Step - 01


Raw Material Preparation



The initial stage involves the extraction and preparation of raw materials:

  • Iron Ore: Mined and crushed into small pieces.
  • Coal: Processed into coke in coke ovens to serve as a reducing agent.
  • Limestone: Crushed and used as a flux to remove impurities.

Step - 02


Automatic Induction Melting Furnace



The raw materials are fed into a blast furnace where a chemical reaction occurs, producing molten iron:

  • Charging: Iron ore, coke, and limestone are charged into the furnace.
  • Heating: The furnace is heated to a high temperature, melting the iron ore.
  • Reduction: Coke acts as a reducing agent, converting iron ore into molten iron.
  • Slag Formation: Limestone binds with impurities to form slag, which is removed.

Step - 03


Ladle



The molten iron is then transferred to a ladle for further processing:

  • Desulfurization: Impurities like sulfur are removed using desulfurizing agents.
  • Alloying: Elements like carbon, manganese, and silicon are added to achieve the desired chemical composition.

Step - 04


Continuous Casting Machine



The refined molten steel from the ladle is then poured into a continuous casting machine:

  • Tundish: Acts as a reservoir and controls the flow of molten steel.
  • Mould: The molten steel is poured into a water-cooled mould where it solidifies.
  • Cooling: The partially solidified steel is rapidly cooled using water sprays.
  • Cutting: The solidified steel is cut into desired lengths (billets).

Step - 05


Conveyor Belt



The billets are transported to the rolling mill via a conveyor belt:

  • Transportation: Billets are moved on conveyor belts to the heat maintenance furnace.
  • Temperature Maintenance: Ensures billets remain at the required temperature for rolling.

Step - 06


Rolling Mill



The billets are heated and rolled into TMT bars in the rolling mill:

  • Roughing: Billets are passed through roughing stands to reduce their cross-section.
  • Intermediate Rolling: The billets are further rolled to intermediate sizes.
  • Finishing: Final shaping and sizing of TMT bars.

Step - 07


Thermax Box



The hot-rolled bars pass through the Thermax box for quenching and self-tempering:

  • Quenching: High-pressure water jets rapidly cool the outer surface of the bars, forming a hardened surface layer (martensite).
  • Self-Tempering: The core remains hot, allowing heat to flow from the core to the surface, tempering the outer layer and giving the bars a tough, ductile core with a hard surface.

Step - 08


Cooling Bed



The quenched and tempered bars are transferred to a cooling bed:

  • Cooling: Bars are laid out to cool uniformly in ambient air.
  • Straightening: Ensures bars are straight and free of bends.

Step - 09


Stocks Yard



The finished TMT bars are then transported to the stock yard:

  • Cooling Bed: The bars are placed on a cooling bed to ensure uniform cooling.
  • Inspection: The bars are inspected for quality and compliance with standards.
  • Bundling: Bars are bundled and tagged for identification.
  • Storage: Bundles are stored in the stock yard, ready for dispatch.

Step - 01



Raw Material Preparation



The initial stage involves the extraction and preparation of raw materials:

  • Iron Ore: Mined and crushed into small pieces.
  • Coal: Processed into coke in coke ovens to serve as a reducing agent.
  • Limestone: Crushed and used as a flux to remove impurities.

Step - 02



Automatic Induction Melting Furnace



The raw materials are fed into a blast furnace where a chemical reaction occurs, producing molten iron:

  • Charging: Iron ore, coke, and limestone are charged into the furnace.
  • Heating: The furnace is heated to a high temperature, melting the iron ore.
  • Reduction: Coke acts as a reducing agent, converting iron ore into molten iron.
  • Slag Formation: Limestone binds with impurities to form slag, which is removed.

Step - 03



Ladle



The molten iron is then transferred to a ladle for further processing:

  • Desulfurization: Impurities like sulfur are removed using desulfurizing agents.
  • Alloying: Elements like carbon, manganese, and silicon are added to achieve the desired chemical composition.

Step - 04



Continuous Casting Machine



The refined molten steel from the ladle is then poured into a continuous casting machine:

  • Tundish: Acts as a reservoir and controls the flow of molten steel.
  • Mould: The molten steel is poured into a water-cooled mould where it solidifies.
  • Cooling: The partially solidified steel is rapidly cooled using water sprays.
  • Cutting: The solidified steel is cut into desired lengths (billets).

Step - 05



Conveyor Belt



The billets are transported to the rolling mill via a conveyor belt:

  • Transportation: Billets are moved on conveyor belts to the heat maintenance furnace.
  • Temperature Maintenance: Ensures billets remain at the required temperature for rolling.

Step - 06



Rolling Mill



The billets are heated and rolled into TMT bars in the rolling mill:

  • Roughing: Billets are passed through roughing stands to reduce their cross-section.
  • Intermediate Rolling: The billets are further rolled to intermediate sizes.
  • Finishing: Final shaping and sizing of TMT bars.

Step - 07



Thermax Box



The hot-rolled bars pass through the Thermax box for quenching and self-tempering:

  • Quenching: High-pressure water jets rapidly cool the outer surface of the bars, forming a hardened surface layer (martensite).
  • Self-Tempering: The core remains hot, allowing heat to flow from the core to the surface, tempering the outer layer and giving the bars a tough, ductile core with a hard surface.

Step - 08



Cooling Bed



The quenched and tempered bars are transferred to a cooling bed:

  • Cooling: Bars are laid out to cool uniformly in ambient air.
  • Straightening: Ensures bars are straight and free of bends.

Step - 09



Stocks Yard



The finished TMT bars are then transported to the stock yard:

  • Cooling Bed: The bars are placed on a cooling bed to ensure uniform cooling.
  • Inspection: The bars are inspected for quality and compliance with standards.
  • Bundling: Bars are bundled and tagged for identification.
  • Storage: Bundles are stored in the stock yard, ready for dispatch.