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Manufacturing  
 
 
Technical details regarding certain key processes are explained below:
 
Manufacturing Process of Existing Billet Manufacturing Unit
 
To make stainless steel, the raw materials — scrap is melted in an electric induction furnace. This molten scrap is transferred to the AOD unit where the other raw materials such as iron scrap, chromium, silicon, nickel, etc are added. This step usually involves 8 to 12 hours of intense heat. Next, the mixture is cast into one of several shapes, including blooms, billets, and slabs
 
Manufacturing Process of Existing Bright Bar Unit
 

Once Bars/Rods are rolled out of the Rolling Mill, they can be sent to the Bright bar unit for the following processes:

Annealing: Annealing restores ductibility and removes residual stress from processed metals. We have 2 pot furnaces as well as an in-line strand annealing to enable us to produce intricate shapes without overly taxing the material.

Pickling: The pickling process may be broken into two sections: mechanical scale breaking and chemical pickling. The surface of the strip is flexed and stretched so that the scale is cracked, which allows the hydrochloric acid to penetrate to the substructure (richer in iron) dissolving the scale (iron oxide) from the strip surface. The reaction between the hydrochloric acid and the scale is complex but the end result is that the scale is almost completely removed in the acid.

Rinsing: Following the pickling of the strip, the residue of acid solution on the surface is removed prior in the dip and rinse spray tanks. The strip then passes through a set of squeeze rolls and a hot air drier.

Coating: Post Rinsing the strip is coated using borax, lime, phosphate, and reactive lubes.

Cold Drawing: Cold drawing forms metal wire from a pre-rolled or pre-drawn condition into a secondary or final shape by pulling it through precision draw dies.

Straightening: Two different strengtheners that can handle a wide variety of shaped straightening are used. In addition, heat treated bars can be straightened directly off of the heat treat line.

Cutting: The Finished Bright Bars are now sent for cutting depending on customer specifications.

 
Manufacturing Process of the Proposed Rolling Mill
  • Billets are either moved to the platforms of shearing machines or are cut into pieces of smaller lengths by oxy-acetylene torches. Pneumatically operated shearing machines shear the billets into smaller sizes.

  • Sheared billets are piled over one another manually and these piles are picked by overhead crane that lifts it to the raised platform of pusher. Billets are placed manually in front of pusher. Pusher then pushes the billets into the furnace.

  • In furnace billets are heated to over 1200 degree Celsius. When billets reach the other end of the furnace they are hot enough to be rolled.

  • Red-hot billets are then pulled from the furnace on to the conveyor, which transports it to the rolling stand. After passing through rolling stands several times (depending upon the type of bar required) they are taken to the cooling bed. Bars rolled by the 18” mill are transported to the cooling bed by conveyor

  • Bars are air-cooled while on cooling bed. Chains carry the bars and transport them at snail’s pace to the conveyor. Slow speed of chains allows sufficient time for bars to cool down. Cooling bed adjacent to 18” mill drops the bars on to a conveyor which takes them to the bar yard. The other cooling bed drops them directly in to the bar yard without employing any conveyor.