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Product Range |
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| Product: Billets / Ingots |
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| Introduction |
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Steel is a dynamic, versatile and eco-friendly product with diverse use and applications. An ingot is a mass of metal or semi conducting material, heated past the melting point, and then recast, typically into the form of a bar or block.
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| Properties of the product |
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| Quality and certification |
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With two coreless induction furnaces of 10 tonnes each, WPSL produces 30,000 MT of steel ingots annually. |
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| Steel Ingot Specification |
| Elements
Length |
Range
3.5” X 4.5” X 60” |
| C |
0.15 - 0.25 % |
| Mn |
0.50 - 0.70 % |
| Si |
0.35% max. |
| P |
0.055 % Max |
| S |
0.055 % Max |
| Note: Length variance as per customer requirements. |
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| Technology |
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The coreless induction furnace is composed of a refractory container, capable of holding the molten bath, which is surrounded by a water cooled helical coil connected to a source of alternating current.
The principle of operation of the induction furnace is the phenomena of electro-
magnetic induction.
The induction (generation) of the electrical current in a conductive metal (charge) placed within a coil of conductor carrying electrical current is known as electromagnetic induction of secondary current.
The alternating current applied to the coil produces a varying magnetic field which is concentrated within the helical coil. This magnetic field passing through the charge induces secondary current in the charge piece. The current circulating in the charge produces electrical (I 2 R) losses which heat the charge and eventually melt it. |
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| Process |
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| Charging |
| Charging is the process by which raw materials such as pig iron, limestone, coke or steel are fed into the furnace.Exposure to toxic metal fumes, carbon monoxide, heat stress, and other toxic gases are the main hazards associated with furnace charging. |
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| Melting |
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Melting is the process by which the charge material is liquefied. For melting metals, different varieties of furnaces are available. |
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| Removal of slag |
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This is the process by which unwanted debris is removed from the melt. This process is carried out either manually or by using limestone additives. |
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| Refining |
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Refining is the process by which unwanted contaminants are removed from molten metal to bring it to a predetermined chemical specification. |
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| Tapping |
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Tapping is the process of transferring the molten metal into a ladle from the furnace. |
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| Raw Materials and procurement of the same |
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Scrap |
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Sponge iron |
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Met Coke |
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Silico Manganese |
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Ferro Silicon |
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Aluminum |
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| Any specific features if any |
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| Induction Furnace in Steel Production
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The induction furnace-as a complimentary aggregate for i.e. premelts-plays an important role in steel plants producing high quality and stainless steels. In the field of iron casting and foundries the induction furnace is known as a standard. For both named industry sectors the products of RHI Refractories and its partners belong to the safest and most efficient solutions since many decades.
The high-quality mixes of the ANKERINDUX-product range are standing for |
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highest chemical durability |
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lowest alloy losses |
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leading to highest steel quality with respect to impurities |
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high refractoriness |
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Induction heating is a subfield of industrially used electric heating. All electrically - conductive materials can be heated quickly and cleanly with pollution free induction heating. Features include |
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Selected parts of the workpiece can be heated. |
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Heating time and temperature can be precisely controlled. |
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There is no smoke or soot pollution |
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Heating operation can be integrated in semi - automatic production sequences |
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Induction equipment can usually be operated by unskilled personal |
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| Key advantages of induction heating |
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Very fast partial hardening |
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High production rates |
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Significant reduction in pollution, distortion, forging scale, energy and space requirements |
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High degree of reproduction and automation |
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Mini Steel Plants (MSPs)
Raw Material : Raw materials are scrap, fluxes and ferro alloys. Sponge iron can substitute scrap upped 50%.
Melting : Scrap/ sponge iron, fluxes, Ferro alloys are melt in an electric arc furnace, wherein electric current passed through electric rods (normally 3 rods) creates an arc and melts the metal. Alternate method is induction furnaces, which are very small and being phased out.
Refining : The molten metal from electric arc furnace is taken in a ladle, for refining. The metallurgy of steel in terms of carbon, phosphorus content, alloy elements etc, is controlled at this stage. Manufacture of stainless steel requires addition of nickel (7-8%) and chromium (15-18%).
Casting : The liquid steel is cast into semi finished products such as billets, blooms, slabs etc. This process called continuous casting is different from old technology (still in use in older plants) where liquid steel is first solidified in large blocks called ingots and then rolled into semis, involving higher energy and waste in re-heating.
Rolling : The semis such as billets, blooms, slabs are heated at 1200°C to make metal malleable and then rolled into finished products. There are different rolling mills for different products. Rolling mill for long products such as bars, angles, structural etc. can be part of steel making plant or an independent small-scale industry. Flat product rolling mills are capital intensive, as they have to meet strict quality parameters. Rolling rolls slabs in flat product HR plate/ strip/ coil by process of heating the slab followed. HR sheet's thickness can be further reduced by cold rolling i.e. rolling in CR mill at room temperature. CR can be zinc coated in a galvanizing plant to make galvanized plates or coils. |
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