A REPORT OF ONE-MONTH TRAINING

at
ONKAR MULTEMETALS & ALLOYS

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE AWARD

OF THE DEGREE OF

BACHELOR OF TECHNOLOGY

(Mechanical Engineering)

July – August 2023

SUBMITTED BY:
NAME: NITISH GUPTA

UNIVERSITY ROLL NO: 2005085

DEPARTMENT OF MECHANICAL & PRODUCTION ENGINEERING

GURU NANAK DEV ENGINEERING COLLEGE LUDHIANA

(An Autonomous College Under UGC ACT)

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CERTIFICATE

iii
GURU NANAK DEV ENGINEERING COLLEGE, LUDHIANA

iv
 CANDIDATE'S DECLARATION

I “NITISH GUPTA” hereby declare that I have undertaken One - month training at “ONKAR

MULTIMETALS & ALLOYS ” during a period from July,2023 to August,2023 in partial

fulfillment of requirements for the award of degree of B.Tech (MECHANICAL

ENGINEERING) at GURU NANAK DEV ENGINEERING COLLEGE, LUDHIANA. The

work which is being presented in the training report submitted Department of Mechanical &

Production Engineering at GURU NANAK DEV ENGINEERING COLLEGE, LUDHIANA is

authentic record of training work.

Signature of the Student

The six-month industrial training Viva–Voce Examination of _____________________ has

been held on ________________________and accepted.

Signature of Internal Examiner Signature of External Examiner

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 ABSTRACT

This abstract provides an overview of my one-month internship at Onkar Multimetals & Alloys

in the steel melting plant. During this period, I gained practical knowledge of steel production

processes, equipment operation, and process optimization.

This project focused on optimizing the melting process of alloy steel by analyzing the impact of

various process parameters, such as temperature, furnace lining, and raw material quality.

Through extensive data analysis and experimentation, I identified the optimal process

conditions, resulting in an increase in the yield of high-quality alloy steel.

Throughout my internship, I faced several challenges, including communication barriers,

equipment breakdowns, and process deviations. However, I successfully overcame these

challenges and gained valuable experience working in a team and adapting to changing

situations.

This report file highlights my achievements, provides recommendations for process

improvement, and demonstrates my ability to apply theoretical knowledge to real-world

situations. Overall, my internship in the industry was an enriching and valuable learning

experience, and I look forward to applying the knowledge and skills I gained to future projects.

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 ACKNOWLEDGEMENT

I would like to express my sincere gratitude to Sh. Jaskaran Singh (Director) Onkar

Multimetals & Alloys for providing me with the opportunity to undertake my six-month

internship in their steel melting plant.

I am immensely grateful to the management team and staff of Onkar Multimetals & Alloys for

their warm welcome, guidance, and support throughout my internship. I would like to thank HR

Manager Mr. Shubinder Moudgil, SMS GM R.K. Chopra, my supervisor Mr. Sachin Kumar,

and Mr. Prince for providing me with valuable insights into the steel production process and for

his constant encouragement and guidance.

I would also like to thank the colleagues at Onkar Multimetals & Alloys for their support,

cooperation, and for sharing their expertise with me. Their contributions were instrumental in

the successful completion of my internship.

I would be failing in my duty if I do not acknowledge the help and support of Dr. J. S. Grewal

(Professor & Head) of mechanical department, Guru Nanak Dev Engineering College

Ludhiana. I would like to extend my heartfelt thanks to faculty members who provided me with

the necessary theoretical knowledge and encouraged me to undertake this internship.

Finally, I would like to thank my family and friends for their unwavering support and

motivation throughout my internship.

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 About the Company

Onkar Multimetals & Alloys . represents a fully integrated steel manufacturing company with

manufacturing facilities of Carbon and Alloy Steel, Rounds and Squares, Sponge Iron, and

Ferro Alloys. The Company also manufactures Spring Steel Wires and Tyre Bead Wire. The

total products portfolio of the company is assigned to the automobile industry.

viii
 List of Figures

Figure Name Page No.

Fig 1.1 PROCESS FLOW CHART OF STEEL MAKING 14

Fig 1.1 Automobile Old Car Appliances 15

Fig 1.3 Scrap Types 17

Fig 1.4 Detailed Fig. Of EAF 21

Fig 1.5 Primary Electrical System 23

Fig 1.6 Power Cables 24

Fig 1.7 Fume Extraction System 26

Fig 1.8 Refractory Bricks & Ramming Mass 28

Fig 1.9 Ladle Refining Furnace Setup 33

Fig 1.10 Wire Drive System 33

Fig 1.11 Wire Feeder Machine 34

Fig 1.12 Systematic Diagram of VD 35

Fig 1.13 Vacuum degassing roof 36

Fig 1.14 VD Control Room Display 37

Fig 1.14 VD Control Room Display 38

Fig 1.16 Systematic Diagram of CCM 39

Fig 1.17 Tundish with name of component 40

Fig 1.18 Continuous Casting of billets 41

Fig 2.1 Scrap Charging using Bucket 43

Fig 2.2 ELECTRIC ARC FURNACE 47

Fig 2.3 Systematic Diagram of L.R.F 51

Fig 2.4 Systemic diagram of V.D 54

Fig 2.5 Billet coming from C.C.M 57

Fig 2.6 Some imp. Part of casting 59

List of Tables

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 Table Content Page No.

Table 1.1 SALIENT FEATURES OF EAF 26

Table 1.2 Salient features of LRF 31

Table 1.3 Tundish component’s 39

Table 2.1 Typical constituents of an EAF slag 48

Table 2.2 Heat cycle of EAF 49

Table 2.3 Example Of Steel Grade With Its Liquidus Temp. 52

Table 2.4 Chemistry of steel grade with cal. Of Liquidus Temp. 52

Table 2.6 Specification of CCM 59

Table 2.7 Billets size with casting speed 59

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 Definitions, Acronyms and Abbreviations

SMS- Steel Melting Shop

EAF- Electric Arc Furnace

AC- Alternating Current

DC- Direct Current

BOP- Basic Oxygen Process

DRI- Direct Reduced Iron

EBT- Eccentric Bottom Tapping

S/G- Spout and Slag Door

LRF- Ladle Refining Furnace

VD- Vacuum Degassing

CCM- Continuous Casting Machine

LPM- Litre Per Minute

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 CHAPTER 1 INTRODUCTION
1.1 INTRODUCTION TO STEEL MELTING SHOP

The Steel Melting Shop (SMS) is an integral part of the steel production process. It is a facility

where various types of steel are produced by melting and refining iron and other metals. The SMS

is responsible for transforming raw materials, such as iron ore, coal, and limestone, into steel,

which is a vital component in the manufacturing of many different products.

In the SMS, steel is produced through various processes, such as Electric Arc Furnace (EAF),

Basic Oxygen Furnace (BOF), Induction Furnace, and Ladle Furnace, depending on the type of

steel being produced and the specific requirements of the application. The SMS also includes

secondary refining processes, such as vacuum degassing, ladle treatment, and continuous casting,

which help improve the quality of the steel.

In this report, we will explore the various processes involved in the SMS, the raw materials used,

the equipment used in the production process, quality control measures, safety measures, and the

environmental impact of the SMS. We will also look at the future of the SMS in the steel industry

and the opportunities and challenges that lie ahead.

Steel making has for millennia, but it was not commercialized until the 19 th century. The ancient

craft process of steelmaking was the crucible process. In the 1850s and 1860s, the Bessemer

process and Siemens-Martin process turned steelmaking into a heavy industry. Today there are

two major commercial process for making steel, namely basic oxygen steel making, which has

liquid pig-iron from the blast furnace and scrap steel as the main feed materials, and electric arc

furnace (EAF) steelmaking, which uses scrap steel or direct reduced iron (DRI) as the main feed

materials. Oxygen steelmaking is fueled predominantly by the exothermic nature of the reaction

12
inside the vessel where as in EAF steelmaking, electrical energy is used to melt the solid scrap

and/or DRI materials. In recent times, EAF steelmaking technology has evolved closer to oxygen

steelmaking as more chemical energy is introduced into the process.

Modern steel making process can be broken into two categories: primary and secondary

steelmaking. Primary steelmaking is the process of converting iron ore and other raw materials into

liquid iron, which is then refined into steel. The two most common methods of primary

steelmaking are the basic oxygen process (BOP) and the electric arc furnace (EAF) process.

Secondary steelmaking is the process of refining liquid steel after it has been produced in the

primary steelmaking process. This is done in ladles, which are large vessels used to hold and

transport liquid steel. During secondary steelmaking, alloying agents such as manganese, nickel,

and chromium are added to the steel to improve its properties. Dissolved gases in the steel are also

lowered through the use of degassing agents, and inclusions such as oxides and sulfides are

removed or altered chemically to ensure that high-quality steel is produced after casting.

Overall, both primary and secondary steelmaking are important processes in the production of

high-quality steel, and they require specialized equipment, skilled workers, and strict quality

control measures to ensure that the steel meets the required specifications and standards.

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1.2 RAW MATERIAL
Steel is a versatile material that is used in a wide variety of industries. It is strong, durable, and can

be shaped into different forms. The raw materials used in steelmaking are an important factor in

determining the quality and properties of the finished product. In this article, we will discuss the

various raw materials used in steelmaking, including scrap metal, Direct Reduced Iron (DRI), and

other inputs.

Scrap metal is one of the most important raw materials used in steelmaking. It is obtained from

discarded or obsolete products, such as old cars, appliances, and machinery. The scrap is sorted

and processed to remove any contaminants or non-metallic materials. The resulting clean scrap

metal is then melted down and used in the steelmaking process. There are two types of scrap metal

used in steelmaking: ferrous and non-ferrous.

Fig 1.2:- Automobile old car appliances

Ferrous scrap metal is made up of iron-containing metals, such as steel and cast iron. It is the

most commonly used type of scrap in the steel industry. Ferrous scrap metal can be further

classified into three categories: home scrap, prompt scrap, and obsolete scrap.

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Home scrap is generated during the steelmaking process, such as from trimming and cutting

operations. It is usually of high quality and can be recycled back into the steelmaking process

without further processing.

Prompt scrap is generated from the production of finished products, such as stamping or forming

operations. It is usually of higher quality than obsolete scrap and can be recycled back into the

steelmaking process.

Obsolete scrap is obtained from discarded or obsolete products. It is usually of lower quality than

prompt or home scrap and requires additional processing before it can be used in the steelmaking

process.

Non-ferrous scrap metal is made up of metals other than iron, such as copper, aluminum, and

zinc. Non-ferrous scrap metal is not commonly used in the steel industry, but it can be used in the

production of other metals and alloys.

Different types of scraps that are used to manufacture the billets are as follows:

STEEL SCRAP: Steel scrap is a valuable source of raw material for the steelmaking industry. It is

typically collected from various sources, such as old cars, appliances, and construction sites. The

scrap is sorted and processed to remove any non-ferrous metals or contaminants before being

melted down in the steelmaking process. The types of steel scrap used in the steelmaking process

include:

 Heavy melting scrap (HMS): This is the most common type of scrap used in the

steelmaking process. It includes scrap from old cars, appliances, and construction sites.

 Shredded scrap: This is a type of scrap that has been shredded into small pieces, making it

easier to melt down in the steelmaking process.

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  Plate and structural scrap: This type of scrap includes scrap from buildings, bridges, and

other structures.

ROLL IRON: The roll iron contains about 2-3% of the carbon. It is obtained from the rolling

mills. It’s also contains nickel and molybdenum is very small quantity.

PIG IRON: Pig iron is the intermediate product of smelting iron ore with a high- carbon fuel such

as coke, usually with limestone as a flux. Charcoal and anthracite have also been used as fuel. Pig

iron has a very high carbon content, typically 3.5- 4.5%, which makes it very brittle and not useful

directly as material except for limited applications.

TURNING AND BORING CHIPS: This type of scrap is obtained from the turning boring

operations done on the lathe machine. During these operations the extra material in the form of

chips is obtained called as Scrap.

Fig 1.3:- Scrap types

SPONGE IRON: The Sponge iron is like a small balls used to set the carbon content of the billets.

Increase of carbon can be controlled by sponge iron. This is of two types: GAS based and COAL

based.

Another raw material used in steelmaking is Direct Reduced Iron (DRI). DRI is produced by

heating iron ore in a reducing atmosphere, which removes the oxygen and leaves behind a solid,

sponge-like material. DRI can be used in place of scrap metal in the steelmaking process, or it can

be used as a supplement to scrap metal to improve the quality of the finished product. DRI is a

16
relatively new input in steelmaking and is gaining popularity due to its lower carbon footprint and

potential cost savings.

Other inputs used in steelmaking include fluxes, alloys, and additives. Fluxes are used to remove

impurities from the molten steel, such as sulfur and phosphorus. Alloys are added to the molten

steel to impart specific properties, such as increased strength or corrosion resistance. Additives are

used to adjust the composition of the molten steel, such as to increase or decrease the carbon

content.

COKE

CPC (Calcined Petroleum Coke), NUT (Nut Coke), and Met Coke (Metallurgical Coke) are

different types of carbonaceous materials used in various industrial processes, including

steelmaking.

Calcined Petroleum Coke (CPC): Composition: CPC is produced from high-quality petroleum

coke through a calcining process. It is primarily composed of carbon, with carbon content typically

ranging from 95% to 99%. CPC also contains small amounts of sulfur, nitrogen, hydrogen, and

ash.

Metallurgical Coke (Met Coke): Composition: Metallurgical coke, also known as met coke or

blast furnace coke, is produced by heating specific types of bituminous coal in a coking oven. It

consists mainly of carbon, typically ranging from 60% to 65%, along with small amounts of

moisture, volatile matter, ash, and sulfur.

Nut Coke (NUT): Composition: Nut coke, also known as size coke or buckwheat coke, is

produced from metallurgical-grade coal. It is characterized by its larger size compared to other

coke types, typically ranging from 10 to 40 millimeters. Nut coke consists primarily of carbon,

17
with carbon content generally above 60-65%. It may contain small amounts of volatile matter,

sulfur, ash, and moisture.

Lime (Calcium Oxide, CaO): Composition: Lime is primarily composed of calcium oxide (CaO)

and may contain small amounts of impurities such as magnesium oxide (MgO), silica (SiO2), and

alumina (Al2O3).

Use: Lime is widely used in steelmaking as a fluxing agent and desulfurizing agent. It helps

remove impurities, promotes the formation of slag, and adjusts the chemical composition of molten

steel.

Dolomite (Calcium Magnesium Carbonate, CaMg(CO3)2): Composition: Dolomite is

composed of calcium carbonate (CaCO3) and magnesium carbonate (MgCO3) in varying

proportions. The ratio of calcium to magnesium can vary from nearly equal to predominantly

calcium or predominantly magnesium.

Use: Dolomite is used in steelmaking as a fluxing agent to improve the fluidity of the slag and

enhance the desulfurization process. It also provides a source of magnesium, which can influence

steel properties.

Calcined Lime (CaCO3): Calcined lime is essentially lime (CaCO 3) that has been heated to high

temperatures to remove any remaining carbon dioxide (CO2).

CaCO3 + heat ↔CaO + CO2 This chemical reaction produces quicklime.

Use: Calcined lime has similar applications to regular lime, serving as a fluxing and desulfurizing

agent in steelmaking. The calcination process enhances its reactivity and removes any impurities.

Other alloying elements are also used according to the need of the customer. All these have

different alloying properties and are used to make the composition of the billet good.
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 ELECTRIC ARC FURNACE

A furnace is a device used to heat materials to high temperatures for industrial processes. It

consists of a heat source and an enclosed chamber where materials are placed. Furnaces are crucial

in industries like metalworking, ceramics, and chemical processing. They vary in size, shape, and

heating methods but are designed to create controlled, elevated temperatures for various

manufacturing processes.

Electric Arc Furnace

An electric arc furnace (EAF) is a furnace that heats charged material by means of an electric arc.

Industrial arc furnaces range in size from small units of approximately one ton upto about 400 ton

units used for secondary steelmaking. Industrial electric arc furnace temperatures can be upto

1800°C. Arc furnaces differ from induction furnaces, in that the charge material is directly exposed

to an electric arc and the current in the furnace terminals passes through the charged material.

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Here, electric arc is produced between the electrodes. This electric arc is used for melting the

metal. The electric furnace is in form of a vertical vessel of fire brick. There are mainly two types

of electric furnaces. They are alternating current (AC) and direct current (DC) operated

electric furnaces.

In AC electric furnace, current flows between the electrodes through the charges in metal. In this

furnace three graphite electrodes are used as cathode. The scrap itself acts as an anode. When

compared to DC arc furnace, this is cost effective. This furnace is most commonly used in small

furnaces.

VACCUM DEGASSING UNIT

1.5 Components of Vacuum Degassing Unit
The VD (Vacuum Degassing) process is a crucial step in steelmaking that involves the removal of

impurities and gases from molten steel under vacuum conditions. During the primary steelmaking

process, gases like oxygen (O2), hydrogen (H2) and nitrogen (N2) dissolve in the liquid steel.

These gases have a harmful effect on the mechanical and physical properties of steel. Dissolved O2

from liquid steel cannot be removed as molecular O 2 and its removal is termed as deoxidation. The

term degassing is used for the removal of H2 and N2

gases from liquid steel. Since the degassing process of

liquid steel is carried out under vaccum, it is also know

as vaccum degassing of liquid steel. Vaccum degassing

processes are carried out in steel teeming ladles.From a

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Fig 1.12 :- Systematic Diagram of VD
mechanical standpoint, the VD system consists of various equipment and components that

facilitate the degassing operation.

Here's an overview of the VD process, highlighting the key components involved:

Vacuum Chamber: The vacuum chamber is a large, sealed vessel where the VD process takes

place. It is designed to withstand the vacuum conditions and high temperatures of the molten steel.

The chamber is typically made of a refractory material to handle the corrosive nature of the molten

steel and the gases released during degassing.

Vacuum Pumping System: The vacuum pumping system creates and maintains the required

vacuum level inside the chamber. It consists of vacuum pumps, valves, and piping systems that

remove air and other gases from the chamber, creating a low-pressure environment. The pumping

system is crucial for achieving and maintaining the desired vacuum conditions during the

degassing process.

Dust Catcher: The dust catcher is a component designed to capture and collect any solid particles

or dust generated during the degassing process. It helps prevent the release of particulate matter

into the atmosphere and maintains a clean working environment.

Bag Filter: A bag filter system is often employed to further remove particulate matter from the

gases extracted from the vacuum chamber. It consists of a series of fabric bags that capture and

filter out solid particles, ensuring cleaner exhaust gases before they are released into the

atmosphere.

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Pressure Equalizing Valve: The pressure equalizing valve is used to control the pressure inside

the vacuum chamber. It helps maintain the desired vacuum level and allows for the adjustment of

the internal pressure as needed during the degassing process.

Fig 1.13 :- Vacuum degassing roof

Roof: The roof of the vacuum chamber is designed to withstand high temperatures and provide a

tight seal. It helps maintain the vacuum conditions inside the chamber and facilitates the controlled

release of gases and impurities during the degassing process aslo having a hopper material addtion

if required but it’s better not to do.

Argon Purging Line: An argon purging line is often attached to the ladle before starting the VD

process. It introduces an inert gas, typically argon, into the ladle containing the molten steel. The

argon purging aids in stirring, deoxidation, and desulfurization processes, as explained earlier.

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Control Room: The VD process is typically monitored and controlled from a dedicated control

room. It houses the necessary instrumentation, control panels, and operator interfaces to oversee

and regulate the various parameters and equipment involved in the degassing operation.

Fig 1.14 :- VD Control Room Display

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 Fig 1.15:- Skid’s for Vacuum Pumping System

The combination of the vacuum chamber, vacuum pumping system, dust catcher, bag filter,

pressure equalizing valve, roof, hopper, control room, and argon purging line work together to

create the desired vacuum environment, remove impurities and gases, and enhance the quality of

the molten steel. These components ensure the efficiency and effectiveness of the VD process,

ultimately producing cleaner and more refined steel.

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25
 CHAPTER 2- PROCESS WORKING DISCUSSION

2.1 FURNACE CHARGING

The first step in the production of any heat is to select the grade of steel to be made. Usually a

schedule is developed prior to each production shift. Thus the Melter will know in advance the

schedule for his shift. The scrap yard operator will prepare buckets of scrap according to the needs

of the Melter. Preparation of the charge bucket is an important operation, not only to ensure proper

melt-in chemistry but also to ensure good melting conditions. The scrap must be layered in the

bucket according to size and density to promote the rapid formation of a liquid pool of steel in the

hearth while providing protection for the sidewalls and roof from electric arc radiation. Other

considerations include minimization of scrap cave-ins which can break electrodes and ensuring

that large heavy pieces of scrap do not lie directly in front of burner ports which would result in

blow-back of the flame onto the water-cooled panels. The charge can include lime and carbon, or

these can be injected into the furnace during the heat. Many operations add some lime and carbon

in the scrap bucket and supplement this with injection.

The first step in any tap-to-tap cycle is "charging" into the scrap. The roof and electrodes are raised

and are swung to the side of the furnace to allow the scrap charging crane to move a full bucket of

scrap into place over the furnace. The bucket bottom is usually a clam shell design - i.e. the bucket

opens up by retracting two segments on the bottom of the bucket. The scrap falls into the furnace

and the scrap crane removes the scrap bucket. The roof and electrodes swing back into place over

the furnace. The roof is lowered and then the electrodes are lowered to strike an arc on the scrap.

This commences the melting portion of the cycle. The number of charge buckets of scrap required

to produce a heat of steel is dependent primarily on the volume of the furnace and the scrap

density. Most modern furnaces are designed to operate with a minimum of back-charges. This is
26
advantageous because charging is a dead-time where the furnace does not have power on and

therefore is not melting. Minimizing these dead-times helps to maximize the productivity of the

furnace. In addition, energy is lost every time the furnace roof is opened. This can amount to 5-15

kWh/ton for each occurrence. Most operations aim for 2 to 3 buckets of scrap per heat and will

attempt to blend their scrap to meet this requirement. Some operations achieve a two bucket

charge, where first charge is taken after tapping or starting time then second charge after melting

of first charge around 4000-4500kWh power consumption, if required third charge taken at 8500-

9000kWh power consumption if third charge is not taken then DRI feeding is done.

Fig 2.1: Scrap Charging using Bucket

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2.2 SCRAP MELTING

The melting period is the heart of EAF operations. The EAF has

evolved into a highly efficient melting apparatus and modern designs

are focused on maximizing the melting capacity of the EAF. Melting

is accomplished by supplying energy to the furnace. This energy can

be electrical or chemical. Electrical energy is supplied via graphite

electrodes and is usually the largest contributor in melting operations. Initially, an intermediate

voltage tap 4 is selected until the electrodes bore into the scrap. Usually, light scrap is placed on

top of the charge to accelerate melting. Approximately 15-20% of the scrap is melted during the

initial bore-in period. After a few minutes, the electrodes will have penetrated the scrap sufficiently

so that a long arc (high voltage) tap 2 can be used without fear of radiation damage to the roof. The

long arc maximizes the transfer of power to the scrap and a liquid pool of metal will form in the

furnace hearth at the start of melting the arc is erratic and unstable.

Wide swings in current are observed accompanied by rapid movement of the electrodes. As the

furnace atmosphere heats up the arc stabilizes and once the molten pool is formed, the arc becomes

quite stable and the average power input increases.

Chemical energy is supplied via several sources including oxy-fuel burners and oxygen lances.

Oxy-fuel burners burn natural gas using oxygen or a blend of oxygen and air. Heat is transferred to

the scrap by flame radiation and convection by the hot products of combustion. Heat is transferred

within the scrap by conduction. Large pieces of scrap take longer to melt into the bath than smaller

pieces. In some operations, oxygen is injected via a consumable pipe lance to "cut" the scrap. The

oxygen reacts with the hot scrap and burns iron to produce intense heat for cutting the scrap. Once

28
a molten pool of steel is generated in the furnace, oxygen can be lanced directly into the bath. This

oxygen will react with several components in the bath Including Aluminum(Al), Silicon(Si),

Manganese(Mn), Phosphorus(P), Carbon(C) and Iron(Fe). All of these reactions are exothermic

(i.e., they generate heat) and supply additional energy to aid in the melting of the scrap. The

metallic oxides that are formed will end up in the slag. The reaction of oxygen with carbon in the

bath produces carbon monoxide, which either burns in the furnace if there is sufficient oxygen,

and/or is exhausted through the direct evacuation system also called Fume extraction System

where it is burned and conveyed to the pollution control system. Once enough scrap has been

melted to accommodate the second charge, the charging process is repeated at about 4500kWh

power consumption. Once the final scrap charge is melted, the furnace sidewalls are exposed to

intense radiation from the arc.

As a result, the voltage must be reduced. Alternatively, creation of a foamy slag will allow the arc

to be buried and will protect the furnace shell. In addition, a greater amount of energy will be

retained in the slag and is transferred to the bath resulting in greater energy efficiency. Once the

final scrap charge is fully melted, flat bath conditions are reached.

2.2.1 REFINING
Refining operations have traditionally involved the removal of Phosphorus, Sulphur, Aluminum,

Silicon, Manganese from the steel. In recent times, dissolved gases, especially hydrogen and

nitrogen, been recognized as a concern. Traditionally, refining operations were carried out

following melt down i.e. once a flat bath was achieved. These refining reactions are all dependent

on the availability of oxygen. Oxygen was lanced at the end of meltdown to lower the bath carbon

content to the desired level for tapping. Thus the oxygen will preferentially react with these

29
elements to form oxides which float out of the steel and into the slag. As a result, some of the

melting and refining operations occur simultaneously.

Phosphorus and Sulphur occur normally in the furnace charge in higher concentrations than are

generally permitted in steel and must be removed. Unfortunately, the conditions favorable for

removing phosphorus are the opposite of those promoting the removal of Sulphur. Therefore, once

these materials are pushed into the slag phase they may revert back into the steel. Phosphorus

retention in the slag is a function of the bath temperature, the slag basicity and FeO levels in the

slag. At higher temperature or low FeO levels, the phosphorus will revert from the slag back into

the bath. Phosphorus removal is usually carried out as early as possible in the heat. Hot heel

practice is very beneficial for phosphorus removal because oxygen can be lanced into the bath

while its temperature is quite low. Early in the heat the slag will contain high FeO levels carried

over from the previous heat thus aiding in phosphorus removal. High slag basicity (i.e. high lime

content) is also beneficial for phosphorus removal but care must be taken not to saturate the slag

with lime. This will lead to an increase in slag viscosity, which will make the slag less effective.

Sulphur is removed mainly as a sulphide dissolved in the slag. The Sulphur partition between the
slag and metal is dependent on slag chemistry and is favored at low steel oxidation levels.
Removal of sulphur in the EAF is difficult especially given modern practices where the oxidation
level of the bath is quite high.

Generally, the partition ratio is between 3 and 5 for EAF operations. Most operations find it more
effective to carry out desulfurization during the reducing phase of steelmaking. This means that
desulfurization is performed during tapping (where a calcium aluminate slag is built) and during
ladle furnace operations. For reducing conditions where the bath has a much lower oxygen activity,
distribution ratios for sulphur of between 20 and 100 can be achieved. Control of the metallic
constituents in the bath is important as it determines the properties of the final product. Usually,
the Melter will aim at lower levels in the bath than are specified for the final product. Oxygen
reacts with aluminum, silicon and manganese to form metallic oxides, which are slag components.
30
These metallic tend to react with oxygen before the carbon. They will also react with FeO resulting
in a recovery of iron units to the bath.

For example, Mn + FeO = MnO + Fe

DRI feeder

CaCO3 Feeder

elctrode
Power Cable

Fume Extraction Elbow

Slag Door

Fig 2.2 :- ELECTRIC ARC FURNACE

2.2.2 COKING:- Coking is an essential process in steelmaking that involves the injection of coke
into the (EAF). MET coke is used for coking. The primary reasons for coking during
steelmaking are:

Energy and Heat Generation: Coke, a form of processed coal, is used as a fuel source in the
EAF. When coke is injected into the furnace, it undergoes combustion, releasing heat energy. This
heat is crucial for raising the temperature of the furnace and melting the scrap metal or raw
materials.

Chemical Reactions: Coke also plays a role in various chemical reactions that occur during
steelmaking. The carbon content in coke reacts with impurities in the steel, such as oxygen, sulfur,
and nitrogen. These reactions help remove or reduce the levels of these impurities, improving the
quality and purity of the steel.

31
Carbon Content Adjustment: The carbon content in the steel needs to be controlled and adjusted
to achieve the desired properties. The addition of coke allows for precise control over the carbon
content. The carbon in coke acts as a carbon source, and by adjusting the amount of coke injected,
the carbon content in the steel can be adjusted accordingly.

Foam Formation and Slag Control: Coking aids in the formation of a foamy slag layer on top of
the molten metal. This foam helps insulate the molten steel, retain heat, and protect it from
oxidation. It also assists in the removal of impurities through slag formation and subsequent
removal.

Some reaction happen during coking

Combustion Reaction: C + O2 → CO2

Carburization Reaction: C + O2 → CO (carbon monoxide)

Decarburization Reaction: C + CO2 → 2CO (carbon monoxide)

2.2.3 DE-SLAGGING:- Slag removal is typically done twice, resulting in two different
types of slag: silicious slag and carbide slag. slag type and the reactions involved:

Silicious Slag: Formation: Silicious slag is formed during the initial stages of coking when lime
and other fluxes react with impurities in the molten metal, such as silica (SiO2).

Reaction: CaO(lime) + SiO2(silica) →CaSiO3 (calcium silicate)

Carbide Slag: Formation: Carbide slag is formed during the second stage of coking when coke
reacts with carbon and other elements present in the molten metal.

Reaction: The main reaction that occurs during the formation of carbide slag is the reaction
between carbon (C) and elements like oxygen (O), sulfur (S), and phosphorus (P):

 C + O2 → CO2 (Carbon dioxide)

 C + S → CS2 (Carbon monosulfide)
 C + P → CP (Carbon monophosphide)
De-slagging operations are carried out to remove impurities from the furnace. During melting and
refining operations, some of the undesirable materials within the bath are oxidized and enter the
slag phase. It is advantageous to remove as much phosphorus into the slag as early in the heat as

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possible (i.e. while the bath temperature is still low). The furnace is tilted backwards, and slag is
poured out of the furnace through the slag door.

Removal of the slag eliminates the possibility of phosphorus reversion. During slag foaming
operations, carbon may be injected into the slag where it will reduce FeO to metallic iron and in
the process produce carbon monoxide which helps foam the slag. If the high phosphorus slag has
not been removed prior to this operation, phosphorus reversion will occur.

During slag foaming, slag may overflow the sill level in the EAF and flow out of the slag door.

The following table shows the typical constituents of an EAF slag :

Table 3 .1:- Typical constituents of an EAF slag

Component Source Composition Range

CaO Charged 40 - 60 %

SiO2 Oxidation product 5 - 15 %

FeO Oxidation product 10 - 30 %

MgO Charged as dolomite 3-8%

CaF2 Charged - slag fluidizer

MnO Oxidation product 2 - 5%

S Absorbed from steel

P Oxidation product

The temperature check using Sublance Probes: Sublance probes are specialized devices used for

in-situ temperature and chemical composition measurements in the steelmaking process. These

probes consist of a lance equipped with sensors that are inserted into the furnace or ladle. The

sensors can measure temperature from LM and shows on display.

While takng the sample Aluminum wire is added to the molten steel sample during sampling in an

EAF to aid in deoxidation, modify non-metallic inclusions, ensuring accurate analysis and

improving steel quality. About 4-5 sample are taken and send to Laboratory where chemist check

the chemistry of steel sample.

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2.2.4 Tapping

Once the desired steel composition and temperature are achieved in the furnace, the tap-hole is

opened, the furnace is tilted at 15°, and the steel pours into a ladle for Secondary refining. During

the tapping process bulk alloy additions are made based on the bath analysis and the desired steel

grade. De-oxidizers may be added to the steel to lower the oxygen content prior to further

processing.

This is commonly referred to as "killing the steel". Common de-oxidizers are aluminum or silicon

in the form of ferrosilicon or silicomanganese. Most carbon steel operations aim for minimal slag

carry-over. A new slag cover is "built" during tapping. Slag forming compounds are added in the

ladle at tap so that a slag cover is formed prior to transfer to the ladle furnace. Additional slag

materials may be added at the ladle furnace if the slag cover is insufficient.

2.2.5 Furnace Turn-around

Furnace turn-around is the period following completion of tapping until the furnace is recharged

for the next heat. During this period, the electrodes and roof are raised and the furnace lining is

inspected for refractory damage. If necessary, repairs are made to the hearth, slag-line, tap-hole

and spout. In the case of a bottom-tapping furnace, the taphole is filled with EBT filling mass.

Repairs to the furnace are made using gunned refractories.

This reduces the power-off time for the EAF and maximizes furnace productivity. Furnace turn-

around time is generally the largest dead time (i.e., power off) period in the tap-to-tap cycle.

2.2.6 HEAT CYCLE

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 Table 2.2 Heat cycle of EAF

Melting & blowing tappping

Tap to tap time Approx 2.5 hour

EBT filling time 2-3 minutes

Tapping time 2.5-3 minutes

Power consumption Approx. 20000kWh

2.3 LABORATORY

The laboratory in a steel plant plays a crucial role in quality control and analysis of steel grades.
After grinding and polishing the steel samples, they are carefully prepared for testing. The samples
are labeled with their respective names or identification numbers to ensure accurate tracking.

Several machines and instruments are utilized in the laboratory for testing the composition of steel
grades. One commonly used machine is a grinder, which helps prepare the samples by removing
any surface irregularities or impurities. The grinder ensures that the samples have a smooth and
uniform surface for accurate analysis.

The primary machine used for analyzing the composition of steel samples is a spectroscopy
machine, commonly known as a spectrometer or spectrograph. It can precisely measure the
concentration of various elements present in steel, including carbon, manganese, silicon, sulfur,
phosphorus, and alloying elements like chromium, nickel, and molybdenum.

A spectroscopy machine, such as an optical emission spectroscopy (OES) instrument, analyzes

the composition of a sample based on the principle of light emission. Here's how it works:

 Sample Preparation: The sample is prepared by grinding, polishing, and cleaning the surface
to ensure a smooth and uniform surface for accurate analysis.
 Probe Placement: The spectroscopy machine uses a probe, typically made of tungsten, which
is placed in close proximity to the sample surface. The probe generates a spark or electric arc
that excites the atoms in the sample.
 Light Emission: The intense heat from the spark causes the atoms in the sample to become
excited and emit characteristic wavelengths of light. Each element present in the sample emits
a unique set of wavelengths.

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 Light Detection: The emitted light is collected by the spectroscopy machine's optical system,
which includes a prism or diffraction grating that separates the different wavelengths of light.
The separated light is then detected by a detector.
 Spectrum Analysis: The detected light is converted into electrical signals and analyzed by the
spectroscopy machine's software. The software compares the detected wavelengths to known
standards or a pre-calibrated database to determine the composition of the sample.
 Display and Matching: The spectroscopy machine displays the composition of the sample on
its display screen. The displayed chemistry represents the concentration of different elements
present in the sample. The heat of the sample can also be monitored to ensure it matches the
desired temperature range.

To perform two tests on a sample with a distance of 4-5 mm on the side of the cross-section, the
probe is positioned at the first test point and the spectroscopy machine performs the analysis. The
probe is then moved to the second test point, maintaining the desired distance, and the analysis is
repeated.

The accuracy of the composition analysis is typically validated by comparing the results to
standard samples provided by organizations such as the Bureau of Indian Standards (BIS) or the
International Organization for Standardization (ISO). These standards ensure the accuracy and
reliability of the spectroscopy machine's measurements.

The LECO CS/O/N/S Analyzer is used to test the oxygen, nitrogen, carbon, and sulfur content in
materials. It employs combustion and infrared detection techniques to measure these elements.
Oxygen is determined by weight reduction, nitrogen by thermal conductivity, carbon by infrared
detection of carbon dioxide, and sulfur by trapping and measuring sulfur dioxide gas. The analyzer
provides fast and reliable results for quality control and research purposes.

RAW MATERIAL TETSING

In the laboratory, the efficiency of raw materials such as scrap and alloys in steel production is
assessed through chemical analysis. Representative samples are collected from the production
process and prepared for testing. Various techniques, including wet chemical analysis, X-ray
fluorescence (XRF), are used to determine the composition and quality of the materials.

Wet chemical analysis involves dissolving a small portion of the sample and conducting a series of
reactions to measure specific elements or compounds. XRF is a non-destructive method that uses
X-rays to analyze the elemental composition of the sample.

The obtained data from the chemical analysis is compared to established specifications or
standards. This comparison helps evaluate the efficiency of the raw materials by checking if they

36
meet desired element concentrations or allowable impurity levels. Deviations from the desired
composition may indicate the need for adjustments or potential issues with the raw materials.

By assessing the composition and quality of raw materials in the laboratory, steel producers can
maintain process control, ensure product quality, and optimize the steel production process.

Samples are taken from EAF, LRF and after VD and final chemistry after casting are test here in
lab. During Refining about 4-5 samples are taken according to report alloys addition is done to
adjust the chemistry of steel grades as per customer demand.

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 CHAPTER 3:- RESULTS AND DISCUSSION

The training aimed to provide a comprehensive understanding of the steel manufacturing process,

including practical knowledge of the entire process from raw material to the final product. This

involved various aspects such as steelmaking, steel chemistry adjustment, and quality control.

 Steelmaking Process: During the training, the steelmaking process was observed and studied

in detail. The raw materials used in steelmaking, including iron ore, coal, and limestone, were

analyzed for their composition and properties. The different stages of steel production, such as

charging of materials, melting, refining, and casting, were closely observed. The various

furnaces and equipment utilized in the process were studied, and their functions and operating

parameters were noted.

 Steel Chemistry Adjustment: A significant aspect of the training involved understanding the

adjustment of steel chemistry to meet specific requirements. The importance of alloying

elements, such as carbon, manganese, silicon, and chromium, in determining the properties of

the final steel product was emphasized. Practical demonstrations of adjusting the chemical

composition of steel through the addition of various alloys and additives were observed. The

impact of these adjustments on the final product's mechanical properties, such as tensile

strength, hardness, and ductility, was examined.

 Quality Control: Quality control measures were an integral part of the training. The

procedures and techniques employed for monitoring and ensuring the quality of steel

throughout the production process were explored. This included the sampling and testing of

steel samples to assess their chemical composition. Attention was also given to the

identification and prevention of potential defects and issues that could arise during steel

production.
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 Practical Knowledge: The hands-on experience gained during the training was invaluable in

developing a practical understanding of the SMS operations. The opportunity to observe and

engage in the different tasks associated with steelmaking, including charging of materials,

tapping of molten steel, and handling of refractory materials, provided a comprehensive view

of the entire process. The practical knowledge acquired will contribute to improved decision-

making and troubleshooting skills in a real-world industrial setting.

The training in the SMS highlighted the complex and intricate nature of the steel manufacturing

process. It underscored the importance of precise control over various parameters, such as

temperature, composition, and casting techniques, to achieve the desired steel properties.

Furthermore, the training emphasized the significance of teamwork, communication, and

adherence to safety protocols in ensuring efficient and safe operations within the SMS.

Overall, the training in the SMS provided a thorough practical understanding of the steel

production process. The experience gained through observation, participation, and analysis of the

different stages and aspects of steelmaking will be instrumental in enhancing professional

competence and contributing to the advancement of steel manufacturing practices. The insights

gained from this training will be invaluable in future endeavors within the steel industry.

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 CHAPTER 4:- CONCLUSION AND FUTURE SCOPE

4.1 CONCLUSION

The training conducted at the steel melting plant provided valuable insights into the steel melting

process, efficiency, productivity, quality control, and safety measures. The findings from the

training indicate that the plant is equipped with efficient electric arc furnaces (EAFs) for melting

scrap steel and producing high-quality molten steel. The implementation of measures such as

process automation and advanced control systems has enhanced operational efficiency and

productivity within the plant. Additionally, the plant has demonstrated a strong commitment to

safety, with robust safety protocols in place to ensure the well-being of employees.

The emphasis on quality control procedures has resulted in the production of steel that meets the

required specifications and standards. The training has highlighted the importance of continuous

improvement initiatives to address challenges and optimize various aspects of the steel melting

process. Overall, the training has provided a comprehensive understanding of the operations and

practices within the steel melting plant.

4.2 FUTURE SCOPE

Based on the training and discussions, several areas for future improvement and exploration have

been identified:

Energy Efficiency: The plant can focus on further optimizing energy consumption during the steel

melting process. Exploring energy-efficient technologies and implementing advanced monitoring

systems can help in reducing energy usage and minimizing the environmental impact.

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Process Optimization: Continuous improvement initiatives can be undertaken to optimize various

aspects of the steel melting process. This can involve refining operating parameters, enhancing

furnace performance, and streamlining production workflows to maximize efficiency and

productivity.

Sustainable Practices: The plant can explore the integration of sustainable practices, such as the

use of renewable energy sources, waste heat recovery systems. These practices can contribute to

reducing the plant's environmental footprint and promoting sustainable steel production.

Research and Development: Investing in research and development activities can lead to

technological advancements and innovations in the steel melting process. This can include the

development of new refractory materials, improvement of furnace design, and exploration of

alternative steelmaking techniques.

Training and Skill Development: Continuous training programs and knowledge sharing

initiatives should be implemented to enhance the skills and expertise of employees. This will

ensure that the workforce is equipped with the necessary knowledge to adapt to evolving industry

trends and technologies.

By focusing on these, plant can further enhance its efficiency, productivity, and sustainability,

positioning itself as a leader in the steel industry.

In conclusion, the training has provided valuable insights into the steel melting plant's operations,

efficiency, productivity, quality control, and safety measures. The plant can build upon these

findings to implement improvements, optimize processes, and embrace sustainable practices. By

doing so, the plant can strengthen its competitive position, ensure long-term viability, and

contribute to the advancement of the steel industry as a whole.

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REFERENCES

1. Singh, S., Kumar, A., & Gupta, R. (2019). Energy Optimization in Electric Arc Furnace

Steelmaking: A Review. Journal of Cleaner Production.

2. Yeliz, B., Demir, A., & Turan, O. (2020). Enhancing Productivity in Steel Melting Plants

through Process Automation.

3. American Iron and Steel Institute. (2018). Steel Industry Technology Roadmap. Retrieved

from https://www.steel.org/steel-markets/steel-technology/roadmap.aspx

4. Kim, D. H., Lee, K. S., & Kim, S. S. (2017). Quality Control in Steelmaking Process

through Advanced Monitoring and Control Systems. Journal of Iron and Steel Research.

5. https://www.google.com/

6. https://www.aartisteelsltd.com/

7. https://www.vaibhavfurnaces.com/

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