The Bar cum Wire Rod Block is state-of-the-Art having the latest technological features capable of guaranteeing better dimensional accuracy, straightness and quality of the finished product. Mill guarantee's an increase in material yield and an increase in plant utilization rate with the aim of increasing the output and reducing production costs.
Mill is equipped with the following features:
High quality of product repetitively and consistently.
High outputs even in case of small lots i.e. frequent changes in grades and billet / bloom sizes.
Shall be easy to operate and shall allow fast learning curves by the operators and short time for achieving full production capacity.
Use of optimum automation levels aimed at improving plant efficiency and utilization and product quality with minimum operation personnel.
Annual Production
Approx. 300,000 tons per annum of rolled products
Bar and wire rod Mill
Make Bejing Shougang
Bar Mill
Continuous Mill, Fixed Pass Line
Wire Rod Mill
Garret Coiler Line
Automation
Level I
Steel Grades
Alloy Steels
Cold Heading Quality
Ball Bearing Steel
Free Cutting Steel
Semi-free cutting steel
High Carbon Steel
Electrode Quality
Spring Steels
Mild Steel
TMT Rebar grade
Feed stock
Billets : 160 mm sq. x 6 m long billets
Products
TMT Rebar: 16 – 40 mm Dia. Rebars on Rod Mill: 8 to 12 mm. Rounds / RCS: 20 – 63 mm Dia. Spring Steel Flats : 50 x 5 to 70 x 12 Wire Rod: 5.5 to 16 Mm Dia.
Cooling Bed
66 Mtr long Rack type
Bar Length / Bar Bundle weight
12 m / 2 t & 5 t
Roll pass profiling
Inhouse with CNC machines
SALIENT FEATURES of Re-Heating Furnace
a.
The furnace will be arranged for side charging & side discharging to reduce heat losses
b.
26 Meter roller table of 26 Meter length shall be provided for transporting the material to charging rack.
c.
Walking beam typecharging grate having a holding capacity of forty(40) billets shall be provided.
d.
From charging rack, the billets will be delivered one by one to the approach charge roller table (16 Meter). Billets will then be driven inside the furnace by means of water cooled charge rollers placed in between walking hearth.
e.
The walking hearth of the furnace will take the materials through the furnace length and move the same on to discharge end and billets will be discharged from one side with the help of water-cooled discharge rollers.
f.
In order to achieve better temperature uniformity of the billet, the furnace will be designed with three(3) Nos. independent thermal control zones, namely for two(2) nos. heating zones and one(1) no. soaking zone. There will be another unfired preheating recuperative zone to preheat cold Billets.
g.
The furnace will be equipped with Wesman North American Dual Fuel (Oil/Oil-Producer Gas) Refractory Lined Magnaflame Burners, specially suitable for steel reheat furnaces. These burners can easily handle air preheat temperature upto 350°C. Wide operating pressure range of these burners shall ensure high turndown ratio without any difficulty. This will ensure stable burner operation even at lower furnace output. Producer Gas should be free from Tar, Dirt and Solid Particles content for trouble-free operation. Gas Pipes, Fittings & Valves are to be cleaned periodically at regular intervals.
h.
We have provided a convection type multi tubular recuperator for preheating the combustion air upto 350°C from the flue gas leaving the furnace. Therefore, the furnace would be very effectively designed in terms of fuel economy
i.
The furnace zone temperature will be automatically controlled through PLC-PC based system. In order to maintain positive pressure in the furnace, furnace pressure will also be controlled through PLC-PC
j.
Complete interlocking & sequential control of the furnace with respect to furnace charge door, charge rollers, discharge door, and discharge rollers will also be carried out through Programmable Logic Controllers (PLC) of reputed make complete with control processors, power supply module, I/O module and digital input as well as off-line programmer
k.
The furnace shall be provided with two(2) nos. CCTV Cameras – one(1) for the charging end and other for discharging end for viewing the charge materials on the roller tables. The pictures shall be transmitted to the control room on two(2) nos. 14” TV Screens.
l.
The furnace shall be provided with an on-line oxygen monitoring system. The system shall be connected to PLC and shall raise an alarm in case the free oxygen percentage in the combustion products cross a safe set value.
PRODUCTS TO BE HEATED
Type of Furnace
Walking Hearth Type Billet Reheating Furnace
Fuel to be used
Furnace Oil /70% Producer Gas supported by 30% Furnace Oil [ Burner = Dual Fuel; suitable for FO / LDO / Producer Gas ]
Material to be charged
Low / medium / high carbon steel / mild steel / ball bearing steel / spring steel / free & semi-free cutting steel
Number of Charge Row
Single
Billet Dimensions :-
Width
Height
Length
160 mm. 160 mm. 6,000 mm. – single row
Temperature of Material to be charged
Cold stock (ambient temperature 300C.)
Maximum Furnace Temperature
1280 deg.C.
Billet Discharge Temperature
1230 deg.C. (max.)
Temperature Differential Across Billet
+10 deg.C.
Combustion Air Preheat
350 deg.C.
System of Heating
By direct firing with dual fuel burners
Type of Burner
Wesman North American Magnaflame dual Fuel Burners suitable for firing furnace oil/Furnace Oil & Producer Gas
Number of Walking Hearth
Two(2)
Number of Temperature Control Zone
Three(3)
Type of Control :-
For Furnace Pressure Control
For Zone Control
For Sequential Operation
Automatic through PLC-PC based system Automatic through PLC-PC based system – Control shall be achieved through Furnace Oil, Producer Gas flow control shall be manual. Through PLC
Fuel Usage
For the rated production based on reference size ingot, the expected specific fuel consumption in case of 100% Furnace Oil Firing would be 0.32 X 106 K Cal/MT while discharging reference size billets at 1230 deg.C. for cold charging for normal continuous production rate of 45 Ton per hour
Connected Fuel Load :- based on furnace oil having a calorific value of 10000 K Cal /Kg.
18.0 X 106 K Cal/hour
Utilities Requirement :- [To be provided by Purchaser]
Furnace Oil
1800 Kgs./hour based on 100% oil having a calorific value of 10,000 K Cal/Kg.
Producer Gas
12000 M3/hour of Producer Gas with a calorific value of 1100 Kcal/Nm3 supplied at a pressure of 1000 MMWG within a distance of 5 Meters of burners.
Water :- - Indirect Cooling [soft water] - Direct Cooling [untreated water] - Emergency Water Supply [ in case of normal water supply failure this emergency water shall be supplied for 8 hrs. for safe shut-down
40 M3/hour at 3.5 Kgs./cm2 at 350C. 25 M3/hour at 3.5 Kgs./cm2 at 350C. 40 M3/hour at 3.5 Kgs./cm2 at 350C.
Electric Power
415V, 3-phase, 50 c/s. AC supply excepting control circuit for which 110V, single phase, AC supply For Instruments : 220 / 240V or 110 / 120V supply
Installed connected load(without stand by)
408.1 KW
Installed Capacity (with stand by)
601.8 KW
Compressed Air ( approximate)
7 NM3/hour at 5 – 6 Kgs./cm.sq.(g) For cleaning purpose to be made available from the shop compressed air line system.
