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    Internship Report

    Structure Property Correlation of Thermo-

    Mechanical Tempered Bars & Hot Rolled Coil

    Submitted by

    Anubhav Jain#

    Enrolment no.: Mett 32/13

    National Institute of Technology Srinagar

    Guided by

    Mr. Neel Kant*

    Research and Development Department

    Jindal Steel Works Dolvi

    Head of Department

    Mr. Pardip Kumar Patra*

    Research and Development Department

    Jindal Steel Works Dolvi

    * #

    Duration: 4 Weeks w.e.f. 1/02/2016

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    Acknowledgement

    During this industrial internship in JSW (Jindal Steel Works) Dolvi, Maharashtra, in

    Research and Development Department was a memorable one for me as it was rich in

    experience sharing and helped me to discover my potential. I had so many rich experiences

    and opportunities that I personally believe will forever shape and influence my professional

    life while fostering personal growth and development.

    In this report, I hope to highlight the work that I have performed and learned. Working here

    not only given me the industrial experiences, but also teaches me how to sustain in tough

    environment. Good working conditions and friendly behaviour of everyone inspires me to

    be productive in work.

    These few details lead me to realize that, like all human endeavours, this report is not perfect

    and may contain errors and shortcomings.

    Thus, I remain open to all criticisms and suggestions which could present me with new

    sources of inspiration as I develop in my ability to research and learn.

    This report would not have been possible without the contribution and collaboration of

    others. My sincere gratitude:

    Mr. Pardip Kumar Patra, HOD, R&D, JSW Dolvi.

    Mr. Mrigandra Singhai, AGM, R & D, JSW Dolvi.

    Mr. Srimanta Sam, Senior Manager, R & D, JSW Dolvi

    Mr. Amit Mogale, Deputy Manager, R & D, JSW Dolvi.

    Mr. Dravid, Jr. Manager JSW Dolvi

    Mr. Krishana, Deputy Manager JSW Dolvi.

    Mr. Vivek, JSW Dolvi.

    To all of you, I extend my deepest gratitude and always owe my respect to them.

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    History

    JSW was set up as Nippon Denro Ispat Limited in May 1984 by founding Chairman Mr M.

    L. Mittal. The company have operations in iron, steel, cement, energy and infrastructure. It is

    an integrated steel plant, located at Dolvi in the state of Maharashtra.

    The 1,200 acres (4.9 km2) Dolvi complex houses the 3.3 million tonnes per annum HR Coils

    plant, and 1.5 million tonne per annum TMT Bar Mill (Newly established) which combines

    the latest technologies the Compact Strip Process (CSP) introduced in Asia. It is

    headquartered at Mumbai and employs about 3000 people.

    On 21 December 2010 it was declared that JSW Steel will buy this industry at $3 billion to

    emerge as India's largest private producer of the steel. On April 2013, the complete merger

    has been completed. Currently this industry is owned by Mr. Sajjan Jindal.

    The Dolvi unit features a sponge iron plant (1.6 million tonnes per annum), a blast furnace, a

    sinter plant, a hot strip mill (3.3 million tonnes), an oxygen plant and a lime calcining plant.

    The plant uses a combination of ConArc and CSP processes to produce hot rolled coils.

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    List of Abbreviation

    TMT Thermo mechanical tempered

    HR Hot Rolled

    MTPA Million tonnes per annum

    MM Millimetre

    MPA Mega Pascal

    YS Yield strength (MPa)

    UTS Ultimate Tensile Strength(MPa)

    CSP Compact Strip Process

    QTB Quenched & Tempered Bar

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    Contents 1. Introduction ............................................................................................. 7

    1.1 Safety awareness ............................................................................... 7 2. Literature Review ................................................................................... 8

    2.1 Compact Strip Process (CSP)....8 2.2 ConArc Process (Converter & Arcing) ............................................. 8 2.3 Quenched & Tempered Bars (QTB) ................................................. 8 2.4 Standards of TMT and HR Coil ........................................................ 9

    2.4.1 TMT Bar Chemical Composition ............................................... 9 2.4.2 TMT Bar Mechanical Standards ................................................. 9 2.4.3 HR Coil Chemical Composition ................................................. 9 2.4.4 HR Coil Mechanical Standards ................................................... 9

    2.5 Testing ................................................................................................. 10 2.5.1 Chemical Analysis ........................................................................ 10 2.5.2 Mechanical analysis ..................................................................... 10

    2.5.3 Microstructure .............................................................................. 10 3. Projects .................................................................................................. 12

    3.1 TMT Bars: ....................................................................................... 12 3.1.2 Observation: .............................................................................. 13 3.1.3 Inference: .................................................................................. 13

    3.2 HR Coil:........................................................................................... 15 3.2.1 Observation: .............................................................................. 15 3.2.2 Inference: .................................................................................. 16

    Appendix A: IS:1786:2008...18

    Appendix B: Mechanical Properties.19

    Reference..20

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    1. Introduction

    Industrial Training in Research and Development, Deartment of Jindal Steel Works, Dolvi,

    Maharastra has given chance to work in their newly established TMT Bar Mill installed by

    'Danieli Italy', with capacity of 1.5 MTPA (Million tonnes per annum) which produces TMT

    bars of different diameters from 8 MM to 40MM and HR Coil Mill with capacity of 3.3

    MTPA (Million tonnes per annum), which produces Coils of thickness from 1.2 MM to

    25MM and 25 tonn.

    In this period of training, I worked on the Microstructure of TMT bars & HR Coil,

    Mechanical properties of Fe500D Grade of bar of diameters 25MM & 40MM and TR34Al Z

    of HR Coil.

    In TMT Bar, I figure out the Microstructures, Tensile test and Chemical composition.

    Due to trial of TMT bar mill it become difficult to go further, so they suggested me to also

    work on HR Coil also.

    In HR Coil, I worked on the Microstructures of Coils with excess of Nitrogen and normal

    Nitrogen coil and find correlations with the YS, UTS and Grain Size of Microstructures in

    both of them. I used two samples of Excess Nitrogen and one sample of normal Nitrogen.

    TMT Bars are used for General reinforcement of high rise building, bridges and other

    concert constructions; it is highly used in earthquake prone areas.

    HR Coils are used for fabrications like automobiles, pipes, gas cylinders, etc.

    1.1 Safety awareness

    Wear safety shoes or boots, preferably with steel toes.

    Wear a hard hat while framing or when required by supervisor.

    Wear safety glasses when working with any power tool and when recommended by

    the supervisor.

    Wear dust masks when needed.

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    2. Literature Review

    It is essential to understand some basic process and terms used in this report, I refer some

    papers. Hence brief ideas of these processes are as follows.

    2.1 Compact Strip Process (CSP)

    CSP combines cost-effective and environmentally friendly production with a high

    productivity and excellent strip quality in an ideal way. CSP stands for Compact Strip

    Production. In a CSP caster, the liquid steel is cast into thin slabs which after temperature

    equalisation in a tunnel furnace are rolled directly in the rolling mill without roughing

    (removal of scales).

    2.2 ConArc Process (Converter & Arcing)

    ConArc combines two traditional methods making steel using solid charge like

    steel scrap, pig iron or sponge iron as well as making steel through the blast furnace route.

    This provides the unit with the flexibility of using any combination of solid charge and liquid

    hot metal. It chooses feed mix depending on market demands.

    2.3 Quenched & Tempered Bars (QTB)

    QTB plus is a recently established model by Danieli Italy in TMT bar mill, which is

    used for the better control for mechanical properties of quenched & tempered bars. This

    gives an accurate estimation of YS, UTS and Hardness at different points across the section

    of the bars. It calculates the thermal histories of different segments, finally the system uses

    these histories to estimate the final microstructures.

    This system is useful in producing the desired mechanical properties through proper process

    control. It can be used to design new grades of bars with superior quality such as improves

    elongation and bend ability.

    An Additional Neural Network (ANN) model is set up to considered uncertainties of

    processing in the plant.

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    2.4 Standards of TMT and HR Coil

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