JSW, STEEL

WORKS
BELLARY
presented by:
ranjit kumar singh
amaresh kumar nayak

OPERATION
MECHANICAL
ELECTRICAL
QUALITY CONTOL

REHEATING FURNACE
MILL AREA
COOLING BED AND STACKER AREA

INTRODUCTION
TERMS AND DEFINITION
PROCESS FLOW
PROCESS PARAMETERS
GUIDE ASSEMBLY/DIASSEMBLY
PASS SCHEDULE

Mill area is basically the assembly of

different stands namely roughing mill,
intermediate mill, finishing mill, no twist
mill, water box and brake slide with pinch
rolls, shears, and crop and divide shears in
between different stands.

It forms the path for the hot billet from the re-heating furnace to travel to
the roughing mill without much loss in temperature. It comes with a lifting
hood which cuts the loss of temperature with exposure at top to
atmosphere. Its length is 24m.

ROUGHING MILL:
It is a combination of six rolling stands arranged in V-H-V-H-V-H order with
V and H for vertical and horizontal arrangement respectively. These rolls
are of conventional type with no-housing stand and are made of cast iron
rolls.
Some features of no-housing stands areQuick disconnect service couplings for water and lubrication.
Stand positioning through hydraulic cylinder and etc.

INTERMEDIATE MILL:
It is also a combination of six rolling stands arranged in H-V-H-V-H-V order
with V and H for vertical and horizontal arrangement respectively. These
rolls are of conventional type with no-housing stand and are made of cast
iron rolls

FINISHING MILL:
It is a combination of four rolling stands arranged in H-H-H-H order with H
for horizontal arrangement.
PINCH ROLL :
It aids in feeding billet into following stands. Both rolls are symmetrically
adjusted by hydraulic system and are driven by electric motors through a
parallel shaft gear reducer and pinion stand.

NO TWIST VEE MILL:

It is also a rolling stand used in spilt lines, in which the cantilevered roll
housings are oriented at 45 to the horizontal and the tied stand
arrangement with a single input drive. It uses carbide ring rolls, which
enhances the pass life significantly. It also provides superior surface quality
finish. It houses six carbide rolls with full utilization only for 8mm rebar. For
10mm and 12mm re-bar it uses 4 rolls and 16mm, 20mm it uses 2 rolls.
It is only used in the split lines.

CROP AND DIVIDE/TOGGLE SHEARS:

The shear is used for front and tail end shear crop cuts and the cuts are
collected in the bottom scrap buckets. Cobble shear helps to cut the
section in case of cobble.

WATER BOXES:
These are used after the finishing areas after the ntm in the
split lines and directly after the finishing mill in the center
lines. It is used for the cooling of the rolled bars passing at high
speeds. They provide controlled temperature rolling throughout
the mill in order to meet the processing requirements of
various steel grades. The water boxes result in improved
mechanical properties.
GUIDES:
It helps to process section through each mill stand. They are
classified into types such as- 1.single pass guide 2.multipass
guide 3.entryguide 4.exit static guide

SIDE LOOPERS:
It helps to produce tension free rolling between preceding and
following stands. These are provided at the exit of the stand
number 13, 14, and 15 in the brm.

Various shears functionality after splitter

TOGGLE SHEAR
It is placed before roughing mill. It cuts the billet in case of cobble and saves energy in
the further stands.\

DIVIDE SHEAR
It is place after roughing and intermediate stands to chop the front end and chop off
material in case of cobble

CROP/DIVIDE SHEAR
It placed after repeater, just before chopping shear and after pinch rolls.

It cuts the head end as it is cold enough to cause problems in the further stages of
rolling in ntm and may cause cobble.
It collects the head end to know the dimension coming out of stand number 16.

CHOPPING SHEAR
It is placed before ntm and cooling bed

It cuts the tail before cooling bed ,so that the material which has been yielded is lost
for about 3-4 m.
It helps to chop material in case of cobble.

Take clearances from all departments.

Check thats all drives are operational.
Check all the lubricating, hydraulic, grease, pneumatic and water systems are
working.
Check all the parameters.
Shear blade/crop blade angles check.
Feed the roll diameters.
Speed match of rolls according to parameter.
Check loopers functionality.
Check the flow/pressure of the water in the water box.
Rotary system position check.

Cooling bed rake positioning check.

Check the position of entry switch pipe and exit switch pipe.
Request the furnace for billet call.
Observe temperature at exit of the furnace
Observe load current in each stand on Hmi screen
In case of compression of bars in between stands, decrease the speeds of
previous stand and vice versa.
Apply chopping commands in case of cobble.

Pass schedules

CONT.

INTRODUCTION
The reheating furnace of the BRM is used to heat the billet up to desired
temperatures so that it can be further rolled into desired products. The
furnace is supplied by TENOVA, Italy and has a actual capacity of 160 TPH.
The billets used here are of square dimensions. The furnace is divided into
3 zones, namely- 1) pre-heating zone, 2) heating zone, 3) soaking zone.
The furnace is a Walking beam furnace which is top and bottom fired
.The material processed is low medium carbon steel /low alloy steel.

TECHNICAL DETAILS:
Max. no. of billets 81
Charging roller table speed 1.6 m/s
Charge to discharge time 80 minutes
Cooling system Water cooled
Discharge temperature max. 1160C ( generally 950 1020 C)
Furnace operating temperature max. 1230 C
FUEL DETAILS
Fuel type Mixed gas ( LD gas + BF gas + Corex gas)
Inlet gas pressure 950 1080 mmWC
Calorific value of fuel 1850 Kcal/kg
Air/Fuel 1.6
Initial firing Manual ( Zone 6 & 7 are manually fired. For other zones, firing is
enabled only when the relevant zone temperature is higher than 600C)
Mixed gas-Vol %

Carbon Monoxide,CO-18.7
Hydrogen,H2-18.9
Methane,CH4-8.7
Carbon Dioxide,CO2-13.1
Nitrogen-39.2
Oxygen-0.5
CnHm-0.8
H2S-0.2

1900

CALORIFIC VALUE,Kcal/Nm3-1850-

FURNACE DIMENSIONS

Wall to wall internal length = 22000 mm

Wall to wall internal width = 12800 mm

Number of walking beams 4
Number of fixed beams 5
Charging schemes Row (single)
Cycle diagram Upward = 235mm
Forward= 250 mm

FURNACE ZONES : ( FOR IDEAL 160T/HR PRODUCTION)

NO OF BURNERS
ZONE 1

8
2
3
4
5
6
7

TEMPERATURES( C)
980

6
6
12
12
4
4

1020
1040
1060
1060
1070
1080

COMBUSTOIN AIR FAN

Type - Centrifugal
Numbers 2
Suction 52500 Nm3/hr
Rated speed 1480 rpm
Motor rating 315 kW
Combustion air set point temperature 440 C
Avg. temperature 330 375 C
Exit gas temperature max. 675 C (If more than this, dilution fan is
turned on)

DILUTION AIR FAN

Type Centrifugal
No. of fans 1

Rated speed 2940 rpm

Suction pressure 7700 Nm3/hr
Motor rating 37 kW
Set point temperature 675 C

REFRACTORY TYPES Thickness (mm)

Roof 300
Side walls 420
Hearth discharge 495
Hearth charging 330
Waste gas outlet 250

WALKING BEAM
Shifting : Beam stroke = Cylinder stroke = 265 mm
Lifting : Beam stroke = 200 mm
Cylinder stroke = 685 mm

KICK OFF MECHANISM

Shifting stroke = 880 mm (working) + 910 mm(maintenance)
Cylinder stroke = 2000mm
Lifting stroke = 50mm
Central arm to each half machine is equipped with a detector called
TOUCHER. It is operated by a double acting pneumatic cylinder with a
stroke length of 250mm.

To heat and soak a billet to the desired temperature for

rolling in the mill
In case of the furnace being restarted after a capital
shutdown, the pre-startup checks are made.
All the connected flows like combustion air, fuel flow along
with their working pressure are checked for each zone and for
total furnace.
Free flow of recirculated water supply for the skids and
discharge door cooling along with industrial water for the
trough is checked. Pressure and flow can be monitored with
alarm provided in CP-1
All the auxiliary systems are healthy.
All the gas flow circuits are on.
Oxygen analyzer unit is on and healthy.
Charging machine, walking beam are in home position and
selected in auto mode.
Charging and discharging doors are closed and in auto mode.
All the charging and discharging side rollers are in auto mode.
All the zones are lighted up and the temperature maintained
as per requirement.

SPECIAL FEATURES OF MILL

WATER CUT SUPPLY OF MIXED GAS IN THE REHEATING

FURNACE TO ENSURE SAFETY.
WALKING BEAM FURNACE.
INSULATED ROLLER TABLE TO SAVE ENERGY.
BILLET WEIGHING FACILITY.
TWIST FREE ROLLING.
VARIETY OF PRODUCTS RANGING FROM ROUNDS TO
ANGLES.
EASE IN MAINTENACE.

SPECIAL THANKS TO
HR DEPT,BRM JSW
MR. MOHAN REDDY SIR
MR. LOKESH SIR
MR. RAJU SIR