BILLETS MANUFACTURING UNIT BY SCRAP MELTING

The Project profile envisages to set up Con-cast plant for manufacturing of M.S Billet which is the main raw material of Iron & Steel finished products, e.g. T.M.T Bars, angles, channels and sections etc. used in construction activities. Con-cast plant can be simply defined as a mill that carries con-cast process in which the molten steel is poured into laddle mould to perform the gradual solidification of metal into desired forms and shapes. Swiftly, the molten metal is solidified and is drawn down the caster. This gradually gets transformed into a solid steel billet, bloom or slab.

The Induction furnace based on mini steel plant is a versatile installations where provisions are available for producing a range of steel products by Alloying and casting into various shape. The products of steel plants are in the form of Ingots, Billets, Sheets etc. These Induction furnace based steel casting units are suitable  for small scale industries and medium scale industries and yet have the capability to complete in the internal as well as international market at all counts. In mini steel plant operating under Indian conditions small Billets are Cast for rolling into structural sections, Mild steel billets are manufacturing by different types of furnaces such as Blast Furnace, Electric Arc furnace, Induction Furnace, Basic oxygen furnace etc.

INTRODUCTION
THE AVAILABLE SIZES OF THE STEEL BILLETS ARE
IMPORTANT ASPECTS OF CONTINUOUS CASTING OF BILLETS
FACTORS AFFECTING CASTING SPEED AND MACHINE PRODUCTIVITY
MECHANICAL PROPERTIES OF STEEL AT ELEVATED TEMPERATURES
SOLIDIFICATION OF THE STRAND
CAST STRUCTURE
SHELL GROWTH
MACRO-SEGREGATION
USES AND APPLICATION
B.I.S. SPECIFICATION
PROCESS FLOW CHART
MANUFACTURING PROCESS
1. PREPARATIOON OF SCRAP
PROCESSES FOR SORTING AND PREPARATION OF STEEL SCRAP
MECHANICAL PROCESSES
MAGNETIC SEPARATION PROCESS
EDDY CURRENT SEPARATION PROCESS
HEAVY MEDIA SEPARATION PROCESS
SEPARATION BY PHYSICAL AND CHEMICAL CHARACTERISTICS
DECOATING PROCESSES
DEZINCING PROCESS FOR STEEL SCRAP
DETINNING PROCESS FOR STEEL SCRAP
DECOPPERIZATION PROCESS FOR STEEL SCRAP
INCINERATION
RECENT STEEL SCRAP SORTING TECHNOLOGIES
PORTABLE OPTICAL EMISSION SPECTROMETERS
COLOUR SORTING PROCESS
PROCESS UTILIZING LASER INDUCED BREAKDOWN SPECTROSCOPY
2. MELTING
OPERATION OF INDUCTION FURNACE
THERE ARE MAINLY TWO TYPES OF THE INDUCTION FURNACES.
THEY ARE GIVEN BELOW.
BATH AGITATION MECHANISM
REFRACTORY LINING
PRODUCTION OF MILD STEEL BY INDUCTION FURNACE
COMPARISON WITH ELECTRIC ARC FURNACE STEEL MAKING PROCESS
THE INDUCTION FURNACE HAS THE FOLLOWING TECHNICAL
ADVANTAGES OVER ELECTRIC ARC FURNACE.
THE DISADVANTAGES ARE
KEY ADVANTAGES OF INDUCTION HEATING
IMPORTANT ASPECTS OF OPERATION
OTHER ASPECTS OF INDUCTION FURNACE STEEL MAKING
ENVIRONMENTAL EMISSIONS
SAFETY AND INDUCTION FURNACES
(3) CONTINUOUS CASTING OF STEEL BILLETS
STEEL LADLE
TUNDISH
MOULD
SECONDARY COOLING
TUNDISH AND ITS ROLE IN CONTINUOUS CASTING
TUNDISH-A METALLURGICAL VESSEL
TUNDISH REFRACTORY LINING
(4) BILLET INSPECTION AND CONDITIONING FACILITIES
INSPECTION TECHNIQUES
EDDY CURRENT TECHNIQUES
FLUX LEAKAGE TECHNIQUES
MICROWAVE TECHNIQUES
OPTICAL TECHNIQUES
THERMAL TECHNIQUES
ULTRASONIC TECHNIQUES
SELECTION OF INSPECTION TECHNIQUES
BILLET CONDITIONING FACILITIES
MARKET POSITION
RECENT DEVELOPMENTS
THE ECONOMIC OUTLOOK HAS WEAKENED
STEEL MARKET SENTIMENT
FIGURE 2. STEEL PURCHASING MANAGERS’ INDICES (PMIS)
FIGURE 3. TSI SURVEY OF STEEL DEMAND EXPECTATIONS (NEXT
THREE MONTHS)
STEEL CONSUMPTION
STEEL PRODUCTION
WORLD STEEL TRADE
STEEL PRICES
STEELMAKING COSTS
THE STEEL MARKET OUTLOOK: DEMAND WEAKNESS AND OVERSUPPLY
GLOBAL MARKET POSITION
PRODUCTION DATA OF STEEL BILLET IN SRI LANKA
DETAILED EXPORT DATA OF MILD STEEL BILLETS TO SRI LANKA
PLANT LAYOUT    146
MANUFACTURERS/SUPPLIERS OF STEEL BILLET
SUPPLIERS OF RAW MATERIALS
STEEL SCRAP
COKE
LIME
PICKLING CHEMICALS
SUPPLIERS OF PLANT AND MACHINERIES
CONCASTING MACHINE
INDUCTION FURNACE
METAL TESTING MACHINE
PRECISION MEASURING TOOLS
NDT INSPECTION EQUIPMENT
ELECTRICAL MEASURING INSTRUMENTS
EOT CRANES
AIR POLLUTION CONTROL EQUIPMENTS
AIR CONDITIONING EQUIPMENTS
AIR COMPRESSORS
WEIGHING MACHINE (PLATFORM TYPE)
MATERIAL HANDLING EQUIPMENTS
FIRE FIGHTING EQUIPMENTS

APPENDIX – A:

1.      COST OF PLANT ECONOMICS
2.      LAND & BUILDING
3.      PLANT AND MACHINERY
4.      FIXED CAPITAL INVESTMENT
5.      RAW MATERIAL
6.      SALARY AND WAGES
7.      UTILITIES AND OVERHEADS
8.      TOTAL WORKING CAPITAL
9.      COST OF PRODUCTION
10.      PROFITABILITY ANALYSIS
11.      BREAK EVEN POINT
12.      RESOURCES OF FINANCE
13.      INTEREST CHART
14.      DEPRECIATION CHART
15.      CASH FLOW STATEMENT
16.      PROJECTED BALANCE SHEET