Billets

Procurement - The first step of billet production is of raw material procurement. Billets can be made using both steel scrap and sponge iron, In our integrated steel plants, sponge iron is produced in house and is the major raw material. In other plants, we use steel scrap in conjunction with the sponge iron in a ratio of 70:30 to charge the induction furnaces. Processing - The procured steel scrap is sent for processing, where it is refined to remove unwanted articles (Rubber, plastic or dirt) and then segregated. The segregation stage separates the scrap which is directly chargeable (sent directly to the furnaces) from the rest which is either over-sized, or no dense enough to be directly chargeable. This scrap goes through a scrap processing machine which sizes and bundles the scrap ready for melting. Melting- Once the scrap is processed, it enters the furnace. Using electrical induction charging, the copper wires, looped through the cylindrical container holding the scrap, induce heat causing the scrap in the container to melt into hot liquid metal. It is then poured into a ladle which transfers the liquid metal to the casting machine (CCM). Casting- In the CCM, the liquid metal is poured into a water cooled mould after passing through a tundish where it is chemically treated to remove any impurities that may arise. The mould is open at both ends and is continuously withdrawn from the bottom at a controlled rate using support roles, all the while being cooled using water jets. When it comes out the metal takes the rectangular form of billets. Shearing - The billets are cut to the required length at the shearing machine after which they are either stored for later use or more commonly sent directly for rolling to the mill.

Ingot lengths and sizes show variations which lead to unwanted en-cutting and wastage. In continuous casting, the length of the billets can be controlled to minimize losses in end-cuttings. Higher extent of automation is possible. Width of billet can be adjusted for greater productivity. Continuous cast products show less segregation Hot direct charging of billet for rolling is possible leading to energy savings.

Very fast partial hardening High production rates Significant reduction in pollution, distortion, forging scale, energy and space requirements. High degree of reproduction and automation.