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Melt Shop and CCM (Continuous Casting Mills)


Secondary metallurgy has become an essential step for high quality steel production. A significant advancement in quick & efficient secondary steel making processes have propelled a newer direction for improvement in refractories used for this process. The purging of inert gas has become an integral part of modern steel making process for the production of high quality products.

Tap to Tap Time

This is a measure of productivity in electric arc furnace (EAF) steelmaking. It defines the time it takes to complete a melting cycle from the end of emptying (tapping) the molten steel produced in one melting operation to completion of tapping the steel from the next one.

Tundish Jam

Gunning mass and tundish slag are commonly used in this part of the steelmaking process. Rice husk ash (RHA) can be used along the tundish slag to prevent thermal loss. With the objective to study the formation of inclusions by reoxidation in the tundish, and the effects caused by the addition of RHA, the materials commonly used in the tundish were evaluated.

Tapping Temperature

Tapping can be done on 1630d°C instead of 1650°C. While taking temperature at 10,000 KW power & with 28 MT metal total rise in temperature is 15 °C in 1 minute. By reducing tapping temperature of molten metal by 20°C then we can save 48 sec for total power 16,500 KW in one heat.

Shortening of Billets End Cuts

During rolling of long products in continuous or semi-continuous mills, end splitting (alligatoring, split ends) and central bursting may occur, with an impact on productivity and quality. This phenomenon may occur in the roughing passes of the roughing mil, particularly in open mills. Steel grades affected include free cutting steel, rebar, wire rod and shapes. This problem is also known in flat rolling of steel and aluminum. At times, central bursting may occur simultaneously with end splitting or separately. Cobbles may arise as a consequence of the splitting.

Reporting Formats for Cost Control and Data Analysis

The report formatting and data analysis will be depends on the all processes of formation of required products. The data analysis includes its inspection and quality control.

Checklist for Maintenance

Heavy Machinery is the most expensive construction equipment you own. It’s also the costliest to repair or replace. This guide will show you how to save money and extend the life cycle of your equipment with regular maintenance best practices.

We’ll identify commonly overlooked areas of maintenance, and identify simple things you can do to greatly impact the long-term value of your most vital equipment. Even the most powerful and dependable Cat® machinery requires basic attention to ensure it provides the exceptionally long service life and unmatched productivity of construction vehicles.

Tundish and Ladle Weighing System

Tundish and Ladle weighing system includes applications such as overhead crane weighing, car weighing, turret tower weighing and casting process weighing. All of these face high impact forces, harsh environment and extreme temperature. Tundish and ladle weighing based on very robust and high temperature compensated load cells and weigh modules combined with transmitters and indicators, including wireless options.

Recovery of Ferro Alloy

Alloy recovery plays an important role in steel melting economics because the cost of alloying additives such as ferroalloys and pure non-ferrous metals is significantly higher than the cost of steel scrap. Recovery of alloying additives also influences the reproducibility of steel properties from heat to heat. Melting and alloy practices were observed for several plant trial heats in each of the foundries. Alloying and chemistry data were collected for additional 20 – 155 heats at each plant. The recovery of alloying additives depends on the type of furnace and individual foundry practices.

Modification in Chamber/Apron

In a roll bearing machine having an apron movable in suitable manner to form roll bales of crop material and air springs for maintaining tension in the apron, a method of adjusting the apron tension is disclosed. The method comprises adjusting the air pressure in the air springs to any desired level within a predetermined range.

Separation wall of Strands

The tundish as a part of a continuous casting machine combines the discontinuous ladle metallurgy with the continuous solidification of slabs in the mould. The tundish plays a major role in the challenging task of “clean steel” production. That means the smallest number of inclusions and high cleanliness in all steel grades after changing the conditions at the inlet of the tundish. Inclusions hinder the metal forming process and lead often to fatigue. The cleanliness of steels is important to fulfil the customer’s requirements. In the present study inclusion removal was simulated in a 1:3 scaled water model of a single-strand tundish for the production of stainless steels with a particle counter.

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© 2020 Al Rehman International. Developed by ANIFAR

© 2020 Al Rehman International. Developed by ANIFAR