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View of January' 2005 Issue
INDIAN FORGING INDUSTRY – CHALLENGES AHEAD
B.V.R. RAJA, N. PAL, P.L. TALWAR, N.P. JAYASWAL
Alloy Steels Plant, Steel Authority of India Ltd. Durgapur
The dominance of steel as a prime material in forging industry is mainly due to its versatility of providing a wide range of tailor made properties by choosing the appropriate composition/processing to exhibit high strength for load bearing components, toughness for usage in extreme temperatures, high hardness for use as cutting tool, low hardness for machining, shaping & drilling operations, high temperature resistance for application in power plants and not the least, the formability.
Long Term Viability of Sponge Iron Industry
Mr. S. K. Chakrabarti, President, Sterling Plus
The coal based sponge iron industry has seen a spurt in growth in the last couple of years, making India the largest producer of sponge iron in the world. In light of this as also the fact that a number of Greenfield coal based DRI units are nearing completion, it is natural that apprehensions about the long term viability of such units are expressed. Such apprehensions have been further fuelled by the current shortage of raw material for the sponge iron industry.
Tata Ryerson Ltd: Leading and shaping the Steel Service Centre Industry in India
Sandipan Chakraborty, Managing Director, Tata Ryerson Ltd.
Incorporated in 1997 as a 50:50 joint venture between Tata Steel, Asia’s first and India’s largest integrated private sector steel company and Ryerson Tull, USA, a world benchmark in materials management, Tata Ryerson has quickly positioned itself in the rapidly developing service centre industry in India. Over the years Tata Ryerson has emerged as the largest Service Centre Company after starting with a turnover of Rs 1.8 crores in FY97-98, and achieving a turnover of Rs.359 crores in FY03-04. The Company expects to achieve a turnover over Rs.500 crores in FY 04-05. Tata Ryerson is in constant pursuit of excellence through an unique organizational culture based on the company’s Core Values of “Credibility, Customer Focus, Continuous Improvement, Agility and Teamwork”.
Emerging Low Cost Metallic Feeds In Electric Arc Furnace
B.V.R.RAJA, Manager, N.PAL, Dy. General Manager
P.L.TALWAR, General Manager & IC (Works)
N.P.JAYASWAL, Executive Director
Alloy Steels Plant, Durgapur 713 208
Electric Arc Furnace for making steel was commissioned successfully for the first time at France by Dr. Paul Heroult in 1899. The early furnaces were of single phase type. Three phase furnaces were soon developed with parallel developments of the design to improve upon capacity, prodductivity and quality leading to the evolution of large Electric Arc Furnaces that are in use today.
ENERGY MANAGEMENT AT RINL
By Our New Bureau
The imperative need for rapid economic development coupled with aspirations for a better quality life are exerting an immense pressure on the energy demand in India. Growing exploitation of the energy resources has resulted in gradual depletion of the energy reserves. The existing reserves are likely to last for a few decades only. The dwindling energy reserves and spiraling energy costs therefore calls for major technological revolutions and human intervention for substantial reduction in energy.
The steel industry occupies a pivotal position in the economic infrastructure of the country and is a major energy consumer accounting for 15% of the energy consumption in the industrial sector and about 10% of the total energy consumption of the country.
In an integrated steel plant, energy accounts for 30 to 40% of the manufacturing cost. Any reduction in the energy bill can therefore make the difference between the profit and loss of a particular plant especially in the present competitive global environment.
SPONGE & STEEL – A LINKED FEATURE
Rajesh Jha and Bhaskar S J , VISA Industries Ltd.
In the 1970’s the domestic steel making was divided into two major groups.
Auto-Ignition of Sponge Iron: A Review
Dr. Krishna Kant Prasad, Dy. General Manager, R&D Centre for Iron and Steel (RDCIS), SAIL, Ranchi
Due to heavy volume reduction during the sponge iron making process, sponge iron becomes highly porous, surface active and therefore pyrophoric. During the 70s there were a number of incidences reported. in which ocean shipment of sponge iron caught fire and caused damage not only to the cargo but also to the ship and associated equipment. Even though the high reactivity of sponge iron was known beforehand, the phenomenon of auto-ignition was something new and could not be easily explained since normal sponge iron ignites well above 200°C. Studies of burnt sponge iron cargoes and subsequent investigations including a number of simulation studies have led to the evolution of a plausible hypothesis of auto-ignition of sponge iron, which needs to be validated. If the hypothesis is valid, the coal based sponge iron made in rotary kiln would also be prone to auto-ignition but it would take more time. There is no such incidence reported so far.
Steel Concrete Composite Construction In Housing & Infrastructure
Dr. T.K. Bandyopadhyay, Deputy Director General & HOD (Technical Development & Standard)
Institute for Steel Development & Growth (INSDAG), Kolkata.
Design of structural members with efficiency and minimum cost is always a challenge to the architects and engineers. The most important and frequently encountered combination of construction materials is that of steel concrete with application in multi-story buildings, car parks, as well as bridges.
Acceptance of steel-concrete composite construction is dependent on availability of cost effective design, efficient code provisions and culture congenial to steel intensive construction. Use of rolled sections and low fabrication cost help to promote composite construction.
The initial cost of a project varies widely for variation in configuration of the structure including span of the floor supporting members, loading conditions, code stipulations, height of the structures, its location and facilities available for fabrication. In India cost of a project is generally restricted to direct initial cost without any comprehensive study like life-cycle-cost analysis.
Life-cycle-cost considers the total cost incurred by a structure throughout its life instead of only the construction cost. A structure having better techno-economic viability and having lowest life-cycle-cost heads include : direct cost, time cost, periodic maintenance cost, major repair cost, and end use value etc. For a flyover project, life-cycle-cost will also include road user cost in the form of vehicle operation cost due to increased fuel consumption,maintenance, depreciation and overheads due to delay caused by construction activities.
An Overview Of Product Development Activities In Coated Product
R.N. Chattopadhyay, Avtar Singh, S. Beborta, A. Charan, N. Rajesh and
H.C. Kharkar, Tata Steel, Jamshedpur
The interest in continuous galvanizing by many steel companies lies not only in the existence of a growing captive market but also in the potential as an added value in the product mix. Zinc and zinc alloy coatings on steel offer substantial improvements in corrosion resistance not only for automobile bodies but also for appliances, commercial and other general construction applications. In the area of automobile, across the world the use of metallic coated steel sheet both on a volume and percentage basis is continually increasing. This market requires a product with excellent formability along with weldability, paintability and corrosion resistance. With regard to corrosion resistance, most of the advanced countries have the mandatory anti corrosion performance guarantee i.e. 12-5-2 (12 years for perforation corrosion, 5 years for cosmetic corrosion and 2 years for engine compartment corrosion).
Steel Re-Rolling Industry - Its Status, Target And Support Needed From The Policy Makers
Shyam Sunder Beriwala, Chairman, Steel Re-rolling Mills Association of India
The achievements of our large steel mills often hit the headline. But the very useful and significant role-played by the steel-re-rollers is known only to few. There is a large number of steel Rolling Mill Industry in secondary steel sectors across the country and quietly playing their important role in the development of the national economy but still such important contribution rendered by the steel-re-rollers does not come in the lime-light as it should. The capacity of the sector has been assessed by Government of India at 22 Million tonnes as far back as in 1982 by the office of the Steel Control, Government of India.
The progress of a country is largely dependent on the development of its steel industry, which is directly linked to the overall development of the country, in such fields as construction activity, industrialization, transportation, communication, agriculture etc. and several engineering industry as well. The steel industry is considered as core sector and the per capita consumption of steel is a measure of development of any country. Actually every human being requires steel in life.
Perspectives in Indian Steel Marketing in the Global Scenario
Mr. Shoeb Ahmed, Executive Director (Marketing), Steel Authority of India Ltd.
The steel industry world over is essentially divided in to two major product groups - The Long product (Reinforcement bars, Structurals, Wire rods & Rails) and the Flat Products (HR Coil, CR coil, Plates, Galvanized coils/Sheets).
Before we go into looking at what the domestic industry requires in terms of future marketing, we must understand what is the structure of the domestic industry.
Emergence Of The Smart Conveyor Belt For Long-Haul Applications
Mr. Kunal Mukherjee, Chief Marketing Manager (Tech), Phoenix Yule Limited, India
Conveyor Belt through the past quarter century : a transition in perception. The conveyor belt, even as recently as during the late ‘80’s in India, was acknowledged as a product with strong technological origins. Pedigreed manufacturers like Dunlop, Andrew Yule and Nirlon were recognized as being leagues ahead in capacity, equipment, technology, process engineering, quality control and R&D compared to other smaller names beginning to appear in the conveyor belt manufacturing industry.
In this admittedly profitable market, the users were willing to pay the price to use belts that were as good as some of the best products available globally and these products quickly established their value, seamlessly replacing international O.E. supplies in numerous Indian projects across the country.
Indian Steel Industry – Edges, Obstacles and Opportunities.
Mr. M.C. DAS, ISS
The control regime, problems of excess capacity coupled with depressed demand and low price realizations no longer haunts the minds of the steel industry and these have become things of the past. The resurgence of the Indian steel industry with higher price realizations and significant surge in offtake has brought back the sheen of the Indian steel. It is vibrating now and corporate drawing boards are busy in adding new dimensions with fresh investments for higher capacities.
The sector directly accounts for 1.3 percent of GDP. Apart from earning about Rs.3000 crores through exports, steel industry contributes about 8000 crores to the national exchequer in the form of excise and custom duties. Its share in railway revenue comes to about 15%. Today, it is the eighth largest producer of steel in the world and have a cumulative capital investment of over one lakh crores and employs over 5 lakhs people directly.
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