SS TUBE MILL
[CODE NO.4038]
Stainless Steel Tube Mill is an industrial plant that is for manufacturing of steel. This plant is known to execute all the steps of steel making from smelting iron ore to rolled product. This may also be a plant where the best of semi-finished casting products are made from molten pig iron as well as from scrap.
It needs to be understood well that an integrated steel mill has the best of functions for primary steel production. The steel making process refers to conversion of pig iron to liquid steel. The casting process refers to the solidification of the liquid steel. The billet rolling process refers to the process of reducing size of blocks.
The raw materials required for integrated SS mill are iron ore, coal as well as limestone. These raw materials are put forth in a blast furnace where the iron compounds give up excess oxygen as well as liquid iron. The iron ore that is accumulated as liquid iron is tapped much from the blast furnace and is cast into pig iron for further operations related to the steel making process.
The Bessemer process refers to an important procedure for manufacturing of economical steel. However, this process is entirely replaced by other processes such as basic oxygen furnace. During the production process, the molten steel is cat into large blocks called blooms. When the production is being executed, the casting process refers to the methods which refer to addition of aluminium so that the impurities in the steel float much to the surface where they can be cut off as finished bloom.
There is much structural stress and energy cost associated with heating and cooling of blast furnace. It is to be known that these primary steel making vessels shall operate on a continuous production campaign of duration of several years. When there are low steel demand periods, it is not advisable to let the blast furnace grow cold.
The SS tube mills are large facilities that are typically more economical to build in 2,000,000 tons /year annual capacity. Continuous production campaigns are needed for several years of duration. The final products made by an integrated plant are large structural sections which include railway rails, steel bars, steel pipes, wire rod, and others.
There are various environmental hazards that are associated much with the integrated steel mills. For example, there is much pollution produced in the manufacture of coke which is a kind of intermediate product in reduction of iron ore in a blast furnace.
There is also a ‘Mini S Tube Mill’ which is a secondary steel producer. It is known to obtain most of its iron from scrap steel which is recycled from used automobiles and equipments as well as various by-products of manufacturing. The capacities of mini mills might vary as per the finished product being manufactured in the tube mill. The structural processes involved for the functioning of SS tube mill need to be well understood by the technical expert handling it.
COST ESTIMATION
Plant Capacity 20 MT/Day
Land & Building (10,000 sq.mt.) Rs. 7.58 Cr
Plant & Machinery Rs. 2.58 Cr
Working Capital for 2 Months Rs. 30.60 Cr
Total Capital Investment Rs. 41.86 Cr
Rate of Return 35%
Break Even Point 45%
INTRODUCTION
SIZES OF PIPES
SIZES FOR STAINLESS STEEL TUBE
RAW MATERIAL
PHYSICAL PROPERTIES OF PIPING MATERIALS
MALLEABILITY
DUCTILITY
BRITTLENESS
ELASTICITY
CONDUCTIVITY
CHEMICAL RESISTANCE/ RESISTANCE TO CORROSION
USES AND APPLICATION
TYPICAL APPLICATIONS FOR STAINLESS STEEL PIPE:
B.I.S. SPECIFICATION
PROCESS FLOW CHART
MANUFACTURING PROCESS
1. UNCOILED, LAVELED AND WELDING OF STRIP
2. STRIPPING
3. LOOPING
4. EDGE TRIMMING
5. FORMING
6. WELDING
7. BEAD TRIMMING
8. SIZING
9. CUTTING
10. NORMALISING
11. STRAIGHTENING
12. END FACING AND BEVELLING
13. TESTING
ULTRASONIC TESTING
EDDY-CURRENT TESTING
HYDROSTATIC TESTING
MAGNETIC PARTICLE TESTING
RADIOGRAPHIC (X-RAY) TESTING
DYE-PENETRANT TEST
14. PICKLING
15. PASSIVATION
16. POLISHING
DIFFERENCE BETWEEN WET BRIGHT AND DRY BRIGHT:
ADVANTAGES:
ELECTROPOLISHING SUPERIOR THAN MECHANICAL POLISHING:
ELECTROCHEMICAL POLISHING CHARACTERISTICS:
17. MARKING
NOMINAL PIPE SIZE (NOMINAL BORE)
QUALITY CONTROL
QUALITY ASSURANCE PLAN
A. INCOMING RAW MATERIAL
B. STAGE WISE INSPECTION
PLANT AND MACHINERY
(1) UNCOILER
(2) LAVELER
(3) SHEAR AND WELDER
HIGH QUALITY WELDING SEAM.
1. SWITCHGEAR RECTIFYING CABINET
2. INVERTER OUTPUT CABINET
3. CONNECTING OPTICAL FIBER
4. CIRCULATION SOFT WATER COOLING SYSTEM
5. CENTRAL OPERATION CONSOLE
6. MECHANICAL ADJUSTMENT DEVICE
(4) ACCUMULATOR
ACCUMULATOR
THE HORIZONTAL SPIRAL ACCUMULATOR FOR WELDED PIPE LINE
(5) FORMING AND SIZING SECTION
FORMING AND SIZING MILL
MATURE TECHNOLOGY FOR ROLLER COMPATIBILITY
OPTIMIZED FORMING
EDGE BENDING
W-FORMING ON FIRST STAND
UNIQUE MODULE ROLL (ASSEMBLY ROLL) AND JUANTIE (EDGE
GRADUALLY TO CENTER) FORMING TECHNOLOGY
(6) HF SOLID STATE WELDER
HIGH QUALITY WELDING SEAM.
1. SWITCHGEAR RECTIFYING CABINET
2. INVERTER OUTPUT CABINET
3. CONNECTING OPTICAL FIBER
4. CIRCULATION SOFT WATER COOLING SYSTEM
5. CENTRAL OPERATION CONSOLE
6. MECHANICAL ADJUSTMENT DEVICE
(7) ANNEALING FURNACE
(8) FLYING SAW
FLYING SAW
MAIN SPECIFICATION:
MAIN SPECIFICATION:
FLYING SAW ALL DIGITAL CONTROL SYSTEM
(9) FACING AND BEVELING MACHINE
(10) STRAIGHTNER MACHINE
(11) THREADING MACHINE
THREADING MACHINE FEATURES:
(12) HYDRAULIC TESTING MACHINE
MARKET POSITION
STEEL PIPE MARKET
EBITDA/TONE AND LEVERAGE ACROSS PIPE SEGMENTS/PLAYERS
STEADY IMPROVEMENT IN CREDIT PROFILES OF BOTH SEGMENTS
INTEREST COVER ON UPTREND
SO IS NET CASH ACCRUAL TO DEBT
MOVEMENT IN OPERATING MARGINS VIS-À-VIS HR COIL PRICES
EBITDA/TONNE FOR ERW
EBITDA/TONNE FOR S & S
UTILISATION LEVELS HEADED NORTH
PLANT LAYOUT
SUPPLIERS OF SS TUBES
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF CR SS STRIPS
SUPPLIERS OF PACKING MATERIALS
SUPPLIERS OF PICKLING CHEMICALS
SUPPLIERS OF RESSISTANCE WELDING ELECTRODE
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF SS PIPE AND TUBE PLANT
CHINA SUPPLIER
SUPPLIERS OF METAL TESTING MACHINE
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF NDT INSPECTION EQUIPMENT
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
SUPPLIERS OF DG SETS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF POWER TRANSFORMER
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF JIGS AND FIXTURE
SUPPLIERS OF SUBMERSIBLE WATER PUMP
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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