HR SLITTING (SMS ESMECH)

Slitting serves three purposes :

(i) HR coils are available in widths which are wider than the required for Cold Rolling. The
trimming / slitting is done with the HR Slitter.

(ii) The HR coils available may have width variation of the order of up to 20 mm, so to get
the uniform width these coils are slitted.

(iii) The edges of HR coils may get damaged during transportation because of poor
packaging and/or improper handling. In order to remove these damaged edges the HR coils
are trimmed /slitted.

PICKLING (SMS-ESMECH with the technology collaboration with

PRO ECO, Canada)
Pickling Line 01 No

Pickling Line 02 No's

Pickling is a metal surface treatment used to remove impurities, such as stains, inorganic
contaminants, rust or scale from ferrous metals, copper, precious metals and aluminium
alloys.

Thickness Range 1.6 to 6mm

Width Range 700 1700 mm

COLD ROLLING MILL (HITACHI, JAPAN / CMI, INDIA)

6 Hi Mill 3 No's
2 Hi Mill 2 No's
Width Range 650 1700 mm

The primary function of Cold Rolling is to reduce the thickness of Hot Rolled Pickled strip at
room temperature. During the operation overall max reduction of up to 90 % in thickness of
the HR Coil can be achieved. Cold rolling occurs with the metal below its recrystallization
temperature (usually at room temperature), which increases the strength via strain
hardening up to 20%. It also improves the surface finish and holds tighter tolerances.

ELECTROLYTIC CLEANING LINE ( CMI-FPI, INDIA )

Thickness Upto 3 mm
 Width Upto 1700 mm

Electrolytic Cleaning Line is responsible for the electrolyte cleaning of the rolled sheet
surface in order to have its surface contaminations and greases removed in two dipping
tanks containing alkaline solution and electrolyte cleaning.

ANNEALING FURNACE ( EBNER )

Total No. of Bases 49
Annealing Furnaces are H2 furnaces with higher convection are from EBNER, AUSTRIA &
ALLIED, and MUMBAI. Complete automation in the line ensures Clean & flawless surfaces.
Annealing is a process in which metals, glass and other materials are treated to render
them less brittle and more workable. In the steel industry, the steel is heated and profile
controlled, with times and temperatures set according to the properties desired to reach an
increased ductility and relieve strains that lead to failures in service.

KATHABAR ( IMTECH DRYGENIC, USA )

Total No. of Bases 42
BSL is having KATHABAR cooling system from IMTECH DRYGENIC, USA. By this system
we can supply dehumidify air to annealed coil for cooling of coils for best result. In this
system the liquid desiccant can remove contaminants in the air like oil & grease & filter
them out.

NON-OX GALVANIZING/GALUME LINE (CMI FPE with the

technological collaboration with HYPERTHERM, EMG, GFG &
AJAX TOCCO)
Galvanising Line 3 No's

Galume Line 1 No.

The purpose of the Continuous Galvanizing line is to apply a coat of zinc onto the surface of
steel sheets in an effort to increase their corrosion resistance. There is a wide range of
control of zinc coat thickness, and the galvanised steel sheets are used for a board range of
purposes, including construction materials, automobiles and electrical appliances. GALUME
is the trade name for a sheet steel product with a highly corrosion resistant coating
containing nominally 55% aluminium and 43% zinc by weight, the balance primarily silicon
is used to effect excellent adhesion to the steel substrate. This metallic coating which is
applied using a continuous hot-dip coating process combines the galvanic corrosion
protection of zinc with the barrier protection of aluminium.
COLOR COATING LINE ( SMS-ESMECH with the technology
collaboration with EMG, COMENCO & GFG )
BSL is having Color coating line with hot laminator supplied by SMS-ESMECH with the
technology collaboration with EMG, COMENCO & GFG. Embossing (NAWOO, KOREA),
Profiling (AL-KONG, KOREA) & Tension Leveller (SMS, ESMECH) are also installed. we
used RMP,SMP & PVDF type of paint which makes us unique for appliances & high end
products.

H & T LINE: ( SECO WARWICK ALLIED LTD )

Thickness Up to 3.5 mm

Width Up to 550 mm
The strip grinding & polishing line is to achieve the desired surface finish are from BREUER,
Germany.

FINISHING SECTION
Corrugation Machine 13 No's. ( ESMECH & REGAL IRON)
Cut to Length Line - 26 No's. ( IDH, FIMMI, DAEHWA, GEORGE)
Slitting Line 14 No's. ( IDH, FIMMI, DAEHWA)

Slitting Line for cold rolled steel strip coils cut in longitudinally direction to get
the strip in required width as per customer requirement.
 PICKLING DEPARTMENT

Pickling (metal)
Pickling is a metal surface treatment used to remove impurities, such as stains, inorganic
contaminants, rust or scale from ferrous metals, copper, and aluminum alloy. A solution called
pickle liquor, which contains strong acids is used to remove the surface impurities. It is
commonly used to descale or clean steel in various steelmaking processes.

Process
Many hot working processes and other processes that occur at high temperatures leave a
discoloring oxide layer or scale on the surface. In order to remove the scale the work piece is
dipped into a vat of pickle liquor.

The primary acid used is hydrochloric acid, although sulfuric acid was previously more common.
Hydrochloric acid is more expensive than sulfuric acid, but it pickles much faster while
minimizing base metal loss. The speed is a requirement for integration in automatic steel mills
that run production at high speed; speeds as high as 800 ft/min (-243 meters/min) have been
reported.

Carbon steels, with an alloy content less than or equal to 6%, are often pickled in hydrochloric
or sulfuric acid. Steels with alloy content greater than 6% must be pickled in two steps and
other acids are used, such as phosphoric, nitric and hydrofluoric acid. Rust- and acid-resistant
chromium-nickel steels are pickled in a bath of hydrochloric and nitric acid. Most copper alloys
are pickled in dilute sulfuric acid, but brass is pickled in concentrated sulfuric and nitric acid
mixed with sodium chloride and soot.

In jewelry making, pickling is used to remove the oxidation layer from copper surfaces, which
occurs after heating. A diluted sulfuric acid pickling bath is used. Sheet steel that undergoes
acid picking will oxidize (rust) when exposed to atmospheric conditions of moderately high
humidity. For this reason, a thin film of oil or similar waterproof coating is applied to create a
barrier to moisture in the air. This oil film must later be removed for much fabrication, Plating
or painting processes.

Steel pickling is part of the finishing process in the production of certain steel products in which
oxide and scale are removed from the surface of strip steel, steel wire, and some other forms of
steel, by dissolution in acid. A solution of either hydrogen chloride (Hcl) or sulfuric acid is
generally used to treat carbon steel products, while a combination of hydrofluoric and nitric
acids is often used for stainless steel. Steel pickling and the associated process of acid
regeneration result in the emission of hazardous air pollutants (HAPs).

Pickling Process.

ROLLING MILL DEPARTMENT

In metalworking, rolling is a metal forming process in which metal stock is passed through a pair
of rolls. Rolling is classified according to the temperature of the metal rolled. If the temperature
of the metal is above its recrystallization temperature, then the process is termed as hot rolling.
If the temperature of the metal is below its recrystallization temperature, the process is termed
as cold rolling. In terms of usage, hot rolling processes more tonnage than any other
manufacturing process and cold rolling processes the most tonnage out of all cold working
processes.

There are many types of rolling processes, including fiat rolling, foil rolling, ring rolling, roll
bending, roll forming, profile rolling, and controlled rolling.

Hot rolling is a metalworking process that occurs above the recrystallization temperature of the
material. After the grains deform during processing, they recrystallize, which maintains
an equiaxed microstructure and prevents the metal from work hardening. The starting material
is usually large pieces of metal, like semi-finished casting products, such as slabs, blooms, and
billets. If these products came from a continuous casting operation the products are usually fed
directly into the rolling mills at the proper temperature. In smaller operations the material
starts at room temperature and must be heated. This is done in a gas- or oil-fired soaking pit for
larger work pieces and for smaller work pieces induction heating is used. As the material is
worked the temperature must be monitored to make sure it remains above the recrystallization
temperature. To maintain a safety factor a finishing temperature is defined above the
recrystallization temperature; this is usually 50 to 100 C (122 to 212 F) above the
recrystallization temperature. If the temperature does drop below this temperature the
material must be re-heated before more hot rolling.

Hot rolled metals generally have little directionality in their mechanical properties and
deformation induced residual stresses. However, in certain instances non-metallic inclusions
will impart some directionality and work pieces less than 20 mm (0.79 in) thick often have some
directional properties. Also, non-uniformed cooling will induce a lot of residual stresses, which
usually occurs in shapes that have a non-uniform cross-section, such as I-beams and H-beams.
While the finished product is of good quality, the surface is covered in mill scale, which is an
oxide that forms at high-temperatures. It is usually removed via pickling or the smooth clean
surface process, which reveals a smooth surface. Dimensional tolerances are usually 2 to 5% of
the overall dimension.

Hot rolling is used mainly to produce sheet metal or simple cross sections, such as rail tracks.

Material Specification:-
Pickled HR coil/ annealed CR Coil of various Grades

Dimensional Specification:-

Min. Max.
Width 700MM 1700MM

Material I/P Thickness 1.8MM (HR) 7.0MM

Wt. of coil 3.0MT 30MT

CR Thickness 0.11MM 6.95MM

Line Specification:-

Maximum Speed 1200MPM

Tension 16 T max.
 ECL DEPEARTMENT
Electrochemical Cleaning (ECL) is a very effective process using the same physic. Equipment and
chemicals we use in our proprietary "spot" electro polishing technique. Discovered when a
customer had a product residue issue that looked like classic "rouge" yet when industry
accepted de-rouging chemical applications were tried they proved completely ineffective. In an
experiment we used the spot electro polish procedure whereby electrolyte was applied to the
stained surface and the DC current was activated and the "hand tool" was applied to and
moved over the surface the stain was removed immediately. Because of this discovery we were
able to completely clean 5, 10,15K GALLON & larger vessels in hours instead of days.

Once discovered this method has found several v, cost effective applications where ECC can be
used in place A more expensive and less effective chemical or manual processes while
delivering a micro surface improvement to the area being cleaned where optional processes at
best do nothing to improve and at worst can etch the micro surface.

Application

De-rouging: ECC has been found to be very effective for removing rouge for both electro
polished and non-electro polish Surfaces. An added benefit observed on items de-rouged using
ECC is the rouge is very slow to return. Though conventional de-rouging and passivation
methods would yield a clean product contact surface the rouge would begin to reform in a
matter of hours. Equipment de-rouged using ECC has shown the rouge resisted returning for
months and in some cases years.

Grey Residue: On equipment with a sanded or mechanically polished stainless steel

surface only it is common to find a grey residue present when the surface is wiped with an
alcohol soaked cloth. In many instances the entire surface of a vessel, as an example, will be
hand wiped for hours using "clean wipes" until all of the grey residue has appeared to have
been removed. The vessel may then be passivated or cleaned in place and allowed to dry only
to have the grey residue return at visibly the same concentration as observed before the
cleaning operation.

It is believed this grey residue is made up of stainless steel powder created by the sanding
process and electrostatically adhered to the mechanically polished surface (PIC). No amount of
wiping or chemical cleaning has proven to completely remove this residue. Understandably
Quality Control personnel find this condition unacceptable concerned if the grey residue can be
wiped off, it stands to reason it can come loose during product processing and become an
undesirable additive.
ECC can completely remove this grey residue in one application by electrolytic action as metal is
removed ion by ion with the very outermost surface and any residue being removed. In dozens
of applications this condition has successfully been treated in one application eliminating grey
residue from the equation.

Weld Scale and Discolorization: Prior to successful use as a de-rouging or surface

contaminant removal process, ECC was developed specifically for removing weld discoloration
directly on a weld or in the heat affected zones adjacent to the weld.

The process utilizes a mild acid electrolyte solution and DC current that when applied to a weld
or heat affected zone (HAZ) very rapidly removes discoloration. On large construction projects
utilizing austenitic, super-austenitic or nickel alloys, weld discoloration has historically been
removed by mechanical polishing, blasting or a harsh chemical application, all of which alter the
appearance when compared to untreated surrounding surfaces. The process has also been
shown to improve corrosion resistance in these areas comparable to that of the surrounding
base metal.

ANNEALING DEPARTMENT
Annealing, in metallurgy and materials science, is a heat treatment wherein a material is
altered, causing changes in its properties such as strength and hardness. It is a process that
produces conditions by heating to above the recrystallization temperature, maintaining a
suitable temperature, and then cooling. Annealing is used to induce ductility, soften material,
relieve internal stresses, refine the structure by making it homogeneous, and improve cold
wowing properties.

In the cases of copper, steel, silver, and brass, this process is performed by substantially heating
the material (generally until glowing) for a while and allowing it to cool. Unlike ferrous metals
which must be cooled slowly to annealcopper, silver and brass can be cooled slowly in air or
quickly by quenching in water. In this fashion the metal is softened and prepared for further
work. Such as shaping, stamping, or forming.

Thermodynamics
Annealing occurs by the diffusion of atoms within a solid material, so that the material
progresses towards its equilibrium state. Heat is needed to increase the rate of diffusion by
providing the energy needed to break bonds. The movement of atoms has the effect of
redistributing and destroying the dislocations in metals and (to a lesser extent) in ceramics. This
alteration in dislocations allows metals to deform more easily, so increases their ductility.
The amount of process-initiating Gibbs free energy in a deformed metal is also reduced by the
annealing process. In practice and industry, this reduction of Gibbs free energy is termed stress
relief.

The relief of internal stresses is a thermodynamically spontaneous process; however, at room

temperatures, it is a very slow process. The high temperatures at which the annealing process
occurs serve to accelerate this process.

The reaction facilitating the return of the cold-worked metal to its stress-free state has many
reaction pathways, mostly involving the elimination of lattice vacancy gradients within the body
of the metal. The creation of lattice vacancies is governed by the Arrhenius equation, and the
migration/diffusion of lattice vacancies are governed by Fick's laws of diffusion. Mechanical
properties, such as hardness and ductility, change as dislocations are eliminated and the
metal's crystal lattice is altered. On heating at specific temperature and cooling it is possible to
bring the atom at the right lattice site and new grain growth can improve the mechanical
properties.

Stages
There are three stages in the annealing process, with the first being the recovery phase, which
results in softening of the metal through removal of crystal defects (the primary type of which
is the linear defect called a dislocation) and the internal stresses which they cause. Recovery
phase covers all annealing phenomena that occur before the appearance of new strain-free
grains. The second phase is recrystallization, where new strain-free grains nucleate and grow to
replace those deformed by internal stresses. If annealing is allowed to continue once
recrystallization has been completed, grain growth will occur, in which the microstructure starts
to coarsen and may cause the metal to have less than satisfactory mechanical properties.

Controlled atmospheres
The high temperature of annealing may result in oxidation of the metal's surface, resulting in
scale. If scale is to be avoided, annealing is carried out in a special atmosphere, such as with
endothermic gas (a mixture of carbon monoxide, hydrogen gas, and nitrogen gas).

The magnetic properties of mu-metal (Espey cores) are introduced by annealing the alloy in a
hydrogen atmosphere.
Setup and equipment
Typically, large ovens are used for the annealing process. The inside of the oven is large enough
to place the workpiece in a position to receive maximum exposure to the circulating heated air.
For high volume process annealing, gas fired conveyor furnaces are often used. For large
workpieces or high quantity parts Car-bottom furnaces will be used in order to move the parts
in and out with ease. Once the annealing process has been successfully completed, the
workpieces are sometimes left in the oven in order for the parts to have a controlled cooling
process. While some workpieces are left in the oven to cool in a controlled fashion, other
materials and alloys are removed from the oven. After being removed from the oven, the
workpieces are often quickly cooled off in a process known as quench hardening. Some typical
methods of quench hardening materials involve the use of media such as air, water, oil, or salt.

Diffusion annealing of semiconductors In the semiconductor industry, silicon wafers are

annealed, so that dopant atoms, usually boron, phosphorus or arsenic, can diffuse into
substitutional positions in the crystal lattice, resulting in drastic changes in the electrical
properties of the semi conducting material.

Normalization
Normalization is an annealing process in which a metal is cooled in air after heating in order to
relieve stress.

It can also be referred to as: Heating a ferrous alloy to a suitable temperature above the
transformation temperature range and cooling in air to a temperature substantially below the
transformation range. This process is typically confined to hardenable steel. It is used to refine
grains which have been defamed through cold work, and can improve ductility and toughness
of the steel. It involves heating the steel to just above its upper critical point. It is soaked for a
short period then allowed to cool in air. Small grains are formed which give a much harder and
tougher metal with normal tensile strength and not the maximum ductility achieved by
annealing. It eliminates columnar grains and dendritic segregation that sometimes occurs
during casting. Normalizing improves machinability of a component and provides dimensional
stability if subjected to further heat treatment processes. Process annealing Process annealing,
also called "intermediate annealing", "subcritical annealing", or "in-process annealing", is a heat
treatment cycle that restores some of the ductility to a WO. Piece allowing it be worked further
without breaking. Ductility is important in shaping and creating a more refined piece of WO.
Through processes such as rolling, drawing, forging, spinning, extruding and heading. The piece
is heated to a temperature typically below the austenizing temperature, a. held there long
enough to relieve stresses in the metal. The piece is finally cooled slowly to room temperature.
It is then ready again for additional cold working. This can also be used to ensure there is
reduced risk of distortion of the work piece during machining, welding, or further heat
treatment cycles.

SKIN PASS MILL

After annealing, coils may require a final rolling called a temper pass, skin pass or planish pass.
This involves a controlled light reduction to establish the final thickness, impart the desired
surface finish, flatten the strip to improve shape and create the required hardness or temper of
the material.
COLD ROLL SLITTING / CUT TO LENGTH

Some customers require a steel to be of a particular thickness other than the general increment
sizes rolled in the hot mill or thinner than the minimum thickness rolled in the mills. These
steels are processed in the cold roll reduction mill. These mills are capable of rolling steel to the
precise thickness that the customer orders and are a major part of the steel strip production
process. The reduction mill in the plant I worked had four rolls in the mill that were stacked
upon each other. This arrangement is known as a two high mill. There are two working rolls
between which the strip is passed and two large back-up rolls, one on top of the working rolls
and one on the bottom. The back-up rolls apply the tremendous pressures required to cold roll
(reduce) the strip between the working rolls. The working rolls are usually about two to three
feet in diameter while the back-up rolls are about seven to eight feet in diameter. The rolls are
made of high alloy steel so they can withstand the tremendous pressure they are under while
rolling without deforming.
Because of this the rolls are ground in a large lathe using a very large grinding wheel on a
movable carriage. Depending on the surface finish required of the strip the working rolls will
either have a highly polished (mirror like) finish or a dull finish on them. All working rolls are
ground on the lathe in the mill to a highly polished surface periodically. The rolls that have a
dull finish on them are shot blasted after grinding to produce the desired surface.

After grinding to a polished surface the rolls that need a dull finish are placed on a large
carriage which has a set of rubber rolls on it. The carriage then travels on a small rail track into a
large enclosure and the door is closed down. On top of this enclosure is a large hopper filled
with fine steel balls called shot. This shot is very small in diameter (about half the size of a BB or
smaller) and is very hard. It is fed down a chute and using either compressed air or a impeller
type system it is accelerated to high speed (in excess of a hundred miles per hour) and blasted
against the surface of the roll. The rubber rolls on the carriage rotate causing the steel roll to
rotate so all its surface is exposed to the shot blast. The shot comes in a variety of sizes and
hardness grades and different types are used depending on the type of surface finish required
on the rolls. After a predetermined cycle time the roll is removed from the Wheelabrator, as it
is called and is ready to be used in the mill.

A saddle type conveyor runs along the side of the reduction mill. Steel coils are place on this
conveyor by overhead cranes using the same .C. hook as at the entry and exit ends of the pickle
lines. This saddle conveyor moves the coils along to the reduction mill where they are lowered
onto a frame at the entry side of the mill. A transfer saddle operated by the mill operator
moves out to the frame and picks up the coil and moves it back into the feed mandrel on the
entry side. The operator cuts the strap, freeing up the loose end of the coil. He opens a space
between the work rolls and feeds the end of the exit side. On the exit side is another
expandable mandrel the same as the catcher mandrels of the hot mills and pickle line. The
entry operator feed the strip until the exit operator can catch the end in the open segment of
his mandrel, expanding it and trapping the end of the strip. The entry operator then closes the
gap in the working rolls down on the strip. Pressure (thousands of tons) is applied by the back-
up rolls by means of hydraulically operated screws, to the wowing rolls and the reduction
rolling process begins. If the thickness of the steel needs to be greatly reduced, the strip will be
passed back and forth between the rolls a number of times with the rolls adjusted for each
pass. Due to the great amount of pressure exerted in the reduction process the steel strip
becomes very hot. In order to prevent the steel from becoming hot and sticking to the work
rolls, the rolls are flooded with a coolant consisting of 95% water and the other 5% water
soluble oil. The end of the strip that is in the exit mandrel is not released in the multiple pass
process nor is it completely unwound from the entry mandrel. In the final pass through the
reduction mill, the portion that was not reduced from the entry end is trimmed off in a set
shears just before they enter the work rolls to the exit side. A transfer saddle on the exit side
then moves the coil back onto the conveyor that runs beside the mill.

QUALITY SYSYTEM
Quality control is a process by which entities review the quality of all factors involved in
production. This approach places an emphasis on three aspects

1. Elements such as controls, job management, defined and well managed processes,
performance and integrity criteria, and identification of records

2. Competence, such as knowledge, skills, experience, a. Qualifications

3. Soft elements, such as personnel integrity, confidence organizational

The quality of the outputs frisk if any of these three aspects is deficient in any way.

Quality control emphasizes testing of products to uncover defects, and reporting to

management who make the decision to allow or deny the release, whereas quality assurance
attempts to improve and stabilize production, and associated processes, to avoid, or at least
minimize, issues that led to the defects in the first pun For contract work, particularly work
awarded by government agencies, quality control issues are among the top reasons for not
renewing a contract.

"Total quality control", also called total quality management, is an approach that extends
beyond ordinary statistical quality control techniques and quality improvement methods. It
implies a complete overview and re-evaluation of the specification of a product, rather than
just considering a more limited set of changeable features within an existing product. If the
original specification does not reflect the correct quality requirements, quality cannot be
inspected or manufactured into the product. For instance, the design of a pressure vessel
should include not only the material and dimensions, but also operating, environmental, safety,
reliability and maintainability requirements, and documentation of findings about these
requirements.