Sinter Plant 2
SLR Metaliks installed Linear sinter machine, This sintering process is modern sinter making process adopted in steel plant, which employ straight-line machines. This system offers significant benefits over older, circular machines, particularly in terms of operational efficiency, cost-effectiveness, and environmental performance.
Benefits of linear sinter machine :
- Automated process control systems provide precise control over sintering parameters, increasing efficiency and product quality
- waste heat recovery minimize harmful emissions and reduce fuel use.
- Design allows for easier maintenance access.
The total Capacity of Sinter Plant 1 and Sinter Plant 2 is 9,26,000 TPA.
Parameter
Sinter Machine
Size of Sinters
Cooler Area
Gas Cleaning
Capacity
Description
Linear type
5 to 50 mm
60 m2
Head ESP (108.8 M2 )
5,70,000 TPA
Sinter Plant 1
SLRM is operating a 25 m2 sinter plant since 2013. Iron ore fines are processed through the sinter plant to form agglomerates before charging into MBF.
Parameter
Sinter Machine
Size of Sinters
Cooler Area
Gas Cleaning
Capacity
Description
Circular type
5 to 60 mm
30 m2
Gravity, ESP (52 m2 X 3)
3,56,000 TPA
Pulverised Coal Injection System 2
One unit of PCI of 12MT / hr Coal grinding system . Usage of coal reduces total coke requirement of hot metal production.
The total capacity of PCI-1 and PCI-2 is 22 MT/hr.
Parameter
Input Size
Output Size
Mill Capacity
CDI rate
Description
8 – 50 mm
(- 75) micron >80%
12 T/hr
150 -180 kg/Thm
Pulverised Coal Injection System 1
One unit of PCI of 10MT / hr Coal grinding system . Usage of coal reduces total coke requirement of hot metal production.
Parameter
Input Size of Coal
Output Size of Coal
Description
8 – 50 mm
< 75 micron
Captive Power Plant 2
The captive power plant under the consultancy of M/s. MECON Ltd Bengaluru, installed at SLR, utilizes blast furnace gas as basic fuel, which is clean fuel technology. In a smart step for environmental protection, the technology applied is tailor-made to recover the enthalpy of blast furnace gases specifically designed to facilitate power generation of 7 MW.
The total capacity of CPP1 (6 MW) and CPP2 (7 MW) is 13 MW.
Parameter
Fuel
Boiler
Turbine
Air cooled condense
Cooling towers
EOT Crane
Description
Blast Furnace Gas
M/s. Thermax Babcock& Wilcox Energy solutions Ltd. (Capacity 31 TPH )
M/s. Triveni Turbine Limited 7MW
M/s. ENEXIO Power Cooling solution India Pvt. Ltd.
M/S wet bulb cooling towers ltd
Sprint Engineering Pvt Ltd. (10 Ton capacity)
Captive Power Plant 1
The captive Power plant under the consultancy of M/s. CET – SAILCON, installed at SLR, utilizes blast furnace gas as basic fuel which is clean fuel technology. In a smart step for environmental protection, the technology applied is tailor-made to recover enthalpy of Blast furnace gases specifically designed to facilitate power generation of 6MW..
Parameter
Fuel
Boiler
Turbine
Air cooled condense
Cooling towers
DM Plant
Description
Blast Furnace Gas
M/s. Thermax Babcock& Wilcox
M/s. Triveni Engg. & Industries Ltd.
M/s. PAHARPUR COOLING TOWER LTD
M/S wet bulb cooling towers ltd
HITECH AQUA SYSTEM
Mini Blast Furnace 1 & 2
SLRM is Operating 2 Nos MBFs a 262 m3 (working volume) Mini Blast furnace since 2012. and 2nd unit commissioned on 2022, Sinter calibrated lump ore, Ion ore pellet ,limestone, dolomite, quartzite and coke are charged into the MBF from top and hot air is passed from the bottom. Ascending oxygen in the air reacts with the carbon in the coke to form CO which reduces the descending iron oxide to iron. Hot metal at required temperature is collected in the hearth at the bottom of the furnace and is tapped periodically and transferred to steel melting shop (EOF). The annual production capacity is about 2,76,000 tones.
The total Capacity of MBF 1 and MBF 2 is 5,52,000 TPA.
Parameter
No of Units
Working volume
Typical productivity
Sinter usage
Coal injection
Oxygen enrichment
Hot blast stoves
Capacity
Description
2 Plants
262 m3
3.0 MT/m3/day
70% typical
YES
YES
3 no
2,76,000 TPA
Energy Optimization Furnace
Due to use of 80 to 85% hot metal approximately 10% DRI and plant return scrap, primary steel from EOF is virgin steel with low tramp element low phosphorus and low oxygen potential. Oxygen blowing through submerged tuyeres, supersonic lance and atmospheric injection.
Parameter
Size of the furnace
Hot metal
Tap to tap time
No of bottom Shells
Capacity
Description
35 MT
80% to 85%
40 to 50 min
1+1
3,00,000 TPA
Ladle Refining Furnace
In Ladle refining furnace, refining of the primary steel with alloy additions is done. The objective of these process is to make clean steel as per the requirement of the customer.
Parameter
No of LRF
Wire feeding
Ladle capacity
Transformer rating
Electrode Dia
Process time
Argon flow
Description
Two
4Strand
35 T
8 MVA, @6.6 kV primary voltage
305 mm
40 -50min
4 – 10 NM3/hr
Vacuum De-gassing
Mechanical vacuum pump type vacuum degassing system facilitates reaching < 1 Mbar within 4-5 minutes. Lowest vacuum achieved is 0.5 Mbar.Due to twin skid mechanical pumps and specially designed pre vacuum chamber, required < 1Mbar vacuum is achieved well within 6minutes. For precision measurement of vacuum less than 1 Mbar on line Mc Leod Gauge is installed.
Parameter
Ladle Capacity
Cycle Time
Vacuum
Mc Leod gauge
Description
35 MT
20 – 30 min
< 0.5 Mbar
Available online
Auto Billet Grinder
Auto Billet Grinding facility ensures surface defect removal in As cast stage. This helps in eliminating surface defects in rolled products and improves surface quality making steel bar amenable for warm forging, cold forging & complicated forging process.
Continuous Casting Machine
Continuous casting is a process by which molten steel is solidified into a semi-finished billet or bloom, for subsequent rolling in RMS.
Parameter
Machine Radius
Metallurgical length
No of strands
Type of casting
EMS
AMLC Auto start
Casting Section
For rolling
Billet length
Description
9/16
26 mtrs
3
Closed
Mould
SMS Concast
160 dia & 200 dia, 160 Sq, 200 sq & 130 Sq
160X160 & 200X200.
6 - 12 mtrs
Re-Heating Furnace
Double Regnerative, Walking Beam furnaces are the most advanced type of furnaces for the reheating of heavy and thick products. The temperature is generally around 1250°C but can reach 1450°C in some cases. Use of Blast Furnace Gas(FG) as a fuel, Oxygen potential is controlled.This ensures control over decarb and surface quality in rolled products.
Parameter
Type
Capacity
Billet size
soaking zone Billet temperature
Fuel
Description
Walking Beam, Double regenerative
50 TPH
200X200
1150 – 1250°C
BF Gas
Rolling Mill
Rolling mill is state of art technology supplied by M/s Primetals Technologies and is on 5 meter elevated platform with sufficient space for operation and maintenance. Mill is configured with vertical and horizontal stands combination of 20 stands. There are 3 additional unique sizing stands to achieve precise dimensional tolerance of the rolled product, followed by dimensional gauge for accurate control of dimension, confirming to DIN/4. High pressure descaler is installed to remove the primary scale from the billets before it enters into roughing stands for better surface finish of the product. Before and after sizing mill cooling system is provided to control the rolling temperature of the bar to gain better mechanical properties. Natural cooling is adopted on cooling bed. Cold shear and abrasive cutting are installed to meet the requirement. Finally product is bundled with binding machine before transporting the bars for inspection and conditioning facility.
Parameter
Capacity
Descaler
Mill Configuration
Total No of stands
Cooling bed
Sizing Mill
Cut to Length
Garret Coiler
Product section/Size
Coil Weight
Description
3,20,000 MTPA
250 bar
V/H continuous mill
23 stands
54 Mtrs. long & 8 Mtrs. Wide ( Extension under progress)
3 Stands H/V
Cold Shear/Abrasive
16 to 38 Dia.
18 – 95 Rounds
- 17 – 56 A/F Hexagon
- 60 - 101 Flat width
- 10 - 32 flat Thickness
- 55 – 80 RCS
- RCS 122
- RCS 160
- Rectangle 100 X 160
Max 1.8 Tons
- 17 – 56 A/F Hexagon
- 60 - 101 Flat width
- 10 - 32 flat Thickness
- 55 – 80 RCS
- RCS 122
- RCS 160
- Rectangle 100 X 160
Automated Online NDT Inspection System
State of an art Inspection line with - Automatic Phased Array Immersion Type Ultrasonic Testing machine & MFLT.
- No manual intervention.
- Checking feasibility as per FBH or SDH with stringent specification.
- Scanning of 100% portion of the bar.
- Automatic marking and segregation of bar in case flaws are present.
- This ensures mistake-proofing check for internal soundness with good production output.
Magnetic Flux Leakage Test(MFLT) Capability
Channels : 6
Probe distance : / 12.5 mm.
Magnetizing Frequency : kHz
Rotation : Up to 1800 rpm
Inspection speed : Up to 3 m/s (depending on the test piece diameter).
Defect Sensitivity : 0.3mm depth x 10mm length (for Black Bar).
Sorting Class : So(Good) & S1(repairable)
Phased Array Auto UT-Capability
Type : Phased Array Ultrasonic (internal defect detection System).
Model : T2
Product Size Range : to 120mm.
Speed : Up to 120m/Min.
Typical insepction mode : Longitudinal waves, shear waves
DETECTION CAPABILITIES FOR TYPICAL REFERENCE DEFECTS:
Typical defects : FBH ≥ 0.7mm, SDH ≥ 0.5 x15mmHeat Treatment Shop
Heat Treatment section is equipped with State of Art, Ultra Modern, Generation Six Furnaces constituting 2000Mt/Month capacity. All Heat Treatment processes required by the customer in this segment, can be executed under one roof. SLRM can supply world class heat treated products thru Quenching & Tempering, Normalizing, Spheroidized Annealing, Plain Annealing, Stress Relieving categories.
Parameter
CapacityDescription
2000 Mt/MonthEquipment
Size Range
Capacity
Production Rate
Hardness Variation
Micro
Type
Description
20-100mm
1000 MT/Month
2Mt/Hr
1-3 HRC
Uniform Microstructure
Induction Heating Type.
Fully Automatic, G6 machine.
All Power Source - IGBT Base.
Fully Automatic, G6 machine.
All Power Source - IGBT Base.
Equipment
Size Range
Capacity
Batch size
Temp Uniformity
Hardness Variation
Micro
Type
Description
No Constraint
1000 Mt/Month
35 Mt x 2 nos
+/- 10 Deg C (with Load), +/- 6 Deg C (without Load)
15 BHN Max
Uniform Microstructure
Electrical Heating with Bell & Bogie Arrangement Fully Automatic PLC system, With Online TT trend recording.
Bright Bar Shop
At SLRM we have Bright Bar manufacturing facility of 1000Mt/Month. It includes both Peeled & Cold Drawn routed products. Automatic imported Peeling & Reeling line, Branded Center less Grinding machines with driving rollers & auto loading/unloading facilities makes the process of bright bar manufacturing more Precise & Accurate.
Parameter
Size Range
Tolerance
Supply Conditions
Description
17.5mm-75mm
h9-h12
Peeled & Reeled, Peeled & Ground, Cold Drawn & Reeled, Cold Drawn & Ground, (with / without Heat Treatment)
Equipment
Size Range
Type
Description
17.5mm-75mm
Automatic, 4-Tool Type.
Cold Drawing
Equipment
Size Range
Capacity
Tolerances
Description
20mm to 50mm (finish)
200 MT/month
h11
Equipment
Size Range
Type
Description
10-100mm
With Roller Drive in handling system & Auto Loading/Unloading.
Shotblasting Facility
Shot blasting is a surface treatment technique that makes use of particulate grains propelled under high velocity. This process is a highly effective solution for removing contamination on metal substrates or changing the coarseness or smoothness of a surface before coating.
It utilizes a centrifugal blast wheel that shoots steel shots onto the surface of the bars to knock the surface free of debris & scales. It cleans the surface of the bars.