Summer Internship BHUSHAN STEEL LIMITEDSUBMITTED BY:PRATEEK AKSHAY KAISTHA AMOGH BHANDRALIA B.TECH MAE 7TH SEMESTERSUBMITTED TO:MR. ABHISHEK JAIN

ABOUT THIS GROUP Bhushan Steel Ltd formerly known as Bhushan Steel & Strips Ltd. has an existing steel production capacity of 2 million tones per annum (approx.).

It was the vision of the founder - Brij Bhushan Singal. The company has three manufacturing units:Uttar Pradesh Plant(Sahibabad Unit)Maharashtra Plant (Khopoli unit) Orissa Plant(Meramandali unit)

This unit, Sahibabad (Uttar Pradesh) has a power plant of 24 MW.

FINISHED PRODUCTS:COLD ROLLED COILCOLD ROLLED SHEETGALVANISED PLAIN COILGALVANISED PLAIN SHEETGALVANISED CORRUGATED AND COLOR COATED SHEET

SOURCE: bhushan-group.org SOURCE: bhushan-group.org

MANUFACTURING PROCESSES:

Cold rolling:Occurs below metals recrystallization temperature(400 to 700 degree celsius).In cold rolling four-high or cluster mills are used.Increases thestrength, improves thesurface finishand holds tightertolerances.Cold-rolled products include sheets, strips, bars and rods.Width 1700mm(max)

SOURCE: efunda.com/processes

COLD ROLLING INCLUDESPICKLINGELECTROLYTIC CLEANINGANNEALING

1. PicklingMetal surface treatment method.To remove impurities, such as stains, inorganic contaminants, oxides,rustorscale.pickle liquor, which containsstrong acids ( -3 to 2 degree celsius)Use of oil film as waterproof coating.

2. Cleaning:

Rolling oil, grease, dust is removed by electrolytic cleaning. Caustic bath (maintained around 95 degree celsius).Bath - electrolytic cleaner unit that applies 7200V attracting oils and iron fines (dust) off of the strip.A thin film of silicate is plated to prevent sheets from sticking.

3. Annealing:

Metal is heated to a specific temperature and then allowed to cool slowly.Atoms migrate in the crystal lattice and the number of dislocations decreases.Leading to the change in ductility and hardness.Performed to improve ductility by inducing a recrystallized structure in the steel.

Galvanisation: Continuous hot dip coating process is used for galvanizing steel sheet.Hot-dip coating process begins by cleaning steel.The steel passes into the heating furnace to soften it and impart the desired strength.The steel is maintained under a reducing gases, composed of hydrogen and nitrogen, to remove any oxides.

SOURCE: capitalsteel.net/galvanizing process

Continued.Exit end of the furnace is connected with a vacuum chamber, to prevent any air from re-oxidizing The steel product reacts with the molten metal to create the coating. The high-pressure air is used to remove any excess molten zinc. Then the steel is cooled to allow the metal to solidify onto the steel surface.

COLOUR COATED AND CORRUGATED SHEETSCan resist corrosion for about 25-30 yrs as compared to the galvanized sheets (10-15yrs)After galvanisation, the thin sheets are dipped in coloured liquid to coat them with a specific colour.These sheets are further laminated with thin layer of plastic to prevent scratches during transportation and maintain its aesthetic value.These sheets are also corrugated i.e. parallel ridges and furrows are made in them for different uses.

COLOUR COATED AND CORRUGATED SHEETSSOURCE: bhushan-group.org

Major Customers Mahindra MarutiYamahaHondaL.GSamsungWhirpool

ApplicationsConstruction & Infrastructure Industrial / domestic roofing and cladding Airports, atriums in malls and showrooms False ceiling, interiors, Venetian blindsWhite Goods Refrigerator Display freezers Washing machinesAutomotive Bus body Railway coaches /luxury coaches

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