this the atomizing air (for converting
the oil having high density into the small droplets) & combustion air is also used.
At first the PG is made on and then oil is used for lightning the burner. This is
because the Producer gas is cheap.
Specific consumption is given below
Consumption
day)
Producer gas (From PGP)

244000NM

Heavy Furnace Oil ( exported from outside)

5.55kL

Light Diesel Oil (LDO)

133 ltrs

(per

1.5.2.7 Composition of fuel used in RHF

Heavy Furnace Oil

Carbon

Sulphur

Nitrogen

Hydrogen

Calorific
value

84%

4%

1%

11%

9.8 MCal/Kg

Producer Gas
CO

H2

CO2

N2

O2

CH4

Calorific Value

18%

19%

10%

48%

2%

3%

1.100

MCal/Nm3

1.5.2.8 Heat Transfer inside Furnace

At first, the heat generated by fuel is transferred to surrounding atmosphere

through radiation then through the surrounding media the heat is transferred to the
raw material through convection. Lastly, on atomic scale the heat is transferred
through conduction.
Other Details

In case of charging Blooms of 150x150 mm size, maximum of 107 blooms are

charged at a time inside the furnace (minimum of 100mm gap is maintained
between adjacent blooms ) while maximum of 54 blooms are charged at a time
inside the furnace ( here minimum of 250mm gap). The total numbers of material
that can be charge inside the furnace is calculated as the ratio of furnace effective
length to that of stroke length. Again the minimum gap to be maintained between
two adjacent raw materials is give as the difference between the stroke length and
the width of the raw material.
Total 26 thermocouples are installed inside the furnace including both S- type
(15001700deg C) i.e. generally for high temperature measurement & K type (up
to 700-1000deg C) i.e. rather for low temperature measurement. However the K
type thermocouple is mainly used in compressor & recuperator. In Zone 1, four
thermocouples are used to detect the temperature of the particular area/atmosphere
with in the furnace. In case of this always the thermocouple having/showing
maximum value is noted. From Zone 2 and upto Zone 7 there are 2 thermocouples
in each zone. Another 10 thermocouples are used in the Duct line. There are two
types of thermocouples i.e. S and K types. Generally, S-type is used within the
furnace where in the positive wire is of Platinum (Pt) and negative wire is of
Platinum-Rhodium (Pt-Rh). In the similar way the positive wire in K-type is of
Chromel and the negative wire is of Alumel In case of mill shut down, only PG gas
is used for maintaining furnace temperature at 600-800 deg C (depending on the
mill condition) and heavy fuel supply is stopped.

Process Data
Manufacture &
Tenova
identification
(L0IITALIMPIANTS)
Tenova
Supplied By
(L0IITALIMPIANTS)
Commissioning Data
31st March 2010
Walking beam
furnace Top &
Type
Bottom Fired

Furnace is divided in 7 zones

Preheating Zone(1)

10 Lateral Burner

Top Heating Zone(2)

Bottom Heating Zone(3)

8 Lateral Burner
8 Lateral Burner

Top Soaking Right

Zone(4)

12 Roof Radiant
Burner
12 Roof Radiant
Burner

Capacity
200 Tons/Hour
Top Soaking Left Zone(5)
Max. Operating
Bottom Soaking Right
Temperature
1350C
Zone(6)
4 Frontal Burner
Movement of Walking
By Hydraulics
Bottom Soaking Left
beam
Cylinder
Zone(7)
4 Frontal Burner
Cylinder (Lifting,Shifting,Forward & Reverse)
Lifting Stroke
200 MM
Furnace Dimension
Shifting Stroke
250 MM
Effective Length
27.8 M
Skid
Width
12.8 M
Vertical Post
4+4=8
Height
12 M
No. Of Moveable
Horizontal Post
Post=5
Total Burner
58
Furnace having Basic 2 Types of System
No. of tanks
HFO=500kL
Handling System
LDO=20kL
Combustion System

Fluid
Fuel Oil (HFO)
Fuel flow rate
7000 kg/hr
Pressure at top
7 bar
Temperature
Lower Calorific
Value
9800 kcal/kg
Light Diesel Oil (LDO)
LDO Flow rate
2200kg/hr
Pressure at top
Temperature
Ambient
Lower Calorific
Value
10100kcal/kg
LPG for Pilot Burner
Flow Rate
8.10NM/HR
Pressure at top
2000 bar

Types of cooler water used

Indirect Cooling
Water
Skid & Door
Direct Cooling Water
Camera, Jacket
for instrumentation CCTV, Heat
Cooling Water
exchanger
90C at burner
Flow Rate
Inlet Pressure
Max Inlet Temperature
7 bar
Emergency Cooling Water
Flow Rate
Pressure
Max Inlet Temperature
pH value

500 mm/hr
5 bar
35C

350 mm/hr
3 bar
40C
7 to 8

Temperature
Producer Gas (PG)
Flow Rate
5000NM/HR
Pressure at top
1200MMWC
Temperature at
Top
50C MAX
Lower Calorific
Value
1100KCL/NM
Temperature
20C
Nitrogen For Purging
Flow Rate
5000 NM/HR
Pressure
2000 MN
Temperature
Ambient
Compressed Air for Atomizing
Flow Rate
4000 NM/HR
Pressure
7 bar (MIN)
Temperature
Ambient
Type of Charging
Single Row
(Right & Left
Side)
Billet
Bloom
Beam Blank

20C
Refractory Lining & Insulation
Refractory Castable
Plastic Refractory
Anchor Bricks
Standard Bricks
End Arch & others
Combustion Control System
2 No. of Combustion Air Fan
Type
Flow Rate
Operating Pressure
1 No. of Dilution Fan
Flow Rate
Operating Pressure

Centrifugal
56500 NM/HR
800 dapa (MMWC)
23000 NM/HR
500 dapa (MMWC)

1 No. of ID Fan

Bloom Size (INPUT SIZE)

130x130 mm
8.5m - 12m
150x150 mm / 250x250
mm
8.5m - 12m
355x280x90 mm (463
kg/m)
8.5m - 12m

Descaler
After the material is discharged from the furnace, it is then passed to descaling unit
where a high pressure water jet is targeted on the surface of raw material. . Due to
high temperature prevailing inside the furnace and further with the addition of
oxidizing atmosphere in the reheating furnace, mill scale is formed on the surface
of the charge material. Mill scale, often shortened to just scale, is the flaky surface
of hot rolled steel, iron oxides consisting of Iron (II, III) oxide, hematite, and
magnetite. This mill scale should be removed as it causes surface defects in the
finished rolled product.

This descaling unit can produce a maximum pressure of 250 bars. From de scaling
unit the raw material proceeds to Roughing Stands. It helps in improving the
surface quality of finished products.
Roughing Mill
Here we have five continuous rolling stands that are arranged in horizontal and
vertical mode (1H, 2V, 3H, 4H, 5V). In the roughing mill stands the blooms are
reshaped to a preliminary section to be rolled. Maximum change in cross-section
area takes place in these roughing stands. The roll stand is designed for a rolling
force of ___tons.
The roll stand consists of 2 closed top housings which are connected by top and
bottom crossheads and fixed on bed plates. Pressure screws are arranged to
maintain the desired roll gap.
A pass schedule is prepared and maintained by the mill operator. It consists of
various parameters like Pass layout, roll gap, entry speed, rolling speed, kick-off
speed and draft for different cross-sections. However there are manipulators like
guides & stripper that guide the raw material into the roll gap. The maximum limit
of thickness reduction is 60%.
Table by Danieli
Finishing Mill
In finishing mill there are ten continuous stands which are arranged in universal or
horizontal manner (6H, 7H/U, 8H/U, 9H/U, 10H/U, 11H, 12H/U, 13H/U, 14H,
15H/U) according to the product to be rolled. Here the reduction ratio is
comparatively less than the roughing mill as because there is a regular temperature
drop in the material along previous passes and an extra/excessive load is needed to
be applied which may increase the stresses within the material and may lead to
some problems. Like, as if we see in channels or in beams the junction of web &
either of the flange thickness vary from toe to root and it is also clear that the
junction portion is thicker than the other area of the structural part i.e. there might
be some temperature gradient in that region and it may be stressed also. In this type
of case if further stresses will increase then it will increase the tendency of the
defects. Here the contact of the material with the rolls is more.

Also, the reduction amount in particular stand depends on various factor and they
are
What we are rolling
What type of grade is going to be rolled?
What is the composition of the raw material?
What is the effect of temperature on the above described raw material?
On the basis of all this the pressure/load to be given is decided
Due to these things how will it affect the elongation & spread in any
material.
Also, rolling speed is decided accordingly.
Last but not the least the type of motor, gear and what are their capacities is
identified.
Technogamma
It provides online dimensions of the hot rolled sections. It is a kind of laser
measuring device, used for dimensional inspection of hot section without any
physical contact.
Profile
Here the sample is taken from the cooling bed and inspected whether the structural
section produced is in accordance with IS standards or not. Also, all the dimensions
are checked and written.
Cooling Bed
It is a walking beam type of bed.
Length = 90m
Width = 18m
Cooling of the bars is done by natural air and water spray.

Straightening Machine
Its basic purpose is to straighten the cooled sections. There are 10 rolls in it where
in 5 rolls are on the upper side and 5 rolls are on the down side.
Cold Saws
Its main purpose is to cut the rolled sections according to the required length.
There are 2 no. of cold saws. There are 2 saws as because for highest production
both can be used alternately.
Stacker & Tying Machine
It is used for the circumferential wire binding of the stacks.
Collecting Bay
It is used for collecting the bundles. Bundles are color coded here. From here
bundles are transferred to yard.

Products
View of the products at MLSM

The list of products of the MLSM which are covered in BIS is given as follows:
S.No

Section

Covered in BIS (License)

Product Status

Equal Leg Angle

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

ISA 100X100X6
ISA 100X100X7
ISA 100X100X8
ISA 100X100X10
ISA 100X100X12
ISA 100X100X15
ISA 110X110X8
ISA 110X110X10
ISA 110X110X12
ISA 110X110X16
ISA 120X120X8
ISA 120X120X10
ISA 120X120X12
ISA 120X120X15
ISA 130X130X8
ISA 130X130X9
ISA 130X130X10

Available
Available
Available
Available
Available
Available
Available
Available
Available
Available
Available
Available
Available
Available
Available
Available
Available

Rolled
Rolled
Rolled
Rolled
Rolled
Not RolledYet
Rolled
Rolled
Rolled
Rolled
Rolled
Rolled
Not RolledYet
Not RolledYet
Rolled
Not RolledYet
Rolled

18
ISA 130X130X12
19
ISA 130X130X16
20
ISA 150X150X10
21
ISA 150X150X12
22
ISA 150X150X15
23
ISA 150X150X16
24
ISA 150X150X18
25
ISA 150X150X20
26
ISA 180X180X15
27
ISA 180X180X18
28
ISA 180X180X20
29
ISA 200X200X12
30
ISA 200X200X16
31
ISA 200X200X20
32
ISA 200X200X18
33
ISA 200X200X24
34
ISA 200X200X25
Parallel Flange Beam
NPB200X100X18.4
1
2
NPB200X100X22.3
2
6
NPB200X100X25.0
3
9
4
NPB 180X90X21.27
5
NPB 180X90X18.80
6
NPB 180X90X15.37
Channel
1
200X75X22.3
2
175X75X19.6
3
150X75X16.8
4
125X65X13.1
5
125X66
6
100X50
7
75X40

Available
Available
Available
Available
Available
Available
Available
Available
Available
Available
Available
Available
Available
Available
Not covered in BIS
Available
Available

Rolled
Rolled
Rolled
Rolled
Rolled
Rolled
Rolled
Rolled
Not RolledYet
Not RolledYet
Not RolledYet
Rolled
Rolled
Rolled
Rolled
Rolled
Rolled

Available

Rolled

Available

Rolled

Available
Available
Available
Available

Rolled
Rolled
Rolled
Rolled

Available
Available
Available
Available
Available
Available
Available

Rolled
Rolled
Rolled
Rolled
Not RolledYet
Not RolledYet
Not RolledYet

Product Application / End Uses

1. Power Sector
2.Infrastructure constructions
3.Cement & Steel Plant Construction
4. Transmission line tower / telecom line towers

5. Fabrication
6. Bus / truck bodies
7. Electrical towers (SEB / Railways)
8. Industrial sheds
9. Commercial & Industrial Houses
Standards followed for rolling of structurals in MLSM
Certification
1. ISO 9001, ISO 14001 & OHSAS 18001:2007.
2. BIS certification for all sections.
3. PGCIL for all Angle sections.