welcome to jayaswal neco industries...
TRANSCRIPT
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WELCOME
TO
JAYASWAL NECO INDUSTRIES LIMITED(An Integrated Steel Plant)
MAR--2012
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A BRIEF PROFILE :COMPANY
JAYASWAL NECO INDUSTRIES LIMITED (JNIL) is an integrated steel plant of NECO GROUP OF INDUSTRIES, having Corporate Office at Nagpur (MS). It’s an ECO FRIENDLY, GREEN & CLEAN ENVIRONMENTAL Steel Plant, spreaded over 2200 acres of land.
Plant commissioned in 1996 with IRON making by Blast Furnace, later STEEL making by ELECTRIC ARC FURNACE in 2004 & completed ROLLING MILLS in 2009.
LOCATION
Near Raipur, capital city of sate of Chhattisgarh in Central India. City conveniently connected by AIR, RAIL & Highways to all metros and cities across the country.
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BUSINESS
Manufacture & Sale of IRON & STEEL PRODUCTS for Automotives, Engineering, Power, Railways, Bearings, Structural & Fasteners Industries in India.
PRODUCTS
Specialty Steels. In form of Hot Rolled Bars in ROUND & SQUARE shapes, WIRE-ROD in Coils & High Strength LEAF SPRING in FLAT shapes.
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PRODUCT QUALITY & STEEL GRADES
AK – FORGING, COLD HEADING (CHQ), FREE-CUTTING, HIGH STRENGTH LEAF SPRINGS & COILS, BALL BEARING STEELS, etc. (As per IS, AISI, SAE, EN, DIN, JIS Specs. or customers spec.)
• Carbon Steels : Low, Medium & High; from 0.05% to 1.25%
• Alloy Steels: Ni, Cr, Mo & Vanadium;
• Spring Steels :Silico Mn, SiCr & CrV
• Free Cutting Steels: Sulphurised & Sulphurised with Lead.
• Cold Heading Quality Steels: Carbon, Alloy & Boron Bearing Grades.
• Ball Bearing Steels :
• Mostly Al / Si-Al killed steels meant for forged components of automobile & Engg applications.
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Units Nos. Capacity
Blast furnace 1 7.0 lakh Tones/year (650 CuM Cap)
Sponge Iron 2 3.0 Lakh Tones/year (1x350 TPD, 1x500 TPD)
Steel Melting Shop-I 1 3.0 lakh tones/year (1x40 T EOF)
Steel Melting Shop-II * 1 5.70 lakh tones/year (1X75 T EAF)
Sinter Plant 2 6.0 lakh tones/year
Coke Oven 2 2 lakh tones/year
Power Plants 5 60 MW/day
Bar Mill 1 1,25,000 MT/year
Wire Rod Mill 1 2,75,000 MT/year
Mines (Ore & Coal) -- Coal Mines – Operating.Ore Mines – Operation Expected.
SALIENT FEATURES OF PRODUCTION FACILITIES
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POWER PLANT60 MW / DAY
IRON ORESINTER PLANT
6.0 LAC TPA COKE OVEN PLANT2.0 LAC TPA
DRI3.0 Lac TPA
BLAST FURNACE7.0 Lac TPA
EAF - 40T
LRF - 40T Optimum deoxidation / Temp & Chem Control
VD - 40T * Treatment Time 15 Mnts Below 1 milibar CCM - 3ST * SEN CASTING * AMLC * M - EMS ROLLING MILLS
QA INSPECTION / TESTING / TC
PPC - DESPATCH
15% DRI85% Hot Metal
PROCESS ROUTE OF STEEL MAKING
BR MILL (Cap: 1.5 Lac TPA): RDS:24-90mm; RCS: 45-100mm; FLAT: 45X5, 70x8, 80x20mmWR MILL (Cap: 3.0 Lac TPA): 11-32mm & Annealing Facility.BLOCK MILL : 5.5mm to 18.3mm (Commissioned in Feb-12)
CARBON, ALLOY, SPRING, BALL BEARING, BORON, FREE CUTTING & CHQ STEELS
O2 - 20 ppm Max.H2 - 1.5 ppm Max.N2 - 70 ppm Max.
Caster Radius - 6/11 MCast Sizes - 130x130mm, 160x160mm180x180mm & 160mm RD
* SMS-II : Capacity 5,70,000 TPA - Under Installation with Bloom Size: 160x160mm; 250x250mm; 400x340mm* NEW MILL: To Roll up - RD: 80-160mm; RCS: 75-160mm; ANGLE: 75x75x6 - 250x250x25; IPE: 120-300mm
EBT (Slag Free Tapping) Co-Jet Lance Melting, Foamy Slag, P reduction
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Billets- 100x100 mm- 130x130 mm- 160x160 mm- 180x180 mm with rhombodity maintained upto
4 mm max. in all sections &- 160 mm round for Seamless Tube application.
Bars- Rounds : 24 mm – 90 mm Dia- Flats : 45x5 mm – 80x20 mm- RCS : 45 mm – 100 mm
Wire Rods- 5.5 mm – 32 mm
(11-32mm Dia through garrot route)(5.5mm to 18.30 mm through block route)
PRODUCT RANGE
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JNIL'S MAJOR STRENGTH FOR STEEL MAKING
• Competent & dedicated work force.• Upgraded technology in steel making & shaping.• Owns bulk raw material mines.• Use of own HOT METAL and DRI i.e. independent of sourcing charge mix for steel
making. • Use of 100% Oxygen lancing (CO JET practice ) in EAF for melting, oxidation & de-
carburisation & de-phosphorisation.• Foamy slag practice.• Slag free tapping with EBT in use.• Extremely low harmful tramp elements like Cu, Sn, Zn, Cr, Ni, Mo, Ti resulting into
consistent response to heat treatment and uniform mechanical properties.• Vacuum Degassing Unit for control of O2 & H2.• Low Nitrogen level (<70 ppm).• Computerised process control.• Copper Mould : 900 mm long, parabolic type multi tapered.• Casting : 100% SEN Cast for all sections with argon shroud at ladle-SEN joint.• Mould-EMS : 100% Cast are routed through M-EMS.• Automatic Mould Level Controller (AMLC) for superior billet surface.• Extrinsic & Intrinsic Quality : With 100% SEN, AMLC & M-EMS in practice under
controlled conditions, product integraty is superior.
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JNIL ACCOLADES
Using Blast furnace gas for Bar Mill & Wire Rod Mill as a fuel (First of its kind in
India), ensure absence of O2 in furnace atmosphere resulting very low
decarburisation.
Using Energy Optimizing Type Furnace for steel making with hot metal & 100%
oxygen lancing (CO JET practice), enhancing negligible tramp elements, hydrogen as
well as reduction phosphorus ( <0.01%).
Using pulverized coal injection system in Blast Furnace to reduce coke rate.
Using semi-coking coal blends for coke production in Coke Oven.
Using WHR boilers for power generation with hot flue gases from DRI plants.
Non-sinusoidal oscillation mechanism for billets to have better surface condition &
consistent quality of rolled products (to be installed shortly).
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JNIL PROCESS CAPABILITY
CHEMISTRY- Al. killed in restricted range of 0.020% to 0.035%.- Resulphurised in restricted range of 0.020% to 0.035% OR 0.005% max for Low S Gr. - ‘P’ level 0.010% max Or restricted in range of 0.040-0.060%- Carbon : In Three points range- Manganese : In Five points range- Chromium : In Five points range- Nickel : In Six points range- Mo : In Three points range- V : In Three points range- As per customer’s demand to meet any specific requirements like jominy bands & other
mech properties.
CLEANLINESS- Inclusion level of A, B, C, D series well within customer spec.- Gas Level (Total)- Oxygen : 10 to 20 ppm- Nitrogen : 70 ppm max (or) as per TDC- Hydrogen : 1.5 ppm max
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OUR VALUED CUSTOMERS – OEMs / 1ST TIER
FORGING QUALITY STEELS
• TATA MOTORS
• ASHOK LEYLAND
• MAHINDRA & MAHINDRA
• GNA GROUP OF INDUSTRIES
• MAHINDRA SONA
• KALYANI FORGE
• INTERNATIONAL TRACTORS LTD. (SONALIKA GROUP)
• TRINITY DIE FORGE
• TRINITY ENGINEERS
• TAFE – CHENNAI
• CARRARO INDIA – PUNE
• MILE STONE FORGING LIMITED
• AMTEK AUTO
• HIM TECHNO FORGE
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FORGING QUALITY STEELS
• EMSON FORGE
• FORGE & FORGE
• ECHJAY FORGE
• MASO AUTO
• OSHO FORGE
• INDIA FORGE
• DHAR AUTO
• GAJRA GEARS
• JAI PARVATI FORGINGS
• KALYANI THERMAL
• AMERICAN AXLES MANUFACTURERS
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CHQ STEELS (WIRE RODS)
•SUNDRAM FASTENERS LTD – PADI•POOJA FORGE•LAXMI PRECISION SCREWS (LPS)•DEEPAK FASTENERS•NEXO INDUSTRIES (Mostly for PGCL TLT Fastners application)•MAHENDRA FASTENERS
SPRING STEELS, LEAF, STABILISER BARS & COILS
•FRIENDS AUTO•TOYO SPRINGS•JAMNA AUTO•NHK SPRINGS•INDIAN RAILWAYS
FREE CUTTING STEELS (WIRE RODs & BARs)
•MOSTLY BRIGHT BAR UNITS.
BALL BEARING STEELS
•GALAXY BEARING•ORBIT BEARING•DUAL RING•RAJESHWARA FORGINGS•AUSTIN BEARINGS
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AS CAST BILLETS (MOSTLY FOR PGCL TLT APPLICATION)
• SANVIJAY• SHILPA• K.E.C.• KHYATI ISPAT• BAJRANG ALLOYS GT
BRIGHT BAR UNITS• PEELING M/C 2 NOS.• S G M/C 4 NOS.• STRAITENING M/C 2 NOS.• MPI TESTING M/C 1 NO.• CUTTING M/C 1 NO.• CAPACITY
SIZE 16 TO 50 MM RDSLENGTH 6 METERS
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QUALITY ASSURANCE
Quality is synonymous to NECO's products. Infact, the company produces quality &
confidence to valued customers. The company has well equipped a Quality
Assurance Department for chemical / metallurgical / inspection as well as non
destructive testing faciliteis including 100% mobile spectral test for grade mix-up
in addition also MPI & UT test off line.
QUALITY SYSTEM
Quality Plans are in force as per the system, accordingly, all inputs, processes and
final products are subjected to inspection and testings to ensure compliance to
customer‘s TDC.
SYSTEM CERTIFICATION ISO: 9001, BIS, IBR & RDSO for Indian Railways.
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LABORATORY EQUIPMENTS
ARL Optical Emission Spectrometer having 28 channels with additional channels like
N2, Nb in addition to soluble analysis of Al.,B.,Ti. and Ca.
LECO make Carbon & Sulphur analyzer
Well equipped chemical lab
Metallurgical & mechanical testing lab
Hydrogen, Oxygen analyzer (Eltra Make)
ARL-XRF
Spectro test mobile analyzer
Ultra sonic testing equipment.
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LABORATORY EQUIPMENTS
1. MECHANICAL TESTING LAB
• Electronic Universal tensile testing machine (60T), (20T), (10T) capacity.
• 180° Bend test attachment
• Charpy V-notch impact testing
• Charpy notch broaching machine
• Rockwell Hardness tester
• Brinell hardness tester
• Profile projector
• Jominy Hardenability testing machine
• Micro-meter, Vernier caliper etc.
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2. HEAT TREATMENT FACILITIES
• Electrically heated Spherodization Annealing Facility for straight length products as well as for wire rods.
• Muffle furnace for heavy duty sample (Hardening/Normalizing) upto 1200°C.• Muffle furnace for heavy duty sample (Hardening/Normalizing) upto 1000°C.• Infra-red radiation pyrometer
3. MACHINE SHOP FOR SAMPLE PREPARATION
• Lathe machine• Milling machine• Power hacksaw• Pedestal grinding machine
4. NON-DESTRUCTIVE TESTING LAB
• Ultrasonic testing machine• Eddy current testing machine• Magnetic particle inspection machine• Mobile Spectro Meter (Hand Held)
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5. METALLOGRAPHY LABORATORY
• Neophot metallurgical Microscope (Carl-Zesis)
• Trinocular vertical metallurgical microscope
• Image analysis system having facilities for particle count/particle size measurement, percentage area/volume phase analysis, grain size measurement, porosity estimation, nodularity, graphite flake, carbide banding, inclusion rating measurement features
• Bench magnifier (5x, 10x)
• Sample preparation equipments for Metallographic samples like grinding machine, polishing machine, abrasive cutter, double disc variable speed grinder cum polisher, hydraulic mounting press etc.
PLANT SIGHT
AT A GLANCE
ADMINISTRATIVE BUILDING
GARDEN AREA, BACKGROUND IRON COMPLEX
BLAST FURNACE
HOT METAL TAPPING IN PROGRESS
COKE OVEN BATTERY
DRI ROTARY KILN
POWER PLANT
EAF
LRF
VD
LADLE ON TARRET AT CCM FOR CASTING
THREE STRANDS CASTING UNDER PROGRESS
AUTO CUTTING OF CAST PRODUCT
DESCALER IN PROCESS AT BAR MILL
COOLING BED OF BAR MILL
COILING IN PROCESS OF WIRE ROD
HOT COIL ON COOLING BED
FINISHED WIRE ROD PRODUCTS
39BAR PRODUCTS ON INSPECTION BED
FINISHED BAR PRODUCTS
41FINISHED LEAF SPRING FLATS
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UPCOMING PROJECTS
SMS
Steel Melting Capacity : 0.57 MTPA of Continuously cast products
Electric Arc Furnace(1 No.) : 75 TonLadle refining furnace : 75 Ton (1 No., future provision for 2nd)AOD Vessel : 75 Ton VD/VOD : 75 Ton
Producer Gas Plant : 30,000 NM3/hr .
CCM with 4 strand combi caster of radius 12/22 meters.
Bloom Sizes : 130 x 130 mm, 160 x 160 mm,250 x 250 mm, 340 x 400 mm
Steel Grades : Carbon & Low Alloy Steels: Stainless Steels
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ROLLING MILLS
Reheating Furnace : 90 T/ hr capacity with duel fired burnersWater descaling facilities900 mm dia.x2200mm 2 high reversing breakdown millB.D. Hot SawTurn Over type Cooling Bed10 Nos. stands Continuous finishing Mill with horizontal & vertical configuration.Stationary Hot Saws.On line and off line straightening. Bundling, Marking and tying facilities.
Rolling Sizes :
Rounds : 80 to 180 mmRCS : 75 to 160 mmHeavy Structures : Various Profiles
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NEW PROJECT CONSTRUCTION SIGHTS AT A GLANCE
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THANKS