Chandan Steel Plant & production process

Summary

Chandan Steel Limited's manufacturing process begins with high-quality recycled steel, ensuring thorough inspection and radioactivity testing. The steel undergoes melting and refining to remove impurities in induction furnaces and AOD vessels. Emphasis on environmental protection includes exhaust gas filtration and dust extraction. The production line features continuous casting, rolling mills, and forging divisions, all adhering to strict quality checks and employing advanced technology for precision machining. The plant also specializes in seamless tube manufacturing, with a focus on quality, environmental impact, and customer-specific packaging.

Takeaways

• 🚀 Chandan Steel Limited starts the manufacturing process with high-quality recycled steel, ensuring the steel is sourced from certified suppliers and free from hazardous elements.
• 🔍 The company performs a radioactivity test on the stainless steel scrap to confirm its quality before processing.
• 🔥 The steel scrap is melted in a 20-ton induction furnace, followed by refining in a 25-ton argon oxygen decarburization vessel to remove impurities and reduce carbon content.
• 🌿 Environmental protection is a priority, with exhaust gases from the furnace and AOD being filtered and dust extracted to maintain clean air standards.
• 📊 Quality control is rigorous, with melt samples being collected and analyzed at various stages to achieve the desired chemistry.
• 🔩 The liquid steel is cast into various sizes of billets and blooms using a double strand continuous casting machine, ensuring traceability of all heat regards.
• 🔨 The billets are checked for macro structure, and samples are preserved before being transferred to versatile rolling mills for size reduction and shaping.
• 🛠️ Hot-rolled round bars undergo a series of processes including straightening, peeling, drawing, grinding, and polishing in the prybar division.
• 🧪 Post-rolling, sections are annealed, straightened, and subjected to pickling in acid tanks for further processing and quality enhancement.
• 🏭 The forging division operates with the highest capacity under one roof, ensuring strict quality checks and precision monitoring with the latest technology.
• 📏 The final products undergo a series of quality checks, including mechanical and metallic tests, visual inspections, and non-destructive tests to meet specification compliance.
• 🚢 The seamless tube and pipe division is India's only fully integrated plant for manufacturing high-quality stainless steel tubes, emphasizing international standards and environmental impact.

Q & A

What type of raw material does Chandan Steel Limited start with for its manufacturing process?

Chandan Steel Limited starts with high-quality recycled steel, which is thoroughly inspected and sourced from certified suppliers to ensure the removal of hazardous elements.

What tests are conducted to confirm the quality of the stainless steel scrap at Chandan Steel Limited?

Radioactivity tests are carried out to confirm the quality of the stainless steel scrap, ensuring it meets the required standards.

What is the purpose of the 20-ton induction furnace in the manufacturing process at Chandan Steel Limited?

The 20-ton induction furnace is used for melting the stainless steel scrap, which is a crucial step in the manufacturing process.

How does Chandan Steel Limited refine the melted steel to remove impurities?

Refining is done in a 25-ton argon oxygen decarburization vessel, which helps to remove impurities and reduce carbon to the design levels.

What measures are taken to ensure environmental protection during the manufacturing process at Chandan Steel Limited?

Environmental protection is given high importance by processing exhaust gases from the furnace and AOD into the back house, where gases are filtered and dust is extracted.

How does Chandan Steel Limited maintain traceability in the production process?

Traceability is ensured by maintaining all heat regards and collecting and analyzing melt samples at various stages to achieve the desired chemistry.

What type of casting machine does Chandan Steel Limited use to produce various sizes of Willits and blooms?

Chandan Steel Limited uses a six by eleven double strand continuous casting machine for producing various sizes of Willits and blooms.

How are the cast billets checked for quality at Chandan Steel Limited?

The cast billets are checked for macro structure, and samples are preserved to ensure quality throughout the manufacturing process.

What types of products can be produced by the versatile rolling mills at Chandan Steel Limited?

The versatile rolling mills at Chandan Steel Limited are capable of producing a wide range of products, including round, hexagon, square shapes, and sections like angles, flattened channels, and tee sections.

What is the process for quality checks on the finished products at Chandan Steel Limited?

Finished products undergo quality checks for specification compliance, and quality and grades are rechecked using a BMI test facility, mechanical and metallic Rafi tests, followed by visual inspection.

How does Chandan Steel Limited ensure the quality of raw materials received in the forging division?

Every order received in the forging division first goes through Quality Assurance and is monitored with an Enterprise routing program, ensuring the raw materials are suitable for further processing.

Outlines

00:00

🔧 Steel Manufacturing Process at Chandan Steel Limited

Chandan Steel Limited's manufacturing process begins with the selection of high-quality recycled steel from certified suppliers. The steel undergoes a rigorous inspection to remove hazardous elements and is tested for radioactivity. The stainless steel scrap is melted in an induction furnace and refined to remove impurities using an argon oxygen decarburization vessel. Environmental protection is emphasized through the processing of exhaust gases. Melt samples are analyzed to achieve the desired chemistry, and the liquid steel is cast into various sizes using a continuous casting machine. The billets are checked for macro structure and then processed in versatile rolling mills to produce different shapes. The products undergo quality checks, including mechanical and metallic tests, before being sent to the forging division, which operates under strict quality assurance.

05:04

🌐 High-Quality Seamless Stainless Steel Tube Production

Chandan Steel Limited also specializes in the production of high-quality seamless stainless steel tubes and pipes, being India's only fully integrated seamless tube plant. The plant receives thoroughly inspected billet bars with controlled delta ferrite content. These bars are cut and drilled to achieve a better inner diameter finish. The billets are then heated uniformly and pierced using glass lubrication and molybdenum plugs for improved surface finish. The pierced bars are straightened, pickled, and ground. High-speed cold drawing machines and decreasing setups are used for better surface finish and dimension control. The tubes undergo solution annealing, straightening, and various testing processes including ultrasonic, eddy current, hydro, and underwater testing for quality assurance. The final products are visually inspected, undergo destructive testing, and are硬度 checked for compliance before being packed for shipment according to customer requirements.

Keywords

💡Recycled Steel

Recycled steel refers to the steel that is obtained from melting and reprocessing scrap metal. It is a crucial aspect of sustainability in the steel industry. In the video's context, Chandan Steel Limited starts its manufacturing process with high-quality recycled steel, emphasizing the company's commitment to environmental responsibility by using only the best scrap from certified suppliers.

💡Radioactivity Test

A radioactivity test is a procedure used to determine the presence of radioactive materials in a sample. In the script, Chandan Steel conducts radioactivity tests to confirm the quality of the stainless steel scrap, ensuring that the recycled material is safe and free from hazardous elements, which is vital for maintaining product integrity and safety standards.

💡Induction Furnace

An induction furnace is a type of furnace that heats materials with an electromagnetic field, which is highly efficient for melting metals. The video mentions a '20-ton induction furnace' used by Chandan Steel for melting the stainless steel scrap, highlighting the company's use of advanced technology in its production process.

💡Argon Oxygen Decarburization (AOD)

Argon Oxygen Decarburization is a metallurgical process used to reduce the carbon content in steel. The script describes the use of a '25-ton AOD vessel' for refining, which is essential for removing impurities and achieving the desired chemistry in the steel, contributing to the production of high-quality steel products.

💡Environmental Protection

Environmental protection is the practice of preserving the natural environment by minimizing harmful human impact. The video script highlights Chandan Steel's commitment to environmental protection by mentioning the careful handling of exhaust gases and the extraction of dust during the manufacturing process, showcasing the company's efforts to reduce its ecological footprint.

💡Continuous Casting Machine

A continuous casting machine is used to solidify molten metal into a continuous strand for further processing into various shapes. The script refers to a 'six by eleven double strand continuous casting machine' at Chandan Steel, which is indicative of the company's capability to produce a wide range of steel products with different dimensions.

💡Macro Structure

Macro structure refers to the visible features of a material on a scale that is large enough to be seen with the naked eye. In the context of the video, the macro structure of the cast billets is checked, which is an important quality control measure to ensure that the steel has the desired physical properties before it is further processed.

💡Versatile Rolling Mills

Versatile rolling mills are used to reduce the size of metal billets and shape them into various forms. The script mentions that Chandan Steel's mills are capable of producing a wide range of products, demonstrating the company's versatility in steel production and its ability to meet diverse customer needs.

💡Forging Division

A forging division is a part of a manufacturing facility that specializes in the process of forging, which involves shaping metal through the application of force. The video script describes Chandan Steel's forging division as having the highest capacity under one roof, indicating the company's significant capabilities in producing forged steel products.

💡Seamless Tube

A seamless tube is a long, hollow cylinder made without a seam. The script discusses Chandan Steel's seamless tube and pipe division, which is engineered to manufacture high-quality stainless steel tubes to international standards, emphasizing the company's expertise in producing precision steel products.

💡Quality Assurance

Quality assurance is a process that ensures products meet certain standards of quality. The video script mentions that every order at Chandan Steel goes through Quality Assurance, which is a critical step in ensuring that the final products are of the highest quality and meet customer specifications.

Highlights

Chandan Steel Limited's manufacturing process begins with the selection of high-quality recycled steel from certified suppliers.

Hazardous elements and radioactivity are carefully removed and tested to ensure the quality of stainless steel scrap.

Melting of stainless steel scrap is done in a 20-ton induction furnace, followed by refining in a 25-ton argon oxygen decarburization vessel.

Environmental protection is prioritized, with exhaust gases from furnaces and AOD being filtered and dust extracted.

Melt samples are analyzed at various stages to achieve the desired chemistry and maintain traceability.

Liquid steel is cast using a six by eleven double strand continuous casting machine to produce various sizes of billets and blooms.

Ingot casting is performed depending on the end product requirements.

Billets are checked for macro structure and samples are preserved for quality assurance.

Rolling mills are capable of producing a hundred thousand metric tons of role products per annum.

Hot rolled round bars undergo straightening, peeling, drawing, grinding, and polishing processes.

Sections like angles, flattened channels, and tee sections are made from preheated billets using cross-country rolling mills.

Quality checks for specification compliance and mechanical properties are performed using BMI test facilities.

Forging division operates under the highest capacity in India, with orders monitored by an Enterprise routing program.

Raw materials undergo strict quality checks before being processed on fully automatic sharing machines.

Forgings are heat treated using a fully automatic furnace to achieve mechanical properties as per relevant specifications.

Precision machining is carried out using CNC machines to ensure close adherence to standard dimensions.

Seamless tube and pipe division is India's only fully integrated stainless steel seamless tube plant.

Bars are cut and deep hole drilled to achieve better ID finish before entering the calibrated walking beam furnace.

Hot piercing process is adapted with indigenous technology for improved surface finish and reduced stress deformation.

Tubes undergo online and offline decreasing, solution annealing, and straightening for uniform heating and desired straightness.

Final inspections include PMI tests, non-destructive tests, and dimensional checks as per applicable standards and QAP.

Quality team approval is required before the material is packed for overseas shipment or domestic supply.

Transcripts

[Music]

welcome to Chandan Steel limited

at Chandan steel manufacturing starts

with the right perches of recycled steel

only high quality scrap is bought from

certified suppliers it is thoroughly

inspected and hazardous elements are

carefully removed radioactivity test is

carried out to confirm the quality the

stainless steel scrap is then

transferred to 20-ton induction furnace

for melting refining is done in 25 ton

argon oxygen decarburization vessel to

remove impurities and carbon is brought

down to the design levels environmental

protection has given high importance by

further processing exhaust gases of

furnace and aod into the back house when

gases filter and all the dust is

extracted melt samples are collected and

analyzed at various stages to achieve

the desired chemistry all heat regards

are maintained to ensure traceability

the liquid steel is transported to six

by eleven double strand continuous

casting machine to produce various sizes

of Willits and blooms

ingot casting is also done depending on

the end product the cast billets are

been checked for macro structure and

samples are preserved the billets are

transferred to for versatile rolling

mills capable of producing a hundred

thousand metric tons role products per

am the preheated billets are rolled with

the help of cross country rolling mills

where size reduction is done and feed

his shapes like round hexagons square

and sections like angles flattened

channels and tea sections are made hot

rolled round bars are sent to prybar

division here bars are straightened

peeled drawn ground and polished and

thoroughly cleaned hot rolled sections

of an

channels flats D sections a solution

annealed straighten

[Music]

and dipped into acid tanks for pickling

and massive ation the bright or the

finished products are subjected to

quality checks for specification

compliance quality and grades are

rechecked using BMI test facility

mechanical and metallic Rafi tests this

is then followed by visual inspection

located just 100 feet away is a forging

division that has the highest capacity

under one roof

every order received first goes through

Quality Assurance and is precisely

monitored with our newly installed

Enterprise routing program once the raw

material mattes ingots and billets are

received from the mother plant they go

through a set of strict quality checks

to ensure that the material is suitable

for further processing it is loaded on

to the fully automatic sharing machine

controlled with a Siemens PLC system

and/or automatic length adjusting

bandsaw machines

enabling the right size weight and count

of the pieces while cutting is in

process the tool room prepares the dies

and rolls required to force the products

according to drawings developed and

controlled using the latest gam

software's the cut piece is then loaded

on to the digitally controlled

preheating furnaces or PLC control

induction heaters temperatures are

monitored and recorded it is then forged

using three optional roots of the glows

dye forgings

[Music]

open-die forging x' and ringed rolling

process a fully automatic heat treatment

furnace is used to heat treat the forged

material in order to achieve the

mechanical properties as with irrelevant

specifications the latest technology and

any bill approved calibrated testing

machines ensure that the results shown

are error less precise machining is done

with C and C and VMC machines ensuring

very close standard dimensions use of

special purpose machines has also done

during this process final inspections

include PMI test all non-destructive

tests visual and dimensional checks as

per applicable standards and QAP are

carried out at this stage after the

tests it is sent for stamping and then

is packed in plywood boxes ask for

customers specific packaging

requirements seamless tube and by

division the plant has been engineered

for manufacturing high quality

international standards stainless steel

seamless tubes and pipes it is India's

only fully integrated stainless steel

seamless tube and by plant the to plant

receives thoroughly inspected and build

pride bars along with the test

certificates the bars have controlled

delta ferrite content to suit the

extensive mechanical work performed on

the material they are cut as per plan

and then deep hole drill to achieve

better ID finish bars then enter

calibrated walking beam furnace and the

uniformly heated billets are ready for

piercing use of glass lubrication for

alter an inner diameter of bars minimize

surface torsional and circumferential

stress deformation with use of

molybdenum plugs

result in improved surface finish of the

product during the indigenous hot

piercing process adapted by chundan

steel the pierced hollow bar is captain

straightened pickled and grounded if

necessary for any surface imperfections

specially designed high speed Auto

feeding cold builder machines supported

by in-house tool room setup and high

cross-sectional reduction result in

better surface finish tight dimension

control and long lengths in the finished

tubes the tubes are then decreased in

the online and offline decreasing setup

our natural gas-fired solution annealing

furnace with auto set temperature

control for uniform heating it has a

minimum impact on the environment the

tubes are then passed through a tendril

straightening machine to achieve desired

straightness the tubes are then cut and

sent for final pickling in acid bath

solution the law passes through

ultrasonic machine eddy current testing

machine hydro testing machine air

underwater testing for checking leakages

and the tubes then it is visually

checked for defects and dimensions the

lock bosses destructive testing like

flaring flattening tensile and inter

granular corrosion practice a C and E it

is also checked for hardness and

microstructure once approved by the

quality team the lot is then passed to

the packing Department along with the

material test certificate the material

is packed suitably for overseas shipment

and also domestic supply based on

customer requirements

[Music]

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