SECTION : M2006B42 REG NO. :11007860 COLLEGE : LOVELY PROFESSIONAL UNIVERSITY
In GAGAN FERROTECH LIMITED, DURGAPUR(WB)
TYPES OF RAW MATERIALS 1. BILLETS 2. INGOTS
INGOTS : TRAPEZOIDAL SHAPE STRUCTURE MANUFACTURED BY CASTING FROM IRON ORE COLOR CODE IS ALLOTTED TO MINIMIZE THE ERROR THREE TYPES OF CROSS-SECTIONAL DIMENSION 34 X 44 inches 32 X 42 inches 4 X 5 inches 50-60 INCHES INGOT LENGTH IS USED IN TMT PRODUCTION
BILLETS : ALMOST SIMILAR TO INGOTS BUT HAVE BETTER SURFACE FINISH LESS CHANCE OF BLOW HOLES BEING PRESENT THE FINAL PRODUCT HAS BETTER FINISH WHEN COMPARED TO INGOTS NO STANDARD COLOR CODING REQUIRED
COLOR CODING OF INGOTS : COLOR CODING IS DONE IN BASIS OF PRESENCE OF PERCENTAGE OF CARBON IN INGOTS Below .18 white paint .18 to .20 blue paint .21 to .23 green paint .24 to .26 yellow paint .27 to .30 orange paint Above .30 red paint PARAMETERS Fe 415 Fe500 Fe550 Fe415D Fe500D CARBON(MAX)
.30 .30 .30 .25 .25 SULPHUR(MAX) 0.060 0.055 0.055 0.045 0.040 PHOSPHORUS(MAX) 0.060 0.055 0.055 0.045 0.040 SULPHUR AND PHOSPHORUS(MAX) 0.110 0.105 0.100 0.085 0.075 CE(MAX) 0.42 0.42 0.42 0.42 0.42 Manganese (Mn) improves hardenability, ductility and wear resistance Nickel (Ni) increases strength, impact strength and toughness, impart corrosion resistance in combination with other elements. Copper (Cu) improves corrosion resistance Chromium (Cr) improves hardenability, strength and wear resistance, sharply increases corrosion resistance at high concentrations Silicon (Si) improves strength, elasticity, acid resistance etc....... Tests involved on ingots and billets are Carbon percentage Sulphur percentage Phosphorus percentage Coal gas is used to produce heat energy in the Furnaces Peak temperature goes up to 1200C Billets are being heated for 4 hours There are total 8 burners in the furnace Burners are so adjusted that uniform temperature is attained Three processes involved in Furnace i.e. Feeding, Heating and ejection.
FEEDING : Feeding mechanism consists of worm gear arrangements HEATING : Preheating zone, intermediate heating zone and final heating zone FURNACE EXIT : Red hot billets are exited by Authorized personnel in proper time and lead to Rolling mills
There are three mills present in the line
ROUGHING MILLS
INTERMEDIATE MILLS
FINISHING MILLS ROUGHING MILL: First mill amongst three mills Gear ratio used is1:6 to provide sufficient torque to rolls Three sets of roller present vertically In Roughing mill very small elongation and gradually decreasing diameter is attained
After Roughing mill billets moves to next Rolling mill that is Intermediate Rolling Mill But before entering the Intermediate Rolling mill billets needs to accelerate its velocity. Pinch rolls are used to accelerate billets with the help of a motor of 50HP. After Pinch rolls there is a set of CUTTER or SHEARER with a cone shaped guide ways to cut the ends of the rods for the better entering to the Intermediate rolls. INTERMEDIATE ROLLS: The purpose of the Intermediate mill is to attain considerable elongation and to prepare the rod to enter in the Finishing mill Before entering to the Finishing Mill two Pinch rolls and a shearer are used. FINISHING MILL: Precision Rolls are used to get nearly accurate dimensions Also facilitates the brand imprint
This quenching process is called Thermex Technology. TMT bars are made to pass through specially designed pipes carrying nozzles and pressure gauges Water is sprayed through the nozzle to change the temperature of the rods abruptly Velocity of the water and pressure of the water results the hardening of the rods After the TMT treatment the rods are made to fall on the Cooling bed. Before falling on the Cooling bed, the speeds of the bars are reduced by using a speed breaker After complete cooling on the cooling bed, the TMT rods are sent for the Inspection and Dispatch