Bhushan Steel is leading the technological revolution in Indian Cold Rolled Steel Industry today and defining new frontier of customer satisfaction. Be it through technology and product upgrades, R&D efforts or stringent quality control measures, company is consistent in its pursuit of value.

Bhushan Steel has earned a Quality Standards by getting many Certifications.

PLANT AND FACILITY

HR SLITTING (SMS– ESMECH)

Slitting serves three purposes :

(i) HR coils are available in widths which are wider than the required for Cold Rolling. The trimming / slitting is done with the HR Slitter.

(ii) The HR coils available may have width variation of the order of up to 20 mm, so to get the uniform width these coils are slitted.

(iii) The edges of HR coils may get damaged during transportation because of poor packaging and/or improper handling. In order to remove these damaged edges the HR coils are trimmed /slitted.

PICKLING (SMS-ESMECH with the technology collaboration with PRO ECO, Canada)

Pickling Line – 01 No

Pickling Line – 02 No's

Pickling is a metal surface treatment used to remove impurities, such as stains, inorganic contaminants, rust or scale from ferrous metals, copper, precious metals and aluminium alloys.

Thickness Range – 1.6 to 6mm

Width Range – 700 – 1700 mm

COLD ROLLING MILL (HITACHI, JAPAN / CMI, INDIA)

  • 6 Hi Mill – 3 No's
  • 2 Hi Mill – 2 No's
  • Width Range – 650 – 1700 mm

The primary function of Cold Rolling is to reduce the thickness of Hot Rolled Pickled strip at room temperature. During the operation overall max reduction of up to 90 % in thickness of the HR Coil can be achieved. Cold rolling occurs with the metal below its recrystallization temperature (usually at room temperature), which increases the strength via strain hardening up to 20%. It also improves the surface finish and holds tighter tolerances.

ELECTROLYTIC CLEANING LINE ( CMI-FPI, INDIA )

  • Thickness – Upto 3 mm
  • Width – Upto 1700 mm

Electrolytic Cleaning Line is responsible for the electrolyte cleaning of the rolled sheet surface in order to have its surface contaminations and greases removed in two dipping tanks containing alkaline solution and electrolyte cleaning.

ANNEALING FURNACE ( EBNER )

Total No. of Bases – 49

Annealing Furnaces are H2 furnaces with higher convection are from EBNER, AUSTRIA & ALLIED, and MUMBAI. Complete automation in the line ensures Clean & flawless surfaces. Annealing is a process in which metals, glass and other materials are treated to render them less brittle and more workable. In the steel industry, the steel is heated and profile controlled, with times and temperatures set according to the properties desired to reach an increased ductility and relieve strains that lead to failures in service.

KATHABAR ( IMTECH DRYGENIC, USA )

Total No. of Bases – 42

BSL is having KATHABAR cooling system from IMTECH DRYGENIC, USA. By this system we can supply dehumidify air to annealed coil for cooling of coils for best result. In this system the liquid desiccant can remove contaminants in the air like oil & grease & filter them out.

NON-OX GALVANIZING/GALUME LINE (CMI FPE with the technological collaboration with HYPERTHERM, EMG, GFG & AJAX TOCCO)

Galvanising Line – 3 No's

Galume Line – 1 No.

The purpose of the Continuous Galvanizing line is to apply a coat of zinc onto the surface of steel sheets in an effort to increase their corrosion resistance. There is a wide range of control of zinc coat thickness, and the galvanised steel sheets are used for a board range of purposes, including construction materials, automobiles and electrical appliances. GALUME is the trade name for a sheet steel product with a highly corrosion resistant coating containing nominally 55% aluminium and 43% zinc by weight, the balance primarily silicon is used to effect excellent adhesion to the steel substrate. This metallic coating which is applied using a continuous hot-dip coating process combines the galvanic corrosion protection of zinc with the barrier protection of aluminium.

COLOR COATING LINE ( SMS-ESMECH with the technology collaboration with EMG, COMENCO & GFG )

BSL is having Color coating line with hot laminator supplied by SMS-ESMECH with the technology collaboration with EMG, COMENCO & GFG. Embossing (NAWOO, KOREA), Profiling (AL-KONG, KOREA) & Tension Leveller (SMS, ESMECH) are also installed. we used RMP,SMP & PVDF type of paint which makes us unique for appliances & high end products.

H & T LINE: ( SECO WARWICK ALLIED LTD )

Thickness – Up to 3.5 mm

Width – Up to 550 mm

The strip grinding & polishing line is to achieve the desired surface finish are from BREUER, Germany.

FINISHING SECTION

  • Corrugation Machine – 13 No's. ( ESMECH & REGAL IRON)
  • Cut to Length Line - 26 No's. ( IDH, FIMMI, DAEHWA, GEORGE)
  • Slitting Line – 14 No's. ( IDH, FIMMI, DAEHWA)

  • Slitting Line for cold rolled steel strip coils cut in longitudinally direction to get the strip in required width as per customer requirement.

PLANT AND FACILITY

HR SLITTING (SMS– ESMECH)

Slitting serves three purposes :

(i) HR coils are available in widths which are wider than the required for Cold Rolling. The trimming / slitting is done with the HR Slitter.

(ii) The HR coils available may have width variation of the order of up to 20 mm, so to get the uniform width these coils are slitted.

(iii) The edges of HR coils may get damaged during transportation because of poor packaging and/or improper handling. In order to remove these damaged edges the HR coils are trimmed /slitted.

PICKLING (SMS-ESMECH with the technology collaboration with PRO ECO, Canada)

Pickling Line – 02 No's

Pickling is a metal surface treatment used to remove impurities, such as stains, inorganic contaminants, rust or scale from ferrous metals, copper, precious metals and aluminium alloys.

Thickness Range – 1.6 to 6mm

Width Range – 700 – 1700 mm

COLD ROLLING MILL ( CMI-FPE, INDIA)

  • 6 Hi Mill – 2 No's
  • 4 Hi Mill – 3 No's
  • Width Range – 250 – 1300 mm

The primary function of Cold Rolling is to reduce the thickness of Hot Rolled Pickled strip at room temperature. During the operation overall max reduction of up to 90 % in thickness of the HR Coil can be achieved. Cold rolling occurs with the metal below its recrystallization temperature (usually at room temperature), which increases the strength via strain hardening up to 20%. It also improves the surface finish and holds tighter tolerances.

ELECTROLYTIC CLEANING LINE ( CMI-FPI, INDIA )

  • Thickness – Upto 3 mm
  • Width – Upto 1700 mm

Electrolytic Cleaning Line is responsible for the electrolyte cleaning of the rolled sheet surface in order to have its surface contaminations and greases removed in two dipping tanks containing alkaline solution and electrolyte cleaning.

ANNEALING FURNACE ( EBNER )

Total No. of Bases – 26

Annealing Furnaces are H2 furnaces with higher convection are from EBNER, AUSTRIA & ALLIED, and MUMBAI. Complete automation in the line ensures Clean & flawless surfaces. Annealing is a process in which metals, glass and other materials are treated to render them less brittle and more workable. In the steel industry, the steel is heated and profile controlled, with times and temperatures set according to the properties desired to reach an increased ductility and relieve strains that lead to failures in service.

KATHABAR ( IMTECH DRYGENIC, USA )

Total No. of Bases – 12

BSL is having KATHABAR cooling system from IMTECH DRYGENIC, USA. By this system we can supply dehumidify air to annealed coil for cooling of coils for best result. In this system the liquid desiccant can remove contaminants in the air like oil & grease & filter them out.

NON-OX GALVANIZING/GALUME LINE (SMS-ESMECH,CMI FPE with the technological collaboration with HYPERTHERM, EMG, GFG & AJAX TOCCO)

Galvanising Line–1

Galvanising Line–1 (Galume)

The purpose of the Continuous Galvanizing line is to apply a coat of zinc onto the surface of steel sheets in an effort to increase their corrosion resistance. There is a wide range of control of zinc coat thickness, and the galvanised steel sheets are used for a board range of purposes, including construction materials, automobiles and electrical appliances. GALUME is the trade name for a sheet steel product with a highly corrosion resistant coating containing nominally 55% aluminium and 43% zinc by weight, the balance primarily silicon is used to effect excellent adhesion to the steel substrate. This metallic coating which is applied using a continuous hot-dip coating process combines the galvanic corrosion protection of zinc with the barrier protection of aluminium.

COLOR COATING LINE ( CMI-FPE , INDIA )

BSL is having Color coating line with hot laminator supplied by SMS-ESMECH with the technology collaboration with EMG, COMENCO & GFG. Embossing (NAWOO, KOREA), Profiling (AL-KONG, KOREA) & Tension Leveller (SMS, ESMECH) are also installed. we used RMP,SMP & PVDF type of paint which makes us unique for appliances & high end products.

H & T LINE: ( SECO WARWICK , ALLIED LTD, DAEHYUN )

H & T LINE : 4 No's

Thickness – Up to 3.5 mm

Width – Up to 550 mm

The strip grinding & polishing line is to achieve the desired surface finish are from BREUER, Germany.

High Tensile Steel Strips ( DAEHYUN , Korea)

Thickness Tolerance– Up to (+-)0.03 mm

Width Tolerance– Up to (+-)0.127 mm

Metal Seals - All variety of seal like,Snap-on seals,Push type seals,Nestak seals are available for various applications with customer Logo/Signature.

Strapping Tools - All Manual / Pneumatic / Power Strapping Tools.

API Pipe's - Large Diameter (Mill Tech Korea,Linsinger Austria,Initech Korea)

Size Range – 219 mm to 360 mm High Frequency Welded

Wall Thickness – 4 mm to 24 mm

Length – 6 Mtr to 18.5 Mtr

In the year 2010,the company comissioned its Large Diameter - High Frequency Welded(HFW) Pipe Mill ( 8" to 24 7/8") at Khopoli.

FINISHING SECTION

  • Corrugation Machine – 7 No's. ( ESMECH & REGAL IRON)
  • Cut to Length Line - 13 No's. ( IDH, FIMMI, DAEHWA, GEORGE)
  • Slitting Line – 11 No's. ( IDH, FIMMI, DAEHWA)

  • Slitting Line for cold rolled steel strip coils cut in longitudinally direction to get the strip in required width as per customer requirement.

PLANT AND FACILITY

DRI (LURGI)

Bhushan Steel has ten DRI with combined capacity of 5000 Mt per day. This DRI complex has RMHS, day hopper for storage of Iron ore and Coal, rotary kiln, discharge cooler, high intensity magnetic separator. DRI production process is one in which the solid metallic iron is obtained directly from solid iron ore without subjecting the ore or the metal to fusion.DRI is used as the raw material for the steel making process

Sinter Plant (CHINA SHOUGANG, OUTOTECH GERMANY)

Iron ore Fines from mines along with other additives like carbon (coke fines) fluxes as refining agent and mill scale is mix in the proportionate to get the quality of sinter as 54% Fe, this mix is being processed in blending plant, this mix is charged in the furnace for combustion to convert into the agglomerate called sinter. The size of sinter is 6-40 mm which is charged in the blast furnace for the melting.

Sinter is used as major raw material in the Blast furnace in order to facilitate the melting and to give the porosity to the charged material.

Coke Ovens (CHINA SHOUGANG, PAUL WURTH GERMANY)

Bhushan steel is operating one of the most modern battery of the time, function of the coke oven is to convert the desired blend of the coking coal into the Coke. This blend is heated in absence of air to remove the Volatile matter into gases. The product from coke oven is used as the reductant/fuel in the blast furnace and the sinter plant

Blast Furnace (DANIELI CORUS, PAUL WURTH)

Raw material for the Blast furnace includes 80-90% sinter, 10-20% Lump ore, Blast furnace coke, Fluxes in the proportion from the top, hot blast is blown from the Tuyeres. This blast at 1500C to be blown from bottom with counter current principle it flows to reduce the top descending charge. Blast furnace has various zones for melting and refining this charge reacts chemically with hot blast. Hot blast from top has been used to preheat the stoves at any time 1 stove is in blast and 2 stoves are on gas.

In a blast furnace, fuel, ore, and flux (limestone) are continuously supplied through the top of the furnace, while a hot blast of air (with oxygen enrichment) is blown into the lower section of the furnace through a series of pipes called tuyeres, so that the chemical reactions take place throughout the furnace as the material moves downward. The end products are usually molten metal and slag phases tapped from the bottom, and flue gases exiting from the top of the furnace. Hot metal / Pig iron is used as the raw material for the steel making process

Steel Melting Shop-1 (DANIELI ITALY, CONCAST INDIA)

Electric arc furnace converts Hot metal/Pig iron/Scrap/DRI into steel by using oxygen as refining agent. An electric arc furnace (EAF) is a furnace that heats charged material by means of an electric arc and refining by means of Oxygen. Major product from SMS 1 is billets and blooms for long product major application in structural steel

Steel Melting Shop-2 (SMS MEVAC, SMS SIEMAG)

SMS 2 has 1 set of Con – Arc and auxiliary facility for the steel making, hot metal/Pig iron/Scrap/DRI into steel by using oxygen as refining agent. Con arc has an flexibility to use any of the charge mix based on the market dynamics

Advantages of Con-Arc Furnace :

  • 1. Flexibility of raw material to be used, it can take Solid as well as liquid charge for steel making.

  • 2. This greatly reduces the energy required to make steel when compared with primary steelmaking from ores.

  • 3. Con-Arc can be rapidly started and stopped, allowing the steel mill to vary production according to demand.

Steel Melting Shop-3 (SMS MEVAC, SMS SIEMAG)

SMS 3 complex consists of 2 Basic oxygen furnaces and along with secondary metallurgy facility as LRF/RH and 2 stands continuous caster.

Process of BOF includes usage of 90% Hot metal and 10% DRI/Scrap/Iron Ore for melting, this inputs is converted into molten steel by blowing the oxygen with high pressure and refining by addition of the fluxes (Lime and dololime)

Secondary metallurgy includes the addition of the prerequisite fluxes and ferroalloy it is refined to the low and medium carbon steel. Treated steel has been converted to the slabs in the slab casters. 70% of the slabs directly charged to the Roughing mill of the HSM through Reheating furnace, through various quality measures we are able to produce the most critical grades like HSLA, IF, API, and Low carbon grades

Lime - Dolo Plant

Bhushan Steel has 4 x 300 Tons per day lime calcination plant, where limestone/dolomite is converted into the quick lime and dololime. LCP is vertical shaft reactor with counter current reaction principle Limestone is charged from top of shaft and Coke oven gas (Reducer gas) is being charged from bottom of shaft furnace, this reacts with each other to convert the calcium carbonate in the calcium oxide.

Hot Strip Mill (SMS, TENOVA)

This is one of the most modern mills with facility of 2x300 TPH walking beam furnace with which takes fuel as mixing of BFG-COG. This combination of fuel is fired in the furnace with oxygen enrichment to give the desired rolling temperature for the Slabs. Temperature ranges from 11500 to 12500 C depending on the section size of the Slabs. RHF is followed by primary de-scaler, roughing mill, decoiler, finishing mill, down coiler and slab conveying arrangement.

All the activity has been carried out in complete auto mode with minimal manual intervention Roughing mill has 5/7/9 reversing passes based on the reduction ratio desired. Further it has 6 Finishing stands which give the desired final size and shape of the strip.

HR SLITTING (SMS– ESMECH)

Slitting serves three purposes :

(i) HR coils are available in widths which are wider than the required for Cold Rolling. The trimming / slitting is done with the HR Slitter.

(ii) The HR coils available may have width variation of the order of up to 20 mm, so to get the uniform width these coils are slitted.

(iii) The edges of HR coils may get damaged during transportation because of poor packaging and/or improper handling. In order to remove these damaged edges the HR coils are trimmed /slitted.

PICKLING (SMS-ESMECH)

Pickling Line – 01 No.

Pickling is a metal surface treatment used to remove impurities, such as stains, inorganic contaminants, rust or scale from ferrous metals, copper, precious metals and aluminium alloys.

Thickness Range – 1.6 to 6mm

Width Range – 700 – 1700 mm

COLD ROLLING MILL (HITACHI, JAPAN / CMI, INDIA)

  • 6 Hi Mill – 3 No's
  • Width Range – 1050 – 1350 mm

The primary function of Cold Rolling is to reduce the thickness of Hot Rolled Pickled strip at room temperature. During the operation overall max reduction of up to 90 % in thickness of the HR Coil can be achieved. Cold rolling occurs with the metal below its recrystallization temperature (usually at room temperature), which increases the strength via strain hardening up to 20%. It also improves the surface finish and holds tighter tolerances.

ELECTROLYTIC CLEANING LINE ( CMI-FPI, INDIA )

  • Thickness – Upto 3 mm
  • Width – Upto 1700 mm

Electrolytic Cleaning Line is responsible for the electrolyte cleaning of the rolled sheet surface in order to have its surface contaminations and greases removed in two dipping tanks containing alkaline solution and electrolyte cleaning.

ANNEALING FURNACE ( EBNER )

Total No. of Bases – 18

Annealing Furnaces are H2 furnaces with higher convection are from EBNER, AUSTRIA & ALLIED, and MUMBAI. Complete automation in the line ensures Clean & flawless surfaces. Annealing is a process in which metals, glass and other materials are treated to render them less brittle and more workable. In the steel industry, the steel is heated and profile controlled, with times and temperatures set according to the properties desired to reach an increased ductility and relieve strains that lead to failures in service.

KATHABAR ( IMTECH DRYGENIC, USA )

Total No. of Bases – 30

BSL is having KATHABAR cooling system from IMTECH DRYGENIC, USA. By this system we can supply dehumidify air to annealed coil for cooling of coils for best result. In this system the liquid desiccant can remove contaminants in the air like oil & grease & filter them out.

NON-OX GALVANIZING/GALUME LINE (ESMECH,TENOVA,CMI-FPE,AJAX TOCCO,SPOONER,THERMOFISHER)

Galvanising Line – 2 No's

Galvanising Line – 1 No. (Galume)

The purpose of the Continuous Galvanizing line is to apply a coat of zinc onto the surface of steel sheets in an effort to increase their corrosion resistance. There is a wide range of control of zinc coat thickness, and the galvanised steel sheets are used for a board range of purposes, including construction materials, automobiles and electrical appliances. GALUME is the trade name for a sheet steel product with a highly corrosion resistant coating containing nominally 55% aluminium and 43% zinc by weight, the balance primarily silicon is used to effect excellent adhesion to the steel substrate. This metallic coating which is applied using a continuous hot-dip coating process combines the galvanic corrosion protection of zinc with the barrier protection of aluminium.

COLOR COATING LINE ( CMI-FPI, INDIA )

BSL is having Color coating line with hot laminator supplied by SMS-ESMECH with the technology collaboration with EMG, COMENCO & GFG. Embossing (NAWOO, KOREA), Profiling (AL-KONG, KOREA) & Tension Leveller (SMS, ESMECH) are also installed. we used RMP,SMP & PVDF type of paint which makes us unique for appliances & high end products.

FINISHING SECTION

  • Corrugation Machine – 10 No's. (REGAL IRON,INDORE)
  • Cut to Length Line - 10 No's. ( FIMMI, ESMECH )
  • Slitting Line – 3 No's. (FIMMI)

  • Slitting Line for cold rolled steel strip coils cut in longitudinally direction to get the strip in required width as per customer requirement.