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Our company is targeting to be amongst prominent S.S. Ingots and S.S. Sheets manufacturers in India. We deal with manufacturing and supplying of S.S. Ingots, S.S. Sheets. Our products are widely acceptable because of its quality control assurance and use of best raw materials. We ensure to offer S.S. Ingots, S.S. Sheets at very reasonable rates.
Manufacturing process for S.S. Steel Ingot
The Process of manufacturing Ingots from raw materials such as scraps and it can be broadly classified as follows :
Melting Of Raw-Material :
- Selection of Raw Material
The Quality of Raw material required depends upon the type of furnace in use. When induction Furnace is utilized, as is the case, the ideal quality of raw material should be clean S.S Steel Scrap of low carbon content.
- Charging and Loading of Raw Material into Furnace
The scrap is stored near to the furnace for easy operation, scrap stored in buckets and lifted by crane on furnace plateform and scrap charged in induction furnace by manually. Besides charging of scraps into furnace it also handles other operation like removal of ingots moulds, removal of S.S Ingots etc.
An induction furnace is a highly sophisticated equipment consisting of a crucible with a lid. Heat is generated by the induction of medium frequency electricity. The furnace is equipped with the necessary control panel, which receives electrical power at normal 50Hz frequency and converts the same to DC power. The DC power generated is again converted to AC power of medium frequency, which induces the heating effect to the furnace. In addition to the control panel, the entire furnace system is thoroughly cooled for protection. A separate water supply system along with cooling tower is installed to feed the furnace continousely with demineralised cool water. The furnace can also be titled to pour out the molten metal. The inside surface of the crucible in normally coated with castable ceramics and fire clay in intervals of 6 to 7 days. This protects the crucible and gives a longer life to the furnace.
The furnace crucible is charged with the requisite quantity of scrap and the lid is put on. Power introduced and the furnace gets hot and the steel starts to melt. Heating is continued till the entire metal mass metal to liquid state. At this stage, a little time is available for adding inclusions like ferro alloys and carbon, if necessary. A sample of molten metal is sent to the laboratories for quality check-up and analysis. Based on the analysis report, ferro alloys and other alloys materials are added after proper weightment. The temperature of the metal bath will be adjusted suitably by adjusting power into the furnace to ensure proper mixing of alloys in the bath. After sometime, when the metal bath has reached the appropriate temperature, sample is send to the laboratories and the process is repeated till the desired is quality is obtained. The molten metal is now ready for pouring into the moulds.
The methodology of casting Ingots is called uphill top and bottom pouring. The advantage is that simultaneously depending on the capacity a number of ingots can be cast. Prepared and set moulds will be kept in casting area in proper sequence. The molten metal is poured through a central shaft and is allowed to rise through the ingot moulds through a “series of channels. By this method, solid non-porous casting can be achieved and the weight of the molten metal ends any possibility of blowholes. Some of the equipments used in arranging a set of moulds are
- Base Plate or Bottom Plate & B.P. Sets
Bottom plate is a heavy C.I. Plate, the size of which varies depending on the number of ingots to be cast which on its part depends on the furnace capacity. The bottom plate has groves to fit in ceramic material made boxed called B.P sets are so places inside the grooves of the bottom plate that they are inter connected to one another between the B.P sets are filled by ceramics bricks. The entire system is called a B.P set Unit. The Ingot bould are kept on the upper opening of the B.P. sets and the whole system is sealed by means of castable ceramics, fire clay and ramming mass. One central hole of larger dia is kept open to receive the molten metal.
A long pouring pipe with ceramic sleeves inside is kept on the central opening of a B.P set and sealed. The molten metal is pourd into the system through this central shaft. Molten metal passes through the central shaft into the B.P sets and next to the ingot moulds. The level of metal rises inside the mouldes till the charge is exhausted. The metal is allowed to cool for a few minutes and then the ingot moulds are lifted away by the E.O.T Crane. Next the entire B.P. set is also removed with the Ingots sticking out, to the finishing yard. Now the Ingots, Runner & Risers are removed for sale. |
