| Products / Coil & Bar / Quality & Testing / Straight Length |
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We practice a Total Productive Maintenance philosophy in all activities to achieve zero defects and zero failures. Dedicated product development and quality improvement teams have been formed to work closely with customers to continuously fine tune our final products and upgrade our quality norms, thus resulting in reduced process loss, reduction in rejection rates and productivity improvement at the customers' end.
Our quality process are ISO 9002 certified. The stepwise checks performed right from raw material stage to round bar/ flat bar supply to ensure stringent quality standards are as follows :
Raw Material Stage
Commitment to quality starts right from the raw material stage. The primary raw materials - iron ore, coke, and limestone are selected after meticulous chemical and fractional size analysis. Further, reputed independent inspection agencies periodically screen and select the best quality vendors. |
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Mini Blast Furnace |
| Operations of the MBF are controlled by a state of the art PLC driven control system thus ensuring a hot metal output that is consistent and repeatable in its properties. The furnace utilizes a low Silicon hot metal suitable for steel making. Typical Hot Metal chemistry is as follows : |
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% Carbon= 4.3 |
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% Manganese = 0.20 |
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% Silicon = 0.80 |
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% Sulphur = 0.07 |
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% Phosphorus = 0.12 |
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| Steel Melting Shop |
| The Mini Blast Furnace - Arc Furnace process route ensures steel with minimal tramp elements and low gaseous content. Close monitoring at the Electric Arc Furnace, Ladle Furnace and Vacuum Degassing station controls the chemistry. It is further verified through our fully equipped testing facilities that include sophisticated instruments like optical emission Spectrometer & carbon sulpur analyzer. Some Specific techniques followed at the Steel melting shop for clean steel are : |
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Continuous argon purging in Ladle. |
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Cored Wire Injection in Ladle. |
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Vacuum Degassing treatment for special grades as required. |
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| Some of the characteristics of high quality steel produced are : |
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Low tramp level (Cr + Ni + Cu = 0.10% max). |
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Low gaseous content (Nitrogen - 70 PPM max). |
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Low sulphur (0.025% max.) and low phosphorus (0.025% max.). |
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Clean steel by modified inclusion morphology. |
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Casting |
During casting, the hot metal stream is protected from atmospheric contamination by a ladle shroud and a bellow shroud or submerged entry nozzle as applicable. An Electromagnetic stirrer in the mould and proper lubrication including usage of superior quality granulated fluxes ensure a defect free as cast billet surface. Few highlights of this process are :
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Electromagnetic Stirrer in mould. |
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Intensive secondary cooling. |
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Equiaxed grain structure at billet core. |
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Superior surface finish of billets. |
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| Further to prevent segregation and remnant defects, the first and last billets of any casting sequence are discarded. |
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Final Inspection |
A fully developed infrastructure exists for conducting final inspection tests as per customer specifications and international norms.
Following are the inspections conducted.
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Dimension checking (size, length, ovality and tolerance). |
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Decarburisation. |
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Surface Defect. |
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Surface Condition. |
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Microstructure analysis. |
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Hardness. |
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Step Down Test (on specific request by the customer). |
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Jominy Hardness (on specific request by the customer). |
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Bundling. |
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Macro. |
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| All other physical and metallurgical test are performed as per customer specifications. |
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