4. LD-2 & Slab Caster
• concerned with producing different grades of
Flat Products
• Exs: automobile body application (including
exposed) ,sheets for white goods ,LPG
cylinders ,Tube Making, High tensile plates
etc.
5. • Has 3 units
PSM
• Primary Steel Making
SSM
• Secondary Steel Making
Slab Caster
• Casts slabs with the material received
from SSM
6. Primary Steel Making
molten steel primary refined steel
Process Description
Hot metal from Blast furnaces brought in using
torpedoes.
unloaded in hot metal ladles (170 T) at the torpedo
unloading pit
7. Desulphurisation
Unit – 3 Nos.
Capacity – 30 heats/DS/day
Co-injection process –
CaC2 & Mag97 injection
Raking
Unit – 3 Nos.
Slag raked off initially
and after the DS Operation
8. LD Vessel
Unit – 3 Nos. (2/3 Vessel in Operation)
Capacity – 38 Heats/day/Converter
Total Charge (Hot Metal +
Scrap)
Vessel Blowing
The impurities (C, Si, P,
Mn) are removed by
blowing Oxygen through
a Six hole lance at
Supersonic speed.
9. Online Purging
Steel is tapped in a steel ladle capacity 160T, necessary
additions are made with argon rinsing from top lance.
11. Slab Caster
Unit – 3 Nos. Capacity –80 heats;
with 94 to 98% metal in mould
casting of molten iron into slabs
of definite dimensions as required
by different customers.
Casting
Continuous
Batch
12. Process of casting :
Turrets - To accept full ladle & to hold the ladle above tundish during
casting
Driven by means of D.C. Motor
The ladle is equipped with a hydraulically controlled slide gate system.
Refractory tube shrouds - high Alumina graphite.
Mould - open-ended box structure, containing a water-cooled inner
lining casted and machined from a high purity copper alloy
Tapered to compensate for the shrinkage of the shell
Oscillator provides necessary movement of the mould to prevent
sticking of the strand shell to copper plates .
14. OVERVIEW OF SLAB CASTER
Mould – 900 mm (Copper coated mould, open ended, Indirect Cooling),
oscillated by motor driven cams to reduce mould strand adhesion and the risk of
breakouts.
RAM – Width change online 10 mm/min/side. The adjustment could be made
either by electromechanically or hydraulically. The mould taper adjusted by gear
mechanism.
Sec. Cooling – Spray type (Air Mist)
Section size – 950-1550 mm Wide;
210 mm Thick
Slab Length – 8-11 m
Slab Cutting – TCM (uses propane gas)
PINCH ROLL – Inserting dummy
bar and withdrawal during casting.
DUMMY BAR – Provides base in the
Mould Before casting & withdraw slab.
15. SYMS
Slab Yard
Management System
automatic tracking of
the slab
inspection of slab is
done and surface
defects if any,
removed by scarfing
17. Hot Strip Mill
a part of FP division
converts slabs supplied by LD2 & Slab Caster into Hot
Rolled Coils, Sheets and Plates
Reduces the thickness of coils from 210 mm to about 1.2-16
mm
18. Process Flow
Walking Beam Furnace
Re-heating the slabs
Mixed gas – coke oven+ BF gas+ LD gas
Calorific value 2700
19. Slab support and
movement inside the
furnace through skids.
Four different zones of
Heating
Designed to heat till 1250oC.
20. High Pressure Descalers
• High pressure water jets applied
to remove scale formed on the
metal surface during heating
and rolling process.
23. Vertical Edger
A set of vertical rolls installed ahead of roughing mill to
control the strip width.
24. 4 Hi Reversing Roughing Mill
Reduces thickness from 210mm to 20-40mm
Roller Tables
Types:
25. Coil Box
an equipment which converts the flat transfer bar into
coil and uncoil for feeding into Finishing mills
Temperature – homogenisation.
Reduces loss of heat of transfer bar between roughing
and finishing mill.
27. Run Out Table
To carry the strip to Down Coiler.
Cool the strip to
desired temperature
at pre-defined cooling
rate with Laminar flow
of water from top
and bottom.
30. Cold Rolling Mill
a part of the FP division
converts hot rolled coils (HR) into cold rolled
(CRCA) and Galvanized coils
Reduces the thickness of coils from 2-6mm to
about 0.27-3.2mm
32. Process Flow :
After this the material is
either coated in continuous
galvanizing line (CGL) or to
CRCA (cold rolled close
annealed).
Coupled Pickling and
tandem cold mill where HCl
pickling is done followed by
5-6HI rolls to reduce the
thickness.
Hot rolled coil from HSM is
brought into CRM for cold
rolling.
Hot Rolled
Coil
PLTCM
CGL - 1 CGL - 2 CRCA
33. Skin Pass Mill is for giving shape and
surface finish to the product.
In BAF the material is heated and
then converted to the desired shape.
Those which come from ECL are
treated with alkali to remove iron
fines from the surface.
From CRCA the material is sent
directly to BAF or via ECL. CRCA
BAF
SPM
Direct
dispatch
RCL Dispatch
ECL
34.
35. business objective :
‘Improve product quality performance as per needs of the
customer’.
reduce non compliance on products and improve process
capability to meet customer’s expectations
36. LD#3 & TSCR
is an integrated department in TATA STEEL
has a capacity of 2.4 mtpa.
relatively new plant which was established in Feb 2012.
37. Process Flow
Desulphurization
• Sulphur decreases
ductility and notch
impact toughness
especially in the
transverse
direction.
Weldability
decreases with
increasing sulphur
content.For above
reasons ‘S’ removal
is necessary.
Primary Steel Making
• Scrap Charging
• Hot Metal
Charging
• Oxygen Blowing
and Flux addition
• Slag Off
• Tapping
• Slag Wash
• Inspection
Secondary Steel
Making
• Sample and
Temperature
• Purging:
• Arcing
• Desulphurization:
• Ca-injection
38. Twin Ladle furnace
one unit two ladle stands
are placed side by side
common arcing facility
bottom purging process
is followed
39. Thin Slab Casting
Continuous Casting
Less cost as
Less number of segments
No slab yard and cross transfer
roller table car
No Deburrer and marking
machine at caster
No roughing mill
Less equipment so lesser
maintenance cost
40. Rolling
Tunnel Furnace
receive thin slab from respective casters
heat up the thin slab for uniform rolling temperature
and conveys it from each caster line exit to the rolling
mill entry.
Entry roller table
convey slab from furnace exit to mill entry.
Pendulum Shear
Chopping of the thin slab in case of failures in the
finishing mill
Emergency cut
41. Descaler
to remove scales from strip before it is rolled
For the descaling process the strip is transported at a
constant speed through this box.
42. Finishing Mill
six four high finishing
stands
two work rolls and two
back up rolls.
reduced to final thickness
PCFC
44. Safety Guidelines
Use Safety Appliances – Safety
boots, helmet, fire- proof jacket
etc.
Beware of overhead cranes
moving with load.
Maintain safe distance from
mobile equipments trucks,
cranes, dumpers etc.
45. Be careful of spilled oil ,
grease on shop floor.
Do not go in furnace area
without an escort.
Use crossovers for crossing
