IIM METAL NEWS Special Issue on Iron & Steel
ISSN 0972-0480 Monthly Vol.23 No. 4 & 5 APRIL & MAY 2020
Source : WSA
Metallurgy Materials Engineering
The Indian Institute of Metals 1 2 IIM METAL NEWS Vol. 23 No. 4 & 5 April & May 2020
C Message from the President’s Desk 5 O Editorial : Steel is Indispensable 7 N TECHNICAL ARTICLE T Special Steels and the Competitiveness of the Indian Special 9 E Steel Sector - Dipak Mazumdar N TECHNICAL ARTICLE T Product Development Efforts in Indian Steel Industry 22 S - Ramen Datta and Mukesh Kumar News Update 26
IIM Chapter Activities 27
Crude Steel Production Affected By Covid – 19 30
Recent Development 30
Members' News 31
Steel Statistics 32
The IIM Metal News and The Indian Institute of Metals do not accept any responsibility for the statements made and the opinion expressed by the author(s) in the technical articles. Printed and Published by Shri Kushal Saha, Secretary General, on behalf of “The Indian Institute of Metals”, and printed at Print Max, 44, Biplabi Pulindas Street, Kolkata-700009 • Email : [email protected] and published at ‘Metal House’, Plot 13/4, Block AQ, Sector V, Salt Lake, Kolkata-700091, West Bengal, India E-mail: [email protected], [email protected] Phone: 033-2367 9768 / 2367 5004 Website: www.iim-india.net Fax: (033) 2367 5335 Facebook - https://www.facebook.com/TheIndianInstituteofMetals/ Instagram - https://www.instagram.com/indianinstituteofmetals/ Editor : Dr. Santanu Ray
Vol.23 No.4 & 5 APRIL & MAY 2020 3 IIM METAL NEWS THE INDIAN INSTITUTE OF METALS
PATRONS Mr R M Dastur Mr Sajjan Jindal Dr Baba Kalyani Mr Satish Pai
ADVISORY COMMITTEE OF FORMER PRESIDENTS Mr R N Parbat Dr Dipankar Banerjee Prof K Chattopadhyay Mr L Pugazhenthy Mr M Narayana Rao Dr R N Patra Dr Sanak Mishra Mr H M Nerurkar Mr S S Mohanty Dr U Kamachi Mudali, Convenor
COUNCIL FOR THE YEAR 2019-20 PRESIDENT Dr U Kamachi Mudali
VICE PRESIDENT & CHAIRMAN VICE PRESIDENT & CHAIRMAN VICE PRESIDENT & CHAIRMAN Non-Ferrous Division Ferrous Division Metal Science Division Prof Amol A Gokhale Mr T V Narendran Dr Samir V Kamat
IMMEDIATE FORMER PRESIDENT Mr Anand Sen
SECRETARY GENERAL Mr Kushal Saha
HON TREASURER CONTROLLER OF EXAMINATION CHIEF EDITOR, TRANSACTIONS MANAGING EDITOR, IIM METAL NEWS Mr Somnath Guha Prof P K Mitra Prof B S Murty Dr Santanu Ray
Jt. SECRETARY (Office of President) Mr Niraj Kumar MEMBERS Mr Raghavendra Adiga Prof Sushil K Mishra Dr Daniel Sagayaraj T A Dr R Balamuralikrishnan Prof N K Mukhopadhyay Mr B Saha Dr Suddhasatwa Basu Dr P Ramesh Narayanan Dr Arjit Saha Podder Mr Anirban Dasgupta Prof Jagannath Nayak Prof S Raman Sankaranarayanan Dr D De Sarkar Dr Vinod K Nowal Mr D K Saraogi Mr Debashis Deb Dr Sarmishtha Palit Sagar Mr Babu Sathian Mr K K Ghosh Prof Prita Pant Dr J D Sharma Mr B M Hasan Dr P Parameswaran Mr Sanjay Sharma Mr S K Jha Mr Sudhanshu Pathak Mr Kaushal Sinha Dr Sunil D Kahar Mr Abhijit Pati Mr Lokendra Raj Singh Dr Vivekanand Kain Dr Pradip Prof Sudhanshu Shekhar Singh Prof M Kamaraj Mr Amarendu Prakash Mr Sushil Kumar Singh Dr J Krishnamoorthi Dr N Eswara Prasad Dr Piyush Singhal Prof Rampada Manna Dr Divakar Ramachandran Dr A Srinivasan Mr K L Mehrotra Mr Pradosh Kumar Rath Dr Dinesh Srivastava Mr Bibhu Prasad Mishra Mr Gajraj Singh Rathore Prof Satyam Suwas Mr Manasa Prasad Mishra Mr Barun Roy Dr P V Venkitakrishnan
FORMER PRESIDENTS 1946-48 Late J J Ghandy 1977-78 Late V A Altekar 1992-93 Late A C Wadhawan 2007-08 Dr Srikumar Banerjee 1948-50 Late P Ginwala 1978-79 Late T R Anantharaman 1993-94 Dr R Krishnan 2008-09 Mr L Pugazhenthy 1950-52 Late Phiroz Kutar 1979-80 Late P L Agrawal 1994-95 Dr S K Gupta 2009-10 Dr Sanak Mishra 1952-54 Late G C Mitter 1980-81 Late EG Ramachandran 1995-96 Mr R N Parbat 2010-11 Dr D Banerjee 1954-56 Late M S Thacker 1981-82 Late C V Sundaram 1996-97 Late P Rodriguez 2011-12 Mr M Narayana Rao 1956-58 Late K S Krishnan 1982-83 Late Samarpungavan 1997-98 Late S Das Gupta 2012-13 Mr H M Nerurkar 1958-60 Late S K Nanavati 1983-84 Late J Marwaha 1998-99 Dr C G K Nair 2013-14 Prof K Chattopadhyay 1960-62 Late G K Ogale 1984-85 Late A K Seal 1999-00 Prof S Ranganathan 2014-15 Dr R N Patra 1962-65 Late Dara. P. Antia 1985-86 Dr J J Irani 2000-01 Mr V Gujral 2015-16 Mr S S Mohanty 1965-67 Late B R Nijhawan 1986-87 Late Y M Mehta 2001-02 Late P Parvathisem 2016-17 Prof Indranil Manna 1967-70 Late M N Dastur 1987-88 Dr V S Arunachalam 2002-03 Late P Ramachandra Rao 2017-18 Dr Biswajit Basu 1970-72 Late Brahm Prakash 1988-89 Late S R Jain 2003-04 Dr S K Bhattacharyya 2018-19 Mr Anand Sen 1972-74 Late P Anant 1989-90 Late L R Vaidyanath 2004-05 Dr T K Mukherjee 1974-76 Late FAA Jasdanwalla 1990-91 Dr P Rama Rao 2005-06 Late Baldev Raj 1976-77 Late S Visvanathan 1991-92 Dr T Mukherjee 2006-07 Mr B Muthuraman
FORMER SECRETARIES / SECRETARY GENERALS* 1946-57 Late Dara. P. Antia 1968-76 Dr M N Parthasarathi 1986-97 Late S S Das Gupta 2006-13 *Mr J C Marwah 1958-67 Mr R D Lalkaka 1977-86 Late L R Vaidyanath 1997-06 Mr J C Marwah 2013-15 *Mr Bhaskar Roy 2015-18 *Mr Sadhan Kumar Roy
IIM METAL NEWS 4 Vol.23 No.4 & 5 APRIL & MAY 2020 MESSAGE FROM THE PRESIDENT’S DESK
In the present scenario, most of the countries in the world being worst hit owing to the novel Corona virus, COVID-19, the cases of outbreak being increased exponentially in the last few weeks, costing significant economic loss due to lockdown situations and maintaining social distancing. During such a traumatic hour, IIM as an Institute vows for its stakeholder’s safety and wellness: physical, psychological and emotional. In order to keep our employees motivated and engaged and to cater to the needs of the fraternity, IIM has incorporated ‘work from home’ option for its Head Office employees, with effect from 23rd March 2020. As the President of the Institute, I believe that the true credibility of an organisation lies in how it is able to support its stakeholders [10,000+ Members, Officials & Employees all across], at times of a crisis. This is the time to find out innovative & alternative ways to roll with the punches; by revisiting the ways to operate & function for adjusting with the pandemic. We wish to adapt to the changing environment fast & build up a robust action plan for initiating normal operations at the earliest. In the meantime, would like to draw your attention to the following: 1. Keep in Communication – This is necessary as we are at home safely, but communicating with each other via online resources. I am happy to inform you that the Apex Committee of IIM had a Zoom VC meeting and deliberated important Agenda on 8th April 2020. The option for next IIM meetings including Council meeting via such online platform was deliberated. Every member/Chapter can utilise the same idea at this time to conduct Chapter EC meetings and lectures via Zoom, Skype, etc. This is necessary as the financial year is ended on March 31, 2020 and closing of accounts, general body meeting and election of new committee are to be done once the lockdown is lifted and everything is normal. 2. Connect with your Members - We would urge all stakeholders to adopt simple health [Primarily diet and work-outs), and sanitation measures while staying at home, during the prolonged lockdown to be physically and mentally sound. Chapter EC members may connect /touch base with the respective members, particularly senior and aged members for any help/support, if / when required towards medical support, sanitation, healthcare etc. 3. Make your Proposals ready - As most of our members would be aware, that much ahead of time, this year, IIM has invited applications for NMD & IIM Awards 2020, mandatorily through its Online Awards Portal, www.nmd- iimawards.com, wef last week of February 2020. However, this unprecedented pandemic outbreak has made some shifts in the process; online site is under temporary maintenance by the Service Providers during this period and would be up soon, with a subsequent notice to Members on IIM Website for the date of submission. So keep your proposals ready for submission. 4. AMIIM is coming back - After a halt of two years, in its last meeting in February 2020 at Vidyanagar, on the recommendation of the Competent Authority, the Council has decided resumption of fresh enrolment of AMIIM, wef 1st April 2020 [For December 2020 Session]. The Associate Membership of The Indian Institute of Metals shall now be considered as an Autonomous program managed by the Institute. An announcement with all relevant details & procedures to apply online through the Institutes’ website has been made available in the home page of https://www. iim-india.net. We hereby request all members to disseminate this information suitably, encouraging participation. 5. Organisation & Nation are important - During this one week, [April 15th to 20th], the fight against coronavirus will become more stringent, till 20th April’20, as announced by Govt. of India, however subsequently a conditional withdrawal of the lockdown is permitted in areas where the spread has either been contained or prevented. Please utilise the opportunity to go back to your work and utilise the stored energy within you to contributes to your organisational efforts in supporting the economic growth of our country. We shall have a lot of things to reflect over, as we emerge from this catastrophe. Your feedback is important for us as an Organization, to chart the right course and enable us to restart our operations at the earliest. IIM stands with you during these hours of crisis; while we work remotely, let’s stay connected ! Best wishes for a Safe and Healthy stay,
U Kamachi Mudali President, The Indian Institute of Metals 16th April 2020
Vol.23 No.4 & 5 APRIL & MAY 2020 Vol.23 No.4 & 5 APRIL & MAY 2020 5 IIM METAL NEWS IIM METAL NEWS 6 Vol.23 No.4 & 5 APRIL & MAY 2020 EDITORIAL
Steel is Indispensable The present special issue on steel covers two technical papers. It is worthwhile to recapitulate the saga of steel. It is the most fundamental engineering material, and has applications covering every aspect of our lives . Starting from household necessities, like, food can, refrigerator, washing machine, crockeries, to car, building, bridge, rail, wagon, ship, electrical motor, generator, transformer, medical equipment, and state-of-the-art satellite – steel is the backbone of modern society. It is directly linked with economic growth and prosperity of billions of people . Growth story Discovered more than 3000 years ago as some complex form of iron, steel as we understand it today, has been perfected over the years in different countries through painstaking efforts and innovations. The journey of development is still on for this versatile and essential material . An archaeological discovery in Cyprus has revealed that as early as the 11 th century BC, craftsmen were producing quench-hardened iron-bearing knives known as “Damascus blades'' . It has been reported that in the 3 rd century BC, craftsmen at some places in India were using crucibles to smelt wrought iron with charcoal to produce “Wootz” steel . This material had been admired those days for its good quality. We are now aware that steel is an alloy of iron and maximum 2 % carbon, with small or moderate addition of other elements . The alloying elements, added for making different grades of steel, impart the desirable properties. A class of steel with a minimum 10.5 % chromium is known for its ¨stainless” surface finish . It is possible to achieve amazing combination of strength, toughness, formability, corrosion resistance, electrical resistivity etc, some of which are contradictory in nature. Today stong steels can have strength of 1500 MPa , which is several magnitude higher than that of iron . Iron is the fourth most common element present in the earth crust, and abundantly present as different oxides in large part of the world. Global steel production has increased three fold in the last 50 years to about 1870 Mt. The growth has been more spectacular in the developing countries, where per capita consumption is increasing more rapidly. We have seen about eighteen fold increase in India from 6 Mt to 110 Mt in the same period . Process improvement and new grades Steel manufacturing is not a single process, it involves several stages , right from cokemaking, sintering / pelletisation , blast furnace / Corex , BOF / EAF , secondary refining , near-net-shape casting , hot rolling to cold processing . Innovative equipment design and process improvements over the years have resulted in remarkable achievements with respect to material yield, productivity, energy reduction and quality enhancement. Development and growth of metallurgical and engineering sciences have contributed significantly towards this achievement . Each process is today knowledge-driven and automation-controlled , with little margin of operator error . Some examples will concretely spell out the improvements. Working volume of blast furnaces has increased from 2000 m3 in the sixties to 4500 - 5000 m3 in recent years . This has resulted in higher production of 11000 - 12000 tpd from the corresponding lower figure of 2000 tpd . Productivity of blast furnace in the same period has consequently improved from 1.0 to 2.7 - 2.9 thm / day / m3 . Energy consumption to produce 1 tonne of steel has come down by about 60 % from 50 GJ / t in 1970 to about 20 GJ / t in recent time . Today we have more than 3500 different grades of steel with varying properties , a range of dimensions and shapes. Each grade has distinct properties designed for its specific application . The degree of innovation is borne out from the fact that 75 % of the total 3500 steel grades have evolved in the last 20 years , and did not exist before that. New lightweight high-strength steels make applications lighter and stronger . The new steels for cars, buildings, bridges and transportation help them reduce their environmental footprint . Automakers are increasingly using Advanced High Strength Steels ( AHSS ) to meet new stringent fuel efficiency regulations. Strength of steel in a modern vehicle's body structure can reach 1500 MPa , eight times stronger than 50 years ago .
Vol.23 No.4 & 5 APRIL & MAY 2020 Vol.23 No.4 & 5 APRIL & MAY 2020 7 IIM METAL NEWS Recyclable Steel is a permanent material that can be infinitely recycled, and is 100 % recyclable without loss of quality . All types of steel can be recycled back into new steel of different grades . In this context, steelmaking route of Electric Arc Furnace ( EAF ) and Induction Furnace ( IF ) have edge over the traditional BF - BOF route . EAF and IF can use 100 % steel scrap, whereas, the maximum limit is 30 % for BOF . A large quantity of steel scrap
( about 630 t ) is presently being recycled globally every year . About 1100 t of CO2 is thus saved annually, which would have been emitted from the production of virgin steel , assuming 1.7 t of CO2 generation per tonne of steel. Additionally recycling of steel scrap helps save raw materials , e.g. coal, iron ore, limestone and dolomite. Amenable to Circular Economy Steel ensures the maximum value of resources through recovery and reuse, remanufacturing and recycling . Steel industry uses its resources efficiently, and produces very little waste . On an average, the conversion figures are : waste generated is 4 % , primary steel product constitutes 63 % , and 33 % are useful coproducts , i.e. slag, process gases, emulsion and oil, chemicals and iron oxides . These coproducts are gainfully utilised in different applications . Slag is used in cement, road construction, fertilisers and sea forestation . Process gases are used to produce heat and electricity in the steel plant , providing 60 - 90 % of the electricity requirement when fully used. Challenge Ahead The steel industry recognises that it has a role to play in sustainable development without damaging the environment. Society at large is conscious about the extent of gaseous, solid and liquid discharges, and stricter regulations are being formulated . Modern plants must have access to technologies to manage most common emissions, e,g. CO2, SOx, NOx, dust, heavy metals, to meet the ever-increasing regulatory requirements. Fabric dust filters in steel plants have achieved a collection efficiency rate of more than 99 % even for very small particles . Modern sinter plant is using more than 40,000 extremely fine filter bags, each about 3 m long and with a total fabric area of 45,000 m3 . This can reduce dust emission by 99.99 % . The steel industry still accounts for 7 - 9 % of global direct emissions from the use of fossil fuels . Carbon plays a major role in this high emission as the reductant of iron ore . In spite of a lot of process improvements, on an average more than 1.7 t of CO2 is emitted even today for every tonne of steel produced . To overcome this problem, we have to revolutionise the way steel is made, by developing breakthrough technologies . This requires sustained and joint initiatives from the whole steel industry . – Dr. Santanu Ray *********
EDITORS CORRESPONDENTS Dr Manojit Dutta Sri S K Basu (Kolkata) Prof J Dutta Majumdar Dr Chiradeep Ghosh (Jamshedpur) Dr R Raghavendra Bhat Sri Rishabh Shukla (Pune) Dr N Eswara Prasad Sri N K Kakkar (Delhi) Prof Sudhanshu Shekhar Singh Sri M N V Viswanath (Hyderabad) Dr Mithun Palit
IIM METAL NEWS 8 Vol.23 No.4 & 5 APRIL & MAY 2020 TECHNICAL ARTICLE
Special Steels and the Competitiveness of the Indian Special Steel Sector
Dipak Mazumdar
Introduction VD-CC based special steel mills and (iii) the EIF-CC Since independence, production of steel in India has based re- melting units. While integrated steel mills increased steadily, touching the 100 million tonne (such as, TATA, JSW, RINL, JSPL etc.) primarily mark for the first time in 2018. India surpassed Japan use BOF technology to produce large volume of flat to become the second largest producer of steel in the products (i.e., hot rolled coils for auto and domestic world. During the period, 2010-2018, production of applications), the special steel sector, on the other steel in India increased nearly by a factor of 1.6 which hand, use EAFs to produce diverse grades of billets has been the highest among all nations. Steel production or blooms catering to the transportation, nuclear, data depicted in Fig.1 (a) shows the growth trajectory defense, health and power sectors. TMT bars, catering and indicates that significantly higher rate of growth is to the construction sector, are the main produce of the needed to meet the target of 300 Million tonnes of steel induction furnace steelmakers. Historically, BF and by 2030-31. Indeed, data on the Ministry of Steel's BOF have been applied in conjunction to produce home page and presented in Fig.1(b) suggests that to steel in integrated mills. Nevertheless, several giant achieve and sustain a 5TnUS$ domestic economy, at steelmakers of the country such as JSPL, ArcelorMittal least 200 Million tonne of steel per annum is required (Essar) and TATABSL have adopted large, world class to be produced in the country by 2024 or so. Clearly, EAFs in their plants and integrated the latter in the BF- steel production, education and research are required to BOF route for economic reasons. Thus, charging of hot be strengthened significantly. metal (from BF) in an EAF is becoming increasingly popular and an emerging trend in liquid steel production. Steel producers and production routes in India can be broadly classified into three distinct groups, namely, Integrated steel mills, both in the public and private (i) the BF-BOF(+EAF)-LF-CC1 based integrated steel sectors, such as TATA steel (at Jamshedpur, Angul mills, (ii) the MBF- OSM-LF-VD-CC or EAF-LF- and Kalinganagar), JSW (at Toranagallu, Salem and
Figure 1 (a) . Domestic steel production in recent years and future projection and (b) the envisaged amount of steel consumption required to drive a domestic, 5 TnUS$ economy (from ref.1) .
Department of Materials Science and Engineering, Indian Institute of Technology Kanpur, E-mail: [email protected]
Vol.23 No.4 & 5 APRIL & MAY 2020 Vol.23 No.4 & 5 APRIL & MAY 2020 9 IIM METAL NEWS Dolvi), SAIL (at Bokaro, Rourkela, Bhilai, Durapur, productivity, production routes and product ranges Burnpur and Salem), JSPL (at Raigarh and Angul) are first presented and discussed. In such context, the are giant steelmakers, each producing several million role of engineering and R&D in special steel plants tonnes of steel annually. These aresufficiently robust, is highlighted. Several specific shop floor problems have nationwide presence and firm footing in the investigated over the years by the present author are market place. Many have captive mines, large pool subsequently discussed, albeit briefly, to demonstrate of highly qualified technically manpower and access the role and importance of collaborative R&D in the to modern technology and process control equipment context of special steel plants. Following such, concept (Level 3 and higher). Some of the integrated steel mills of a unique, R&D centre, in the form of a consortium, in the country have foreign collaborations; routine catering primarily to the domestic special steel sector, is association with solution providers (such as, SMS argued and advanced. It is pointed out that such a centre Semag, Mitsubishi etc.) and in-house R&D ensure can largely fulfil the R&D needs of the domestic special seamless, day-to- day production with high yield. steel plants and solve many plant problems related to In contrast, score of domestic special steel plants, material and energy consumption, productivity and on each of the above mentioned counts, tends to be product quality. It will also be an effort in the direction abysmally poor. Indeed, low volume production, lack of import substitution for the strategic sectors such as, of in-house R&D, old furnaces/ reactors and obsolete Defence, Space, Nuclear etc. process control equipment are serious deterrents that The Indian Special Steel Sector make sustained production of defect free, diverse At present, there are more than twenty special steel grades of steel economically extremely challenging in plants, distributed all over the country and producing special steel plants. For operational advantages, many collectively about nine Million tonnes of different special steel plants in the country have, therefore, grades of alloy steels (Stainless steel, tool steel, high adopted different survival strategies. Thus, while many speed steel, bearing steel, spring steel, free cutting steel special steel plants in recent years have merged with etc., to name a few) primarily for the transportation, giant steelmakers (SISCOL with JSW, Usha Martin nuclear, defense, health and power sectors. It is with TATA steel, Mukand with Sumitomo Metals), important to mention that the special steel sector others have collaborated with renowned international in the country, during the past five years(2013 to steelmakers (e.g., MUSCO with the Sanyo Special 2017) has grown from 5.9 Million tonne to about 8.5 Steels (now in the Nippon steel conglomerate), Japan); Million tonne, increasing by a factor or 1.44 which is a few unfortunate ones have faced closure (viz., somewhat higher than the corresponding growth rate FACOR , near Nagpur) as well. (=1.30) of overall steel production in the country ( The special steel sector in any country is the heart 81.68 to 106.6 Million tonne). Volume wise, special of the manufacturing industry. In the Indian context, steel production in 2017 accounted for about 10% of particularly with reference to the "Make in India" the total domestic steel production. Value-wise, special programme, the special steel industry is, therefore, steel rise is proportionately larger. Key special steel expected to play key roles. Indigenisation and plants in the country and their annual rated productivity concurrent reduction in import of various grades of are summarized in Table 1. special steels necessitates empowerment of the special As pointed out already, although EAF route of steel steel sector that is the need of the hour. It is, therefore, production predominates, there are few MBF (mini blast naturally important to discuss and analyse domestic furnace) based special steel plants as well operational production of special steels and the R&D needs of in the country. The process route, generally followed the sector at length in some forum. Consequently, the in special steel plants (i.e., EAF-LF-VD-CC), is shown present work provides a broad overview of the domestic in Figure.2. Contrary to the practices in integrated special steel sector, worked out on the basis of the steel plants, practically every grade of steel produced present author's association with half a dozen special in special steel plants is subjected to extensive ladle steel plants in the country during the past two decades refining. Thus, Vacuum Degasing (VD) and calcium or so. In the following, Indian special steel plants, their injection are routinely applied in special steelmaking
1BOF=basic oxygen furnace; EAF=Electric arc furnace; EIF=Electric Induction furnace; MBF=Mini blast furnace; OSM=Oxygen steelmaking; LRF=Ladle refining furnace; VD=Vacuum degassing; CC=Continuous casting; TMT=Thermo-Mechanically treated
IIM METAL NEWS 10 Vol.23 No.4 & 5 APRIL & MAY 2020 Table 1 :Prominent special steel producers in the country and their current capacity Steelmakers Locations Current capacity, TPA Usha Martin (Alloys and Steel Jamshedpur, Jharkhand 10,00,000 Div.) (Now under TATA steel) Mukand Thane, Maharastra 340,000 Kalyani Carpenter Special Steels Pune, Maharastra 204,000 Jindal Stainless Limited Hissar, Haryana 800,000 Hospet Steels Ginigera, Karnataka 500,000 L&T Special Steels Hazira, Surat 100,000 Sunflag Steel Bhandara Road, Maharastra 500,000 Uttam Galva Steels Wardha, Maharastra 150,000 Vardhaman Special Steels Ludhiana, Punjab 180,000 Mahindra-Sanyo Special Steels Khopoli, Maharastra 240,000 ISMT Steels Pune, Maharastra 350,000 Uttam Galva Steels Khopoli, Maharastra 800,000 Neco-jaiswal Limited Raipur, Chattisgarh 140,000 Nalwa Sponge Limited Raigarh, Chattisgarh 170,000 Jai Balaji Limited Durgapur, West Bengal 78,720 Viraj Profile Limited Thane, Maharastra 528,000 Remi Metals ( WellSpun Group) Bharuch, Gujrat 150,000 Alloy Steels Plant (SAIL) Durgapur, West Bengal 246,000 JSW, Salem Salem, Tamil Nadu 10,00,000 Salem Steel Plant (SAIL) Salem, Tamil Nadu 364,000 Jindal Stainless Limited Angul, Odhisa 600,000 VISL, Bhadravati (SAIL) Bhadravati, Karnataka 40,000 TOTAL 84,80,720
Figure 2 . Lay-out of a typical special steel plant
Vol.23 No.4 & 5 APRIL & MAY 2020 Vol.23 No.4 & 5 APRIL & MAY 2020 11 IIM METAL NEWS Table 2 : Examples of some grades of steel produced by special steel plants in the form of billets, blooms, rods, bars and wires for different types of final products Grade of steel Chemistry Application Final component Name Picture EN8D C= 0.36-0.44%, Si= 0.10- Automotive Front axle beam 0.40%, Mn= 0.60-1.00%, S= 0.05, P= 0.05
S48C C= 0.45-0.51%, Si= 0.15- Transportation and Crank shaft 0.35%, Mn= 0.6-0.9%, P= manufacturing 0.03%, S= 0.035%, Ni= 0.2%, Cr = 0.2%, Cu= 0.3% SAE4135H Cr= 0.80%, Mn= 0.70%, Si Automotive Steering knuckle =0.15%, Mo= 0.15%
SAE1043M C= 0.4-0.47%, Si= 0.07- Engineering Spindle housing 0.6%, Mn= 0.7-1.0%, manufacturing and P=0.03%, S= 0.05% fabrication
30Mn5 C= 0.27-0.34%, Si= 0.15- Automotive Stub Axle 0.40%, Mn= 1.2-1.5%, P= 0.035%, S= 0.035%, Cr= 0.30%
16MnCr5 C= 0.14-0.19%, Si= 0.40%, Automotive Automotive gears Mn= 1.00-1.30%, P= 0.035%, S= 0.035%, Cr= 0.80-1.10% 42CrMo4 C= 0.38-0.45%, Si= 0.40% Engineering Connecting rod , Mn= 0.60-0.90%, P= manufacturing, 0.035% , S= 0.035% , Cr= Thermal systems 0.90-1.20%, Mo= 0.15- 0.30%
SA106GrC C= 0.35%, Mn= 0.29- Engineering Seamless tubes 1.06%, P= 0.035%, S= manufacturing 0.035%, Si= 0.10%, Cr= 0.40%%, Co= 0.40%, Mo= 0.15, Ni= 0.40%, V= 0.08% 41CrS4 C= 0.38-0.45%, Si= Automotive Axles 0-0.30%, Mn= 0.60-0.90%, P= 0-0.025%, S= 0.020- 0.040%, Cr= 0.9-1.2%, Cu= 0-0.25% SAE8620 C= 0.17-0.23%, Si= 0.15- Engineering Bull gears 0.35%, Mn= 0.60-0.90%, manufacturing S= 0.040%., P= 0.035%, Cr= 0.35-0.60%, Ni= 0.40- 0.70%, Mo= 0.15-0.25%
IIM METAL NEWS 12 Vol.23 No.4 & 5 APRIL & MAY 2020 SAE1043 C= 0.400-0.470%, Mn= Automotive Cam shaft 0.700-1.00%,S= 0.05%, P= 0.04%
EN353 C= 0.10-0.20%, Si= 0.10- Automotive, Crown wheel 0.35%, Mn= 0.50-1.00%, Engineering P= 0.04%, S= 0.04, % Ni= manufacturing 1.00-1.5%0, Cr= 0.75- 1.25%, Mo= 0.08-0.15% 41Cr4 C=0.38- Thermal systems Crank shaft 0.45%,Si=0.4%,Mn=0.6- pulsar LH and 0.9%,P=0.025%,S=0.035% RH ,Cr=0.9-1.2%
42CrV6 C=0.38-0.46%,V = 0.07- Engineering Wheel shaft .12%, Si = 0.15-35%, Mn = manufacturing 0.50-0.80%, P = 0.035%, S = 0.035%, Cr = 1.4-1.70%
Stainless steels C = 0.15%, Si =1.0%, Mn Buildings, Structural sections, (202) = 7.5-10%, P = 0.06%, S = construction, valves, architecture 0.03%, Cr = 17-19%, railways, health and leisure
to produce steel with (i) low dissolved gases (typically defense and nuclear sectors. Production of super less than 1.8 ppm hydrogen or so) and sulphur (except specialty steels, as one might anticipate, necessitates for free cutting grade), (ii) tight chemical composition large capital expenditure and more elaborate process and (iii) better cleanliness. Due to prolonged secondary route than the one shown in Figure 2. Thus, vacuum refining and exotic final chemistry, value-addition melting, refining and casting units as well as Electro in special steel plants is generally more than that in Slag Refining (ESR) are integral to the production of integrated steel mills. More than 98% of crude steel ultra-clean, super specialty steels. Recently, Sunflag in domestic special steel plants are processed through Steels has also embarked on to include different grades continuous billet or bloom casting, though in some of super alloys and special steels in its product range to plants, ingot casting is also practiced to produce very cater to the domestic space, bio-medical, super critical special grades of forging steels for specific applications. power plants and defense applications. A glimpse Beyond casting, heat treatment, rolling and forging of various grades of steels produced by special steel operations are also integrated as final finishing steps plants and some end products are presented in Table 2. in almost all special steel plants. Effective downstream Engineering and R&D needs in Special Steel Plants integration warrants that continuously cast products are Special steel plants produce diverse grades of alloy devoid of inclusions (> 40 p,m) and are free of cracks steels, in small volumes for critical applications and sliver defect. Such requirements tend to make (see Tables 1 and 2). On one hand while continuous defect-free production in special steel plants extremely development of new grades and sustained production challenging on a sustained basis. of defect-free steel economically are generally In addition to those mentioned in Table 1, MIDHANI, big challenges. Inefficient furnaces and reactors, a Govt. of India Enterprise, also produces super alloys inadequate process control, minimal recycling of heat and super specialty steels (viz., Maraging steels, and materials, poor plant facilities and discipline, on precipitation hardening steels, Molybdenum high speed the other hand, tend to make profitable production of steels and so on) for special applications in the aerospace, special steels on a sustained basis extremely difficult.
Vol.23 No.4 & 5 APRIL & MAY 2020 Vol.23 No.4 & 5 APRIL & MAY 2020 13 IIM METAL NEWS In addition to such, increasing trend to convert Blast while approximately 75% of the technical manpower Furnace hot metal directly into special steels in is engaged in the primary steel producing sector and integrated steel mills is making it more competitive and 25% in the secondary sector (EAF and EIF based difficult for special steel plants since price of a tonne of plants combined), barely 3 to 5% of the total technical furnace hot metal is substantially smaller than that of manpower is engaged in research and development in equivalent amount of scrap mix (INR 18000: 24000). Indian steel plants. This is not entirely surprising since Judicious proportioning of various charge materials (scrap, gas based and coal based DRIs etc.) therefore, steel related R&D activities in the country, both in the is frequently practised in special steel plants, such that academia and R&D organisations, despite surge in crude steel turnover is economic. steel production, have long been far from satisfactory. Given the above, it is reasonable to anticipate that Naturally, therefore, our participation in many of the technical man-power in production as well as those recently concluded, important international conferences engaged in R&D has important roles to play in has been insignificant, as data presented in Table 3 domestic special steel plants. As shown in Fig.3 [2], appears to indicate.
Figure 3 (a) . Distribution of total technical manpower in the primary and secondary steelmaking sectors (b) Proportion of total technical manpower engaged in steel plant R&D [2].
Table 3 :Participation from Indian academia and industry in three recently concluded major international conference in the area of steelmaking Conference and Number of Number of Number of Number of contributions from Total number of contributions contributions contributio India papers presented from China from S.Korea ns from Japan ICS-2015, China, 126 18 17 09 263 Industry:5;Academia:4 Asia steel-2015, 64 41 171 10 Japan, 317 Industry:6; Academia-4 Clean Steel 10, 06 04 03 02 2018, Hungary,55 Industry:0; Academia-2
In the above context, it is important to note that most and space constraints have made itdifficult for the of the special plants in the country per se, do not domestic special steel plants to have their individual, have any significant in-house R&D. These run only in house R&D. The bottle neck, in turn, has seriously skeletal R&D services with major emphasis on routine impaired any given plant's ability to favourably quality, inspection and assurance. Indeed, limited translate knowledge to resolve routine shop floor availability of highly qualified technical manpower problems. Fluctuations in raw materials quality and (more specially, metallurgists) coupled with budgetary price, stringent product quality, demanding market
IIM METAL NEWS 14 Vol.23 No.4 & 5 APRIL & MAY 2020 place and fierce competition among fellow producers of smaller inclusions (~40^m or so) from steel melt, necessitate continuous development for improvement on the other hand, tends to be extremely difficult. in steelmaking process and product performance. In Innovative processing of steel melt coupled with tight the absence of in- house R&D and similar, noteworthy process control are the prerequisites for production of external supports, continuous evolution of domestic clean steel on a sustained basis. special steel plants appears to be formidable challenge. To elucidate the above further, extent of nitrogen The present author's two decade long association with pick-up by molten steel (a measure of the extent of re- several special steel plants in the country suggests that oxidation) during transfer of molten steel from ladle production and product related problems of Indian to tundish in five different domestic steel plants is special steel plants are of largely generic nature and can summarised in Table 5. There, evidently, high nitrogen be categorised into eight broad groups, as summarised in Table 4. Of these, perhaps the most important and pick-up is indicative of significant exposure of steel significant is the issue of product cleanliness or, Non- to the ambient. This is generally known to causelarge Metallic Inclusion (NMI) contamination, characterised scale melt re-oxidation during transfer operations in terms of number, size and volume of non-metallic impairing steel cleanliness. During contact with air, inclusions present in steel matrix. Requirements on the dissolved elements like Al, Ca, Si, etc. present in steel above are product specific and generally market driven, are preferentially oxidized, form products which are becoming more and more stringent with time. Allowable typically solid, leading to the formation of various NMI size, as seen from Fig.4 [3], has important bearing types of non-metallic inclusions. Indeed, spinel on the yield strength and this is important since any (MgO.Al2O3 ) formation in low carbon aluminumkilled increase of yield strength tends to prolong service life (LCAK) steel, shown in Figure 5, is known to be caused of engineering components. Indeed, there are several by (i) increased Mg dissolution from slag/refractory grades of special steels wherein, no more than 20^m followed by (ii) oxygen pick-up during ladle to tundish size NMIs are permissible. It is well known that while transfer [4] . The appropriate chemical reaction is: larger size non-metallic inclusions (>80^m or so) can be [Mg]+2[Al]+4[O]= MgO.Al O (s) floated out and removed relatively easily, elimination 2 3
Table 4 : Some common process related problems of the domestic special steel plants Sequence Nature of problem Reasons Consequences 1 Over-blowing in EAF In-adequate end-point and Irreproducible dissolved oxygen in off-gas control melt and erratic FeO content in slag 2 Slag carry-over Absence of slag detection Poor de-oxidation efficiency and devices sub-optimal LRF performance 3 Uncontrolled amount of Poor operating guidelines High argon consumption, large slag- argon purging in ladle and PLC eye area and re-oxidation 4 Ultra-low sulphur grade Absence of deep De-S Poor efficiency of calcium injection (<30ppm) production process and impaired cleanliness 5 Air ingression through ladle Misaligned shroud and poor Air ingression, re-oxidation and shroud shroud design impaired steel cleanliness 6 Final product cleanliness Poor de-oxidation, holding Rolling defects and high rejection and calcium injection rate strategy 7 End discard Poor teeming and tundish Low metallic yield management 8 Defects in continuously cast Improper mold parameters Various types of cracks in final products and mold powder coupled products and high rejection with faulty spray cooling
Vol.23 No.4 & 5 APRIL & MAY 2020 Vol.23 No.4 & 5 APRIL & MAY 2020 15 IIM METAL NEWS Figure 4 . Maximum inclusion size and yield strength for some typical special steels [3].
Table 5 : Extent of Nitrogen pick-up during continuous bloom casting in five different Indian special steel Parameters Plant A Plant B Plant C Plant D Plant E Length, mm 1350±15 1215 1060 1200 1250 Inside diameter at 108-129 65 60 70 70 throat, mm Collector nozzle 50 45 42 45 42 diameter, mm Argon injection rate, 0.5×10-4 - 0.33×10-4 - 1.33x10-4 - 1.33×10-4 4.17×10-4 m3/s 0.66×10-4 0.66×10-4 1.7×10-4 Nitrogen pick up, ppm 6-9 7-22 5-10 10-15 7-10
Figure 5 . Energy dispersive spectrum illustrating the concentration of different species in sampling location 2 on the body of the NMI in a 41CR4 rolled bloom (sample from Plant A, Table 5).
IIM METAL NEWS 16 Vol.23 No.4 & 5 APRIL & MAY 2020 To prevent such re-oxidation reaction completely, Collaborative Research and Special Steel Plant contact/exposure between molten steel and the ambient related R&D Activities at IIT Kanpur must be avoided, as far as possible, particularly during To address process or product related problems the final stages of steelmaking. Impaired product systematically and to arrive at appropriate solutions cleanliness due to re-oxidation, such as the one are not possible always, since in-house research and illustrated in Figure 5, has long been known to be one development is practically non-existent in domestic of the major reasons of rejection in special steel plants. special steel plants. Naturally therefore, scope of Similarly, surface and internal cracks are typical defects collaborative R&D in special steel plants is enormous, that are frequently encountered in ingot and continuous particularly with the academia and R&D laboratories in casting products. In ingot casting, while the problem is the country. The present author, for over two decades more common in round ingots, having large diameters has been engaged in various R&D projects with several (>700mm), continuous casting products are also highly special steel plants namely, Hospet Steel, Mahindra susceptible to diverse types of cracks. Composition and Sanyo Special Steels, Vardhman Special Steels and cleanliness of steel, mold powders, mold design as well Sunflag Steel. Primary objective of association has as teeming practices are important process variables, been concerned with improvement in yield and determining, to a varied degree, the occurrence of such cleanliness of steel [5]. Parallel to such, guidance and defects in continuously cast billets and blooms. consultations were also routinely provided to several A sample of a longitudinal surface crack in a 700mm otherspecial steel plants including Usha-Martin alloy diameter, 9.2 tonnes alloy steel ingot, produced in steels div., Ambica Steel, Jindal Stainless, Larsen and a domestic special steel plant, is shown in Fig.6. Toubro Special Steels and Heavy Forgings and so on. Such defective ingots though are generally rejected, In the following, a glimpse of the collaborative R&D, considerable surface grinding, at the expense of both between IIT Kanpur and different domestic special time and money, can at times resolve the problem steel plants is presented in nutshell. The purpose of the partially. As a consequence of such, plant productivity enumeration is to demonstrate the role, collaborative and performance suffer. The same is true for many R&D can play to improve the overall competitiveness continuous casting products rolled out from various of domestic special steel plants. special steel plants. Systematic investigations are necessary to identify the reasons for such defects (in terms of various process and design parameters) such that remedial measures, necessary to produce defect free castings on a sustained basis, are enforced at the plant level. In such and similar contexts, the role of R&D cannot be undermined.
Figure 6. Photograph showing longitudinal surface in a 9.2 Figure 7. Relative amount of residual steel (skull) in the 10 Tonne solidified round, alloy steel, ingot tonne three strand tundish before and afterdesign modifications
Vol.23 No.4 & 5 APRIL & MAY 2020 Vol.23 No.4 & 5 APRIL & MAY 2020 17 IIM METAL NEWS Yield improvement from a three strand, 11 tonne, ladle, following de-oxidation by Aluminium, to arrive bloom casting tundish at the target chromium chemistry. Since, LCFeCr is Sequence casting is rarely practised in special steel expensive (>US$ 2200 per metric tonne), hence there plants since any given grade of steel is generally is always interest in the industry to use high carbon produced in small volume. As a consequence, furnace ferrochrome (HCFeCr) instead, as the latter is relatively or reactor volumes and heat size tend to be small in cheap (~US$ 1200 per tonne). This is, however, not comparison to those in integrated steel plants. In easy to implement at the plant level since any addition continuous casting, regardless of plant capacity, some of HCFeCr, following tapping and de- oxidation, leads residual metal (this contributes to tundish skull, as it is to significant carbon pick-up by the melt, off-setting popularly referred to) is deliberately left in tundish since target steel chemistry. it is prohibitive to drain the entire volume of liquid steel To incorporate a reasonable amount high carbon ferro- from a tundish towards the end of continuous casting2. chrome in the alloy mix (tends to be predominantly, Given that heat size and volume of steel produced are LCFeCr) during production of ball bearing steel, small, one can therefore readily anticipate that residual alloy addition practice in the melt shop was modified, metal loss from tundish3 is relatively more important wherein, HCFeCr was added to liquid steel in ladle, in special steel plants than it is in integrated steel prior to final aluminum de-oxidation of the melt. To mills. Therefore, for economic reasons, it is naturally this end, well-known theory of relative oxidation of important to optimize the residual metal loss from carbon and chromium under steelmaking environment tundish and drain out maximum possible amount of [7] has been exploited and preferential oxidation of liquid steel without significant entrainment of slag. carbon over chromium ensured during addition process. Thus to reduce skull loss from a 11 tonne, three strand, The following strategies were adopted to fulfill the bloom casting tundish, from its average level of nearly objectives i.e, 1 tonne per heat, water modelling and CFD studies were (i) a relatively more basic slag in ladle ( "V" ratio 3.8 as carried out at IIT Kanpur. Through extensive physical opposed to 3.5), and mathematical modelling, flow control devices (FCD) and their configurations were worked out to (ii) marginally higher tapping temperature (10-150C or ensure desirable tundish hydrodynamic performance. so) and Thus, incorporation of (i) a delta shaped wedge, (ii) an (iii) increased argon purging rate (~20% over and embedded pouring box and (iii) a dam with directional above the rinsing argon flow rate). slots into the main body of the 11 tonnetundish has These collectively resulted in expeditious slag-metal resulted in significant improvement in skull losses, mass transfer and low CO pressure, necessary for higher leading to annual savings of more than INR 10 crores recovery of chromium in the system. On the basis of or so. The improvement is shown in Fig.7. Suggested such, plant scale trials were carried out by judiciously modifications, in addition to the improvement in skull blending HCFeCr with LCFeCr and adding the same in losses, also eliminated strand freezing, generally a a 50 tonne ladle, following tapping, prior to aluminum matter of concern in bloomcasting tundishes having de-oxidation. Results thus obtained are summarized large surface area to volume ratio. Details of the study, in Table 6. Since the plant produces nearly 150,000 together with several other tundish skull reduction tonnes of bearing steel annually, the numbers shown in exercises are available in ref. 6 and are therefore, not Table 6 therefore imply an annual savings to the tune re-iterated here. of INR 50 lakhs or so, which is substantial. Other tacit Optimization of ferro-chrome usage during advantages of the new alloy addition strategy included, production of ball bearing grade steel for example, savings in Aluminum consumption due to Ball bearing grade steel, generally a prime product partial de-oxidation of liquid steel by carbon present in of special steel plants, contains significant amount of HCFeCr. The above discussion evidently demonstrates chromium as one of an important alloy constituents. the role knowledge based engineering can play in Typically, low carbon ferrochrome (LCFeCr) is used in enhancing steel plant process performance.
2Complete drainage of liquid steel from tundish, it is well known, results in large scale slag entrainment into mold impairing seriously the quality of cast products. The last billet or bloom is therefore generally downgraded. 3In domestic special steel plants, heat size typically varies from 30 to 60 tonne. The tundish capacity is about 10-11 tonnes and generally one tonne of residual metal loss occur for every heat. Given that as many as 20 to 30 heats are made on a daily basis, the preceding figure implies a daily maximum residual metal (or, yield) loss of about 30 tonnes. Translating to a full year, this is equivalent to ~9000 tones having a market value of nearly INR 9 to 10 crores!
IIM METAL NEWS 18 Vol.23 No.4 & 5 APRIL & MAY 2020 Table 6 : Industrial scale trial results illustrating the extent of economic benefits due to replacement of a part of LcFeCr by HCFeCr during production of ball bearing grade steel Grade of steel Heat number Cost of ferro-alloy per heat , INR Savings, INR Savings per Previous New practice tonne of liquid practice (with (mix of LCFeCr metal, INR LCFeCr) and HCFeCr) 71283 9780.39 8145.32 1635.08 32.3 SKFGRD3(M) 71284 9780.39 8174.99 1605.40 32.1 71285 9780.39 8057.17 1723.23 34.4 Average 9780.39 8125.82 1654.57 ~33
Figure 8. (a) A ladle shroud in operation and (b) A schematic of ladle shroud with principal dimensionsand (c) A ladle-shroud- tundish assembly Improved ladle shroud designs for restricting air inclusions, particularly in LCAK grades, causing large ingression and reoxidation of steel scale rejection of continuously cast billets and blooms. In clean steelmaking, protection of liquid steel stream In Fig.8, a ladle shroud in operation, a corresponding during transfer, either from ladle to tundish or from schematic and a ladle-shroud-tundish set-up are shown. tundish to mold is extremely important, as exposure In the entire assembly, of considerable importance of steel to the ambient causes re-oxidation and impairs is the shroud-collector nozzle (S-CN) joint. Air cleanliness. Thus, ladle shrouds are invariably used ingression occurs through such joint, due to the low in special steel plants to provide a secure passage to pressure region prevalent inside shroud, particularly molten steel as the latter is transferred from a ladle to if sealing between collector nozzle and ladle shroud a tundish, during continuous casting. Despite such, is not perfect. Typically argon is injected in the throat Nitrogen pick-up data, presented already in Table region of a ladle shroud to provide a 3600 shielding of 5, indicates significant exposure of molten steel to the ambient in practices, suggesting essentially that the shroud-collector nozzle joint. Mounting of a ladle shrouding of liquid steel stream, between ladle and shroud onto a collector nozzle and a relatively more tundish, is neither perfect nor, satisfactory. This is detailed look of the mode of circumferential delivery of of concern since re-oxidation (a direct measure of argon around S-CN joint are presented in Fig.9 (a) and Nitrogen pick-up) tends to generate alumina and spinel (b) respectively. Computational and physical model
Vol.23 No.4 & 5 APRIL & MAY 2020 Vol.23 No.4 & 5 APRIL & MAY 2020 19 IIM METAL NEWS study of the current argon delivery design (i.e., Fig. argon. Since shroud and collector nozzle, in practice, 9(b)), carried out in the author's laboratory, indicate are expected to be rarely perfectlysealed, such non that argon distribution around collector nozzle-shroud homogeneous distribution of the shielding gas, as a joint is highly inhomogeneous; regions opposite to the result, can aggravate steel contamination leading to injection port receiving, practically very little, or no large scale re-oxidation.
Figure 9. (a) Shroud -collector nozzle assembly and (b) the popular, eight gated, inert gas deliveryarrangements in a ladle shroud
Figure 10. Variation of argon mass fraction in the azimuthal direction in the vicinity o shroud-collector nozzle joint illustrating the effectiveness of circumferential argon distribution and shielding ensured by two different shroud gas delivery arrangements.
In our effort to improve the industrial process design, developed as a part of a Ministry of Steel (GoI) performance of ladle shroud, a physical and supported project at IIT Kanpur, is being evaluated mathematical modelling investigation has been carried currently through direct plant scale trials in one of the out. The primary objective has been to develop a domestic special steel plants. relatively more efficient inert gas delivery arrangement Apart from the examples cited above, several other such that 360o shielding of the shroud-collector nozzle investigations have been carried out and implemented joint is accomplished. The on-going investigation in special steel plants by the present author. Most has demonstrated that by marginally altering the gas notable among these have been, (i) the design of an inert delivery geometry and arrangements, substantial gas shrouding system in trumpet during ingot casting improvement in shroud process performance can be (atMSSSL, Khopoli), (ii) Argon injection in tundish achieved in the industry. In Fig.10, distribution of during the initial period of tundish filling operation argon (presented in terms of argon mass fraction) along (at VSSL, Ludhiana), (iii) ladle bottom design and the circumference of shroud-collector nozzle joint, for optimisation of purging rates (at Hospet Steel) and so two different gas delivery arrangements (i.e., existing on. These were undertaken to primarily improve steel and the current ) is shown. This clearly indicates that cleanliness as well as liquid metal yield in a bid to shroud-collector nozzle assembly is more effectively improve steel melt shop efficiency. The case studies secured via the modified design. The new gas delivery presented so far evidently demonstrate the importance
IIM METAL NEWS 20 Vol.23 No.4 & 5 APRIL & MAY 2020 of R&D and suggest that collaborative R&D can play consortium of the domestic special steel sector". important roles and enhance performances of domestic Indeed, it is with this later objective, the present author special steel plants. and his associates in the Department of Materials Epilogue Science and Engineering, have been working, for some For the "Make in India programme", growth of times, towards a Ministry of Steel, GoI supported various manufacturing sectors with minimal imports Special-steel research centre at IIT Kanpur. A proposal is imperative. Of equal importance, in such context, to this end is being worked out and is in its final stage for is the sustenance of the domestic special steel sector submission to the Ministry. Research in steelmaking, with increased productivity and product ranges. since its inception, has always been at the forefront of There is little doubt, as the present work appears to materials research at IIT Kanpur. Given the available indicate, production and product related R&D can expertise and the long history of successful industry- fulfil such objectives to a large extent and in turn, academia collaborations, there is reasonable certainty enhance the general competiveness of the special that such a centre, under the umbrella of IIT Kanpur, steel sector. More specifically, through knowledge shall be able to deliver and fulfil many imminent, R&D based engineering, many impending challenges needs of the special steel sector in the country. can be effectively addressed to improve the overall Acknowledgement: The author gratefully acknowledges efficiency of special steelmaking processes. However, Mr.O.P. Singh of Hospet Steels for sharing plant lack of highly qualified metallurgists in the task force data pertaining to Table 6 and Fig.7 respectively. as well as limited availability of resources, are likely Computational results presented in Fig.10 are due to to be serious impediments and hardly allow, at least Mr. Suvam Mukherjee, a doctoral student in the Dept. for the foreseeable future, special steel plants to have of Materials Science and Engineering, IIT Kanpur. The significant R&D in their own premises. Given the author is also grateful to Dr. B.B.Agarwal, Visiting need to reinforce manufacturing in the country, viable Professor, MSE, IIT Kanpur for his valuable input. alternatives must be worked out to provide necessary References R&D support to the special steel plants, rendering them 1. https://steel.gov.in/ [Ministry of Steel website]. innovative, productive and globally competitive. 2. DipakMazumdar and Indranil Manna: "A study on In recent years, the Ministry of Steel, GoI has established requirement and availability of technical manpower several centres of excellence in steel technology in for steel industry in India", A report submitted to prominent educational institutes in the country. These the Ministry of Steel, Govt. of India, 2015, Internal include, IIT Kharagpur, IIT Mumbai, IIT Chennai and report, IIT Kanpur No. MOS /MET /2014138. more recently, IIT (BHU) Varanasi. Steel technology centres were set-up to primarily strengthen steel 3. J.G.Speers: Brimacombe Memorial Lecture education and research in the country and thereby, help "Continuing development of modern steel produce highly competent and technically qualified products", Iron and Steel Technology (AIST), metallurgists. These centres, it is important to mention, 2018, pp.51-57. were set-up with a one time, substantial, financial 4. L.Zhang and B.G.Thomas: "State of the art in the assistance from the Ministry of Steel (MOS) and are control of inclusions during steel ingot casting", expected to be eventually self-reliant, generating Materials and Metallurgical Transactions, Vol.37B, necessary revenue from the market. Considering 2006, pp.733-761. national importance and the discussion presented so 5. http://home.iitk.ac.in/~dipak/ [Dept. of MSE, IIT far, it is perhaps desirable and time to set-up a dedicated Kanpur, website]. steel research centre, catering predominantly to the 6. DipakMazumdar, O.P.Singh, Joy Dutta, needs of the domestic special steel sector. The centre, ShaktimoyGhosh, D.Satish and Chakraborty as it is envisaged, should not only provide R&D support :"Reduction of tundish skull and yield improvement to improve plant process performance but also play key in steel plants through physical modeling of roles to improve technical manpower quality through steelmaking tundish system", Transaction of Indian continuing education activities. Eventually, with the Institute of Metals, Vol.64(6), 2011, pp.593-606. support of the special steel sector, such a centre can 7. DipakMazumdar: "A first course in Iron and be made self-reliant, flourishing eventually as a"R&D Steelmaking", University Press Hyderabad, 2015, 4Not explicitly discussed further due to proprietary reasons. pp.254-257.
Vol.23 No.4 & 5 APRIL & MAY 2020 Vol.23 No.4 & 5 APRIL & MAY 2020 21 IIM METAL NEWS TECHNICAL ARTICLE
Product Development Efforts in Indian Steel Industry
Ramen Datta and Mukesh Kumar
Introduction strength low alloy (HSLA) steels. Further, adoption Steel is an important material for the development of of thermo-mechanical controlled processing (TMCP) modern economy and is considered the backbone of has revolutionized the art of steel processing and is human civilization. Iron and steel, by virtue of its low extensively used today for the production of a wide cost, versatility and recyclability find use in multifaceted variety of steels for construction, infrastructure, oil and applications ranging from safety pins to smart cars to gas transportation, automobile and defence sector. submarines. Steel development and production of new Current Scenario grades of value-added steels is therefore treated as To maintain a competitive edge in the steel sector, it an important socio-economic indicator, reflecting the is imperative to continuously innovate and develop economic growth potential of the country. While the new grades of steel at competitive cost for existing and annual world steel production has increased four-fold in new end-applications. Product development efforts in the last fifty years from around 460 MT in the end 60’s to India have been driven by the major steel industries, 1800 MT presently, the Indian steel industry has grown particularly SAIL, TATA Steel and JSW. The first at a much faster rate from around 6.3 MT to 106 MT microalloyed steel in the country was made at Rourkela in the corresponding period. Concurrent with increased Steel Plant and rolled into plates. Since then, various steel consumption, the steelmaking and processing grades of microalloyed steels have been made and technologies have undergone dramatic changes leading used in the construction, infrastructure, hydrocarbon to development of a wide array of special steels in tune and automobile sector. An innovative concept of with the expectations of the market and society. This is using silicon in presence of niobium was used for the attested by the fact that around75% of the steels in use development of a series of high strength formable quality today did not exist 30 years ago. steels for commercial vehicles, earthmovers. Weather The steelmaking process has undergone significant resistant steels have been successfully developed improvements with the phasing out of open hearth and used for the fabrication of railway coaches and and Bessemer converters with modern basic oxygen wagons by Indian Railways. SAIL has contributed furnaces (BOF) and electric arc furnaces (EAF). With a to the development of 90 UTS rails for laying of the thrust to produce high quality clean steel for automobile, large railway network across the length and breadth linepipe and other strategic applications, remarkable of the country. Presently, SAIL is supplying around 1 advances have been made to improve the efficiency million tons of 90 UTS rails annually and are gearing of dephosphorisation, desulfurisation and high speed up for production of 110 UTS rails for higher speed and degassing using state-of- art facilities such as VAD, higher axle load tracks .Further, SAIL isproducing long VOD,LF,RH etc. Introduction of continuous casting rails of 260m,which effectively reduces the number of technology and phasing out of traditional ingot casting weld joints and ensures a smooth and safe journey. technology has resulted in substantial improvements in The automotive segment is the fastest growing yield, cost, energy and quality of cast product. The long segment in India and is continuously striving towards term challenge of integrating steelmaking and rolling development of new designs and materials for achieving process has been realised with the development of weight reduction, lower fuel consumption and improved compact strip production (CSP) technology. crash resistance of vehicles. A large number of grades In the product development front, introduction of having high strength and good combination of ductility microalloying has led to a new generation of high and formability properties such as IF, dual phase, TRIP Steel Research & Technology Mission of India , Delhi steels have been developed by TATA Steel and JSW.
IIM METAL NEWS 22 Vol.23 No.4 & 5 APRIL & MAY 2020 Presently, efforts are in progress in India and abroad To meet the above objective, we need to bring together towards development of a new class of steel known as the best talents available in the academic institutes, “Advanced High Strength Steel (AHSS)”. Inspite of R&D organisations and industry together under a the efforts and initiatives by Indian steel producers, a few carefully selected “ national mission programs”, substantial volume of our requirements in this premium funded and monitored through an institutional platform sector are met through imports. created by the major steel industries along with the Steel TMT rebars are the backbone of civil construction. Ministry. Globally, especially in developed countries, The consumption of rebars in India is estimated to be steel research is driven by a consortium of steel around 24 MT annually and valued about Rs 1.2 trillion. companies with a common objective and goal. One such Presently TMT rebars are produced by the primary program carried out in recent times is ULSAB (ultra and secondary sectors in Fe- 500,550 and 600 grades light steel autobodies) by 35 major steel companies while Fe- 650 and 700 grades are in developmental representing 18 countries to design, develop a concept stage. Recent developments include corrosion resistant car with 25% weight reduction over the benchmark at TMT rebars which finds applications in coastal regions no cost penalty, 80% improvement in torsional rigidity where corrosion rates are high. To minimize damage and meeting all crash resistant requirements. Different due to earthquakes, both for civil structures and human laboratories and steel producers were involved in the lives, a special variety of seismic resistant TMT rebars development and based on a synergistic approach have been developed and available in the Indian market between the industry and academia, a concept car for use in locations falling under Zone IV and V of the was developed by Porsche with more than 25% weight seismic map. reduction at no additional cost. Such platforms are functioning today and a few noteworthy ones are CRNO and CRGO steels are used for the power sector. Germany Technology Delivery System, European Cold rolled non oriented(CRNO) steels are principally Steel Technology Platform (E-STEP),National Science used for manufacture of motors, alternators, ballasts Foundation(NSF) of USA, POSTECH of Korea. and a variety of electro-magnetic applications requiring good electrical conductivity such as refrigerator, electric In order to bring synergy and cooperative approach iron, light fittings, fans etc. Though we are producing between the academia and industry, an institutional this class of steel in our country at Rourkela Steel Plant, platform aligned with the national needs “ Steel Research we are yet to achieve the quality requirements needed and Technology Mission of India (SRTMI) was created for higher grades (M-36 and above) and as a result recently to facilitate and oversee fundamental and bulk requirements are being sourced through imports. high impact research of national importance through Cold rolled grain oriented (CRGO) steel is used for the industry-academia collaboration. The platform is manufacture of transformers and generators. Inspite of supported by major steel industries of the country collaboration with ARMCO, USA, we have not been and outputs of the programs in terms of new process/ successful to develop this grade of steel. As a result, the new product development shall be shared equitably entire requirement of CRGO steel of around 2 lakh tons by the stakeholders. The major objective of SRTMI annually are sourced through import. is to spearhead programs of national importance, develop world class products, establish world class Strategic Interventions research facilities, enhance R&D investments to 1% Concerted R&D efforts are required to meet the of turnover and meet the National Steel Policy (NSP- domestic requirements of India in a cost effective and 2017) aspirations through strategic R&D interventions. sustainable manner. Specific attention needs to be paid Keeping the time, cost and competitiveness of the steel towards development of CRNO, CRGO, higher grades industry into consideration, a roadmap needs to be of linepipes (API X-70 and above), automotive high created on the programs to be taken up in the next 5 strength steels, coated products and thinner gauges of years. These programs, based on the expertise available hot rolled coils (HRC), which are being imported in in the country may be driven through academia- large volumes. We should strive to be self sufficient by industry participation or if needed, we may take the 2030 w.r.t. the above grades and a roadmap needs to be help of foreign technology providers and experts to fast evolved for this purpose. track the process.
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Vol.23 No.4 & 5 APRIL & MAY 2020 Vol.23 No.4 & 5 APRIL & MAY 2020 23 IIM METAL NEWS परमाणु �रए�र Nuclear Reactors र�ा अंत�र� थम�ल, उव�रक & पेट� ोकेिमकल BWRs, PHWRs & FBRs Defence Space Thermal, Fertilizer & Petrochemical अनु�योग APPLICATIONS
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IIM METAL NEWS 24 Vol.23 No.4 & 5 APRIL & MAY 2020 Vol.23 No.4 & 5 APRIL & MAY 2020 Vol.23 No.4 & 5 APRIL & MAY 2020 25 IIM METAL NEWS NEWS UPDATE
Coronavirus outbreak may rein in India's steel such as JSW Steel, Steel Authority of India Ltd (SAIL), price rally Rashtriya Ispat Nigam Ltd (RINL), Jindal Steel And The global Coronavirus outbreak is likely to rein in the Power Ltd (JSPL) and ArcelorMittal Nippon Steel rally in domestic steel prices, in step with global steel Ltd are members of the ISA. Mr. Narendran is also a prices which have sharply declined from January highs. member of the Executive Committee of the World Steel Although domestic prices have been trading at around Association. 7% discount to landed price of imports, with Chinese Business Standard mills resuming production, the pricing power of Steel sector may miss peak order season, wants domestic steel majors may be restrained going forward, supply chain opened up fully analysts have said. The rising number of global cases of India's downstream steel industry is unable to operate in Coronavirus may curb steel exports from India, CARE most parts of the country despite lockdown guidelines Ratings said in its latest report. having been eased. Currently, only integrated steel Domestic steel prices started to inch upwards from mid- producers are able to function. They are continuous November in line with the international prices. Over process units that cannot be shut down abruptly and the next three months, prices rose by 9% due to lower have been exempted from the national lockdown that inventory levels, restocking demand and expectation of kicked into gear on March 25. The problem is especially revival in economic growth on government measures. acute in the tubes and pipes segment which constitutes However, the spread of Coronavirus worldwide has led 30 per cent of India's annual steel production. India's to some pull back in prices. International steel prices estimated crude steel production was 8.7 million started to decline from mid-January onwards. tonnes (mt) in March 2020, down 13.9 per cent over Disruptions in Chinese steel production was expected March 2019, said the World Steel Association (WSA). to reduce threat of Chinese exports and provide Around 80 per cent of micro, small and medium domestic players an opportunity to raise domestic enterprises (MSMEs) of the steel sector is employed in prices and increase exports. However, the number of this segment. Despite the ongoing lockdown, there are cases in China has gone down considerably while it has increased enquiries for these products ahead of monsoon increased in other parts of the world. Therefore, there is on account of restoration of projects across the country. fear of build-up stocks from China entering the world It is important to bring this (MSME) category under market and further depressing prices. "Any supply essential services, V R Sharma, managing director at glut from China due to slowdown in Chinese demand Jindal Steel & Power, told Business Standard. may adversely impact global steel prices due to sizable Business Standard share of China in global steel production, consumption JSPL's crude steel output remains flat in Apr 2020 and seaborne trade," the CARE report said. Private steel player Jindal Steel and Power Ltd The Economic Times (JSPL) has said its consolidated crude steel production Tata Steel leaves Indian Steel Association; remained flat at 6.5 lakh tonne ( LT ) during April 2020. Narendran quits president post The company had produced similar amount ( 6.5 LT ) of crude steel during the same month in 2019. Tata Steel has withdrawn its membership from the In April this year, its consolidated sales reduced Indian Steel Association (ISA), an apex steel industry by 29 per cent to 4.55 LT from 6.42 LT in the body. Subsequent to it, the company's CEO and corresponding period a year ago. The company said Managing Director T V Narendran has also stepped the outbreak of pandemic began impacting economic down from the Presidentship of the Association, tenure activity by the third week of March, leading to the of which was scheduled to end in August. Confirming announcement of the nationwide lockdown. The the development, a Tata Steel spokesperson said, company's Managing Director V R Sharma had “Tata Steel has withdrawn its membership from the earlier said that as the demand was low in India Indian Steel Association (ISA) owing to various due to COVID-19, the company is exporting steel considerations. Accordingly, T V Narendran, CEO & to countries like Vietnam, Saudi Arabia, Thailand MD, Tata Steel, has stepped down from his position as and Europe which had placed orders with JSPL. the incumbent President, ISA. ”Leading steelmakers The Economic Times
IIM METAL NEWS 26 Vol.23 No.4 & 5 APRIL & MAY 2020 IIM CHAPTER ACTIVITIES
National Council Meeting and IIM Foundation Day Cake cutting ceremony was done to celebrate the Celebration at Vijayanagar Chapter 74th IIM Foundation Day. An interaction session was Vijayanagar Chapter hosted the National Council conducted at FORUM where the dignitaries shared Meeting # 342 and 74th IIM Foundation Day their journey with IIM, highlighting the activities Celebration on 22nd February, 2020 at the sprawling of IIM, its future plans and benefits for the members campus of Kaladham in Vidyanagar township of JSW in the metallurgical industry. They also answered Steel Vijayanagar works. It is the first of such meetings many queries from the JSW employees. They visited conducted at Vijayanagar chapter and attended by IIM Inspire Institute of Sports and Vijayanagar works. Apex body and national council members representing They appreciated the facilities, housekeeping and a wide range of Government and Private Industries the technologies displayed. The council members and Academia. This meeting deliberated on the IIM expressed their wishes to have many more IIM events administrative issues, its activities and IIM financials. at Vijayanagar and contribute actively to the Indian metallurgical industry. Angul Chapter : IIM Foundation Day celebration and INALT 2020 The 74th IIM Foundation Day and the International Conference on Innovations in Aluminium Technology, INALT 2020 was organised by The Indian Institute of Metals, Angul Chapter during February 8 - 9, 2020 at Smelter & Power Complex, NALCO, Angul, Orissa. The theme of the conference was ‘Innovations in Aluminium Technology - Navigating the future together’. Both the events were inaugurated by Guest National Council Meeting in progress of Honour Prof. (Dr.) Omkar Nath Mohanty, Director, Technology & Academic Initiatives, RSB Metaltech, The meeting was attended by 28 council members from RSB Group and Prof. (Dr.) Amol A Gokhale, Professor, various chapters including President Dr. U Kamachi IIT Bombay and Vice- President & Chairman, Non- Mudali, Vice President Dr. Amol A Gokhale, VC & Ferrous Division, IIM, in august presence of Shri M.P. MD, Neelachal Ispat Nigam Ltd. and Former President Mishra, ED (S&P), NALCO and Chairman of Angul of IIM Mr. S S Mohanty, Secretary General of IIM Chapter, Sri M. Das, GM (Smelter) and Honorary Mr. Kushal Saha. The meeting was represented by Secretary, Angul Chapter, delegates, technocrats, Mr. Rajashekhar Pattanasetty, President Vijayanagar students and members of IIM Angul Chapter. works and Vice chairman, IIM Vijayanagar Chapter and Mr. L R Singh, Sr. VP, (Iron, Energy & Environment) and Secretary, IIM Vijayanagar Chapter from JSW side.
Inauguration Ceremony The event was attended by more than 400 delegates from India and abroad, members from Aluminium 74th IIM Foundation Day Celebration Industries, Research Institutes, technology suppliers,
Vol.23 No.4 & 5 APRIL & MAY 2020 Vol.23 No.4 & 5 APRIL & MAY 2020 27 IIM METAL NEWS equipment manufacturers and local ancillaries. The following invited talks were delivered in the six Besides, student delegates and faculty members from technical sessions spread over the two days. reputed institutes like IIT Madras, IGIT Sarang, CET Kalpakkam Chapter : IIM Foundation Day lecture Bhubaneswar and VSSUT Burla also presented their A special gathering of IIM members was organised papers on the latest technological innovations in on 26th February, 2020 by IIM Kalpakkam Chapter Aluminium technology, Smelting Process, Industry 4.0 at IGCAR to commemorate the Foundation day of and other related fields. Reputed technology suppliers the Indian Institute of Metals, led by Dr. Shaju K. and equipment manufacturers showcased their product Albert, Director, Metallurgy and Materials Group, and service capability in the technical exhibition. A and with senior colleagues, scientists and engineers technical souvenir was unveiled by the dignitaries. from DAE units at Kalpakkam attending. Dr. Divakar Shri M.P. Mishra, Chairman of IIM, Angul Chapter R., the Chapter Chairman and Associate Director, felicitated the Founder Secretary, Shri M.K.B. Nair, Materials Engineering Group recalled the past and Ex-GM (R&D), NALCO. present activities of the Chapter and Head Quarter. Dr. Trichy Chapter : Two Day Programme “E LIFE K. Madangopal, Associate Director, Materials Group, 2020” on IIM Foundation Day Bhabha Atomic Research Centre, Mumbai was the The 74th Foundation Day of IIM was celebrated by distinguished speaker on the occasion. He delivered the the Trichy Chapter with the support of the Welding Foundation Day lecture. He shared his immense research Research Institute, BHEL, Tiruchirappalli by experience on Shape Memory Effect; including aspects organising a Two Day Programme on “Engineering related to microstructural reversibility, irreversibility & Life Extension Aspects of Boilers (E LIFE 2020)” and deformation twinning. Dr. Madangopal shared during February 24 - 25, 2020. The event was organised exciting new applications of shape memory materials at Rangga Hotels, Tiruchy on 24th February 2020. Mr. in various fields such as medicine and civil engineering, R Easwaran, Fellow of IIM and Former GM, in charge covering examples from metallic alloys, ceramics and of BHEL gave the inaugural address. He opined that E even polymers. Applications included stents, actuators, LIFE 2020 is intended to bring out the latest trends in damping for civil structures and architecture, and boiler design and life extension aspects to the doorsteps critical components for Tejas aircraft. Around 100 of the users, OEMs, Consultants, faculty, researchers, participants belonging to different groups participated. students through invited talks by renowned experts in Hyderabad Chapter : IIM Foundation Day Lecture the field. He said that to produce the power from the IIM Hyderabad Chapter organised the IIM Foundation fossil fuel plants as green power, many initiatives are Day Lecture on February 29, 2020 at Royal Rave underway to increase the efficiency of boilers. Few of Hotel, Secunderabad. Prof. B S Murty, Director, IIT them include the advent of super critical technology, Hyderabad, delivered the lecture on “Exciting Journey of CFBC technology and AUSC technology. a Metallurgist through Nanocrystalline Materials using Particulate Technologies”. Prof. Murty opined that high energy ball milling is a far from equilibrium process that has been established as a prominent top-down route for the synthesis of nanocrystalline, quasicrystalline, amorphous materials and high entropy alloys with interesting properties and applications. The size effects in phase formation and phase transformations has been a very interesting and challenging field of study in the advanced materials synthesised by this route. The materials synthesised at these non-equilibrium conditions have shown exciting properties that are significantly different from the conventional materials. This method also has demonstrated its superiority over Dr. T A Daniel Sahayaraj, Chairman of Chapter, other non-equilibrium processing routes such as rapid presided over the function. Mr. G Rajendran, Hon. solidification processing in a number of ways. He also Secretary of the chapter welcomed the gathering. Mrs. mentioned that understanding the high energy ball A. Santhakumari, Vice Chairperson of the chapter and milling process has always been very challenging due Addl. GM of WRI addressed delegates. to its extreme non-equilibrium nature.
IIM METAL NEWS 28 Vol.23 No.4 & 5 APRIL & MAY 2020 welding, steel making technologies etc. Professor K Bhanu Sankara Rao, Pratt & Whitney chair, University of Hyderabad, Dr. S Santhi, Faculty Convener, AMME- 2020, and Ms. KVS Aishwarya, Student Convener, AMME-2020 also shared their experiences about AMME - 2020. The first and second academic toppers of final year students of JNTU, Hyderabad, NIT Warangal, MGIT and RGUKT Basar were awarded cash prizes. Mr. Dr. Dinesh Srivastava, Chairman, IIM Hyderabad GVR Murthy, Assoc. Professor, Department of MME, Chapter and Chairman & CE, NFC welcomed the MGIT gave the closing remarks. gathering. Prof. K. Bhanu Shanker Rao, UoH, and Kanpur Chapter : IIM Foundation Day celebration GMs of NFC, Midhani, DMRL, RCMA, and other The 74th IIM Foundation Day was celebrated on March private organisations graced the occasion. N. Ranga 5, 2020 in the Director's Conference Hall at DMSRDE, Rao, Jt. Secretary introduced the guest speaker. Kanpur. The event started with the welcome address by Dr. Y. Purushotham, Treasurer proposed vote of thanks. Prof. Amarendra Singh, Chairman, Kanpur Chapter. V. Vijaya Kumar anchored the programme. He talked about the history of IIM and activities of IIM Student Affiliate Chapter of Hyderabad Chapter Kanpur Chapter. This was followed by the addresses of The Department of Metallurgical and Materials Dr. N. Eswara Prasad, Director, DMSRDE, Kanpur and engineering of MGIT in association with the Indian Prof. Amol Gokhale, Vice president, IIM. Dr. Prasad Institute of Metals Students’ Affiliate Chapter, emphasised about the pioneering role that IIM has MGIT and Indian National Academy of Engineering played in making India a leader in production of metals (INAE) organised a One-Day National Conference and materials. He further suggested that organising on ‘Advances in Metallurgical and Materials regular conferences/workshops to connect the industry Engineering’ (AMME-2020) on March 4, 2020 in the to academia is the need of the time. Institute premises. Professor K Jaya Sankar, Principal, MGIT welcomed the gathering. Dr. G D Janaki Ram, Professor, Department of MSME, IIT Hyderabad, graced the occasion as Chief Guest and also delivered the keynote address. In his talk, he emphasised about Additive Manufacturing Technology which is emerging as the most sought-after technology in the near future. Graduates of Metallurgical, Materials, and Mechanical Engineering should have thorough understanding on this most happening technology.
Prof. Gokhale shared his views about the present and the future of the Indian Institute of Metals. The keynote address was delivered by the chief guest, Captain Sanjay Roy, CO 1BRD. He discussed BRDs and the materials aspects in the air force. The function concluded with Vote of Thanks by Dr. S. M. Abbas (Sc. ‘G’, DMSRDE). Prof. Sudhanshu Shekhar Singh, Secretary, Office bearers Prof. N. P. Gurao and Mr. G. Invited lectures by Dr. Suresh Meshram, DMRL, Mr. S P. Bajpai, other members of the Chapter, and scientists Kumar, ARCI, Mr. Shiva Kumar Khaple, DMRL, Mr. from DMSRDE graced the occasion. Varun, Epiroc Ltd, and Mr. Akhil of Visakhapatnam Baroda Chapter Steel Plant covered advances and innovations on cold The Indian Institute of Metals, Baroda chapter and Yuva spray coatings, tool steels, low density armour steels, Kaushal Bharat Foundation (YKBF) jointly organised
Vol.23 No.4 & 5 APRIL & MAY 2020 Vol.23 No.4 & 5 APRIL & MAY 2020 29 IIM METAL NEWS one NATIONAL WEBINAR for Graduate and Post Baroda Chapter, and Mr. Nitin Patel, Vice Chairman, graduate students on the topic titled ‘Challenges Yuva Kaushal Bharat Foundation (YKBF) coordinated and Strategies for students to Get Jobs in the face the event. At the end, Q & A session was conducted of COVID-19’ on 19th May 2020. Dr Sunil Kahar, in which participants asked questions regarding job chairman of IIM Baroda chapter and Yuva Kaushal prospect and soft skill improvement. These were Bharat Foundation (YKBF) observed that usually satisfactorily replied by the speaker Mr. Pankaj students after passing out look for jobs, at the same Dudhaiya. One thousand and twenty participants from time, companies also want to recruit good employees. various academic institution and universities from 89 But the hardship faced by the industry during and after cities and 20 states registered and participated in this covid-19 can change many equations in this scenario. event. Mr. Pankaj Dudhaiya Founder and CEO of 51K Growth Hub delivered the talk on this topic. Mr Pankaj opined that job seeker should look for: (i) research on the challenges facing the industry, (ii) challenges the company expects from its employees, and (iii) research on a global scale. Most importantly, the emphasis will be on how to prepare for the best workforce with these three issues in mind. If every student develops himself professionally during his college studies, then the foundation of a bright career can be laid from the very beginning. Mr. Urvesh Vala, Vice Chairman, IIM ********* CRUDE STEEL PRODUCTION RECENT DEVELOPMENT AFFECTED BY COVID – 19 NML develops no-contact thermometer Steel production by all the leading producers have been A team of CSIR-National Metallurgical Laboratory affected by COVID – 19. For China the production (NML) has developed two infrared thermometers that was affected in Februry, but for others including India, are necessary for temperature screening at workplaces. maximum effect was felt in the month of April. The An infrared thermometer facilitates temperature checks following table shows the crude steel production in from a distance, a feature crucial for fever screening in million tonne (MT) from January to April 2020. the wake of the coronavirus pandemic. A team led by senior principal scientist Sharmishtha Jan Feb Mar Apr Palit and comprising principal scientist Tarun Kumar Das, research fellow Chandan Dutta and project World 151.2 144.6 147.3 137.1 assistant Ravi Bhushan developed the thermometers China 79.9 74.8 78.9 85.0 that will be used at the institute’s two entry gates. Ms. Palit said that it was NML director Indranil Chattoraj India 9.3 9.6 8.0 3.2 who motivated the team to develop the mandatory gadget. For the team, the biggest challenge was to Japan 8.2 7.9 7.9 6.6 procure the infrared sensors, capacitors and micro- USA 7.6 7.1 7.0 5.0 controllers. The thermometer can detect temperature in the range of - 20 to + 125°C from a distance of approximately four inches. wolfstreet.com dt : 06-06-2020 The Telegraph ********* ADVERTISERS’ INDEX Name of the Organizations Page No. Bharat Forge Ltd 2nd Cover Rashtriya Ispat Nigam Limited 6 Nuclear Fuel Complex 24 TRL Krosaki Refractories Ltd 25 Brahmos Aerospace Pvt Ltd 3rd Cover
IIM METAL NEWS 30 Vol.23 No.4 & 5 APRIL & MAY 2020 2020 Kavli Prize in Nanoscience Internationally prestigious, ‘The Kavli Prizes’ are awarded once in two years since 2008 to honour scientists for breakthroughs in astrophysics, nanoscience and neuroscience and carry $1 million USD for each Prize. The Kavli Prize was established in partnership with (i) The Norwegian Academy of Science and Letters, (ii) The Norwegian Ministry of Education and Research and (iii) The Kavli Foundation. Fred Kavli (1927-2013), a physicist and philanthropist founded the Kavli Foundation in 2000, to recognise outstanding contributions in science which will greatly benefit society at large. He selected three fields: (i) Astrophysics, (ii) Nanoscience and (iii) Neuroscience for transforming our understanding of the very big, the very small and the very complex respectively, as he believed that these fields, being exceptionally interesting and exciting, would greatly benefit science and society. To quote him: “The fields have longevity and I don’t believe that we will ever run out of questions in these fields.” The Kavli Prize in Nanoscience is awarded for outstanding achievement in the science and application of the unique physical, chemical, and biological properties of atomic, molecular, macromolecular, and cellular structures and systems that are manifest in the nanometer scale, including molecular self-assembly, nanomaterials, nanoscale instrumentation, nanobiotechnology, macromolecular synthesis, molecular mechanics, and related topics. The Norwegian Academy of Science and Letters has decided to award the Kavli Prize in Nanoscience for 2020 to (i) Dr. Harald Rose, Ulm University and Technical University of Darmstadt, Germany, (ii) Dr. Maximilian Haider CEOS GmbH, Germany, (iii) Dr. Knut Urban, Forschungszentrum Jülich, Germany and (iv) Dr. Ondrej L. Krivanek, Nion Co., US., “for sub-ångström resolution imaging and chemical analysis using electron beams." Their pioneering work has helped us attain atomic resolution in electron microscopes and to reveal the structure and chemical distribution of elements of the materials at nano-scale. Dr. Knut Urban is well-known among the electron microscopy and quasicrystal community in India for his outstanding contribution in developing aberration corrected electron microscopes which are extensively used in the research areas of nanoscience and nanotechnology. He was the first to demonstrate the existence and movement of dislocations in quasicrystals during high temperature deformation. He has visited India on several occasions including participation in the International conference on ‘Quasicrystals’ (ICQ8) held in IISc, Bangalore in 2002 under the chairmanship of Prof. S. Ranganathan and Prof. K. Chattopadhyay. He has close interactions with many scientists in India especially with Dr. S. Banerjee of BARC Recently, Dr. Maximilian Haider and Dr. Ondrej L. Krivanek visited India to deliver Plenary Lectures in 12th Asia Pacific Microscopy Conference (APMC-2020) organised by the Electron Microscope Society of India (EMSI) under the chairmanship of Dr Partha Ghoshal during 3-7 February, 2020 in Hyderabad. (For more details: Source:http:// kavliprize.org/prizes-and-laureates/prizes/2020-kavli-prize-nanoscience) - News received from Prof. N.K. Mukhopadhyay, Dept. of Met. Engg., IIT (BHU), Varanasi
********* MEMBERS' NEWS
Dr. S. K. Jha has taken over as Chairman & Managing Director, MIDHANI. Under his leadership MIDHANI has made tremendous progress in both Technological and commercial areas. Earlier to MIDHANI he has about 27 years of experience in Department of Atomic Energy (DAE) in processing of Nuclear materials for India’s Nuclear Power program and for processing of strategic materials used in Missile, Space and Defense projects for nation. Dr. Jha has received many awards and recognition for his efforts at NFC. The most notable being, award for Excellence in Science technology for the year 2006 from Department of Atomic Energy (DAE) and best corporate governance award 2019. He has also received Group award from DAE five times for development of modified route for pressure tube, Development of Niobium alloys, Revamping of extrusion press, extrusion of ODS steel for FBRs application. Steam generator tubes for 700 MWe PHWRs. He is also a Life member of Indian institute
Vol.23 No.4 & 5 APRIL & MAY 2020 Vol.23 No.4 & 5 APRIL & MAY 2020 31 IIM METAL NEWS of Metals, Indian Nuclear Society, ISNT and aeronautical Society of India. He has also Co - authored report on materials for fast breeder reactor for IAEA (Vienna). He has published more than 35 articles in international journals. He has completed his PHD in engineering sciences from Homi Bhabha National institute (HBNI), BARC. ********* This book is coauthored by Prof. Sujay Kumar Dutta. The book presents the fundamentals of iron and steel making, including the physical chemistry, thermodynamics and key concepts, while also discussing associated problems and solutions. It guides the reader through the production process from start to finish, covers the raw materials, and addresses the types of reactions involved in both conventional and alternative methods. Though primarily intended as a textbook for students of metallurgical engineering, the book will also prove a useful reference for professionals and researchers working in this area. Dr. Dutta is a former Professor and Head, of the Department of Metallurgical & Materials Engineering at Maharaja Sayajirao University of Baroda, India. He received his Bachelor of Engineering (Metallurgy) from Calcutta University in 1975 and his Master of Engineering (Industrial Metallurgy) from MS University of baroda in 1980. He completed his PhD at the Indian Institute of Technology, Kanpur, India, in 1992. He joined MS University of Baroda as a Lecturer in 1981 and was promoted to Professor in 2001. Prof. Dutta has received several awards, including Essar Gold Medal (2006), Fellowship (2014) and Distinguished Educator Award (20l5), all from the Indian Institute of Metals, in recognition of his distinguished service to the field, of Metallurgical Education. He has authored of five books, two chapters of "Encyclopedia of Iron, Steel, and Their Alloys”, and published more than 120 research papers in national/international journals and conference proceedings. Very recently Prof. Dutta was awarded “SAIL Award 2019” by The Institution of Engineers (India). ********* STEEL STATISTICS
An Overview of Steel Sector Global Scenario • In CY 2019, the world crude steel production reached 1870 million tonnes (mt) and showed a growth of 3.4% over CY 2018. • China remained world’s largest crude steel producer in same period (996 mt) followed by India (111mt), Japan (99mt) and the USA (88mt). • Per capita finished steel consumption in 2018 was 224.5 kg for world and 590.1 kg for China(Source: World Steel Association). The same for India was 73.3 kg in 2018 (Source: JPC) and 75.7 kg (prov) in 2019. The per capita consumption of India in 2018-19 was 74.1 kg and that in 2019-20 was 74.6 kg (prov.) (Source: JPC). Note: Provisional. Data on per capita consumption yet to be released for 2019 by World Steel Association. For India, figures are quoted based on data released by JPC. Domestic Scenario • Rapid rise in production has resulted in India becoming the 2nd largest producer of crude steel during 2018 and 2019 (prov), from its 3rd largest status in 2017. India is also the largest producer of Sponge Iron or DRI in the world, and the 3rd largest finished steel consumer in the world after China & USA in 2019 (prov.) • Government of India has released the National Steel Policy 2017, which has laid down the broad roadmap for encouraging long term growth for the Indian steel industry, both on demand and supply sides, by 2030-31. The policy provides preference to domestically manufactured Iron & Steel products in Government procurement. Production India was the 2nd largest producer of crude steel in the world in 2019(prov.). • In 2019-20, production of total finished steel (alloy/stainless + non alloy) was102.059 million tonnes (mt) (prov.).
IIM METAL NEWS 32 Vol.23 No.4 & 5 APRIL & MAY 2020 • Production of Pig Iron in 2019-20 was 5.507 mt (prov.), a decline of 14.1% over last year. • India was the largest producer of Sponge Iron in the world in 2019(prov.). The coal based route accounted for 86% of total Sponge Iron production (37.143 mt) in 2019-20(prov.). • Data on production of Pig Iron, Sponge Iron and Total Finished Steel (alloy/stainless + non-alloy) are given below for last five years: Indian steel industry: Production (in million tonne) Category 2015-16 2016-17 2017-18 2018-19 2019-20* Pig Iron 10.24 10.34 5.73 6.41 5.51 Sponge Iron 22.43 28.76 30.51 34.71 37.14 Total Finished Steel 106.6 120.14 126.85 101.29 102.06 Source: Joint Plant Committee; *prov.; For Details, please refer to appendix Demand - Availability Industry dynamics including demand – availability of iron and steel in the country arelargely determined by market forces and gaps in demand-availability are met mostly through imports. • Interface with consumers exists by way of meeting of the Steel Consumers’ Council, which is conducted on regular basis. • Interface helps in redressing availability problems, complaints related to quality. Steel Prices Price regulation of iron & steel was abolished on 16.1.1992. Since then steel prices are determined by the interplay of market forces. • Domestic steel prices are influenced by trends in raw material prices, demand – supply conditions in the market, international price trends among others. • As a facilitator, the Government monitors the steel market conditions and adopts fiscal and other policy measures based on its assessment. Currently, GST of 18% is applicable on steel and there is no export duty on steel items. • A Steel Price Monitoring Committee has been constituted by the Government with the aim to monitor price rationalisation, analyse price fluctuations and advise all concerned regarding any irrational price behaviour of steel commodity. • To avoid any distortion in prices in view of ad-hoc and rising imports, the Government had taken several steps including raising import duty, and imposed a gamut of measures including anti-dumping and safeguard duties on a host of applicable iron and steel items. In a further move to curb steel imports, the Indian government banned the production and sale of steel products that does not meet Bureau of Indian Standard (BIS) approval. To check the sale of defective and sub-standard stainless steel products used for making utensils and various kitchen appliances, it issued the Stainless Steel (Quality Control) Order, 2016 for products used in making utensils and kitchen appliances, that will help contro limports . Imports Exports Iron & steel are freely impor table. Iron & steel are freely exportable. • Data on import of total finished steel (alloy/stainless + • India emerged as a net exporter of total finished steel non alloy) is given below for last five years: in 2016-17, 2017-18 and 2019-20(prov.). • Data on export of total finished steel (alloy/stainless + Indian steel industry : Import of Total Finished Steel non alloy) is given below for last five years: (in million tonne) Indian steel industry : Export of Total Finished FY 2015-16 2016-17 2017-18 2018-19 2019-20* Steel(in million tonnes) FY 2015-16 2016-17 2017-18 2018-19 2019-20* Qty 11.71 7.23 7.48 7.83 6.77 Qty 4.08 8.24 9.62 6.36 8.36 Source: Joint Plant Committee; *prov. Source: Joint Plant Committee; *prov.
Vol.23 No.4 & 5 APRIL & MAY 2020 Vol.23 No.4 & 5 APRIL & MAY 2020 33 IIM METAL NEWS Levies on Iron & Steel SDF levy: This was a levy started for funding modernisation, expansion and development of steel sector. The Fund, inter-alia, supports Capital expenditure for modernisation, rehabilitation, diversification, renewal & replacement of Integrated Steel Plants, Research & Development, Rebates to SSI Corporations among others. The SDF levy was abolished on 21.4.94. An Empowered Committee has been set up to guide the R&D effort in this sector. EGEAF: This levy started for reimbursing the price differential cost of inputs used for engineering exporters. Fund was discontinued on 19.2.96. Growth of Iron and Steel (i) Steel : Crude steel capacity was 142.98 mt in 2019-20 (prov.), up by 0.5% over 2018-19 (ii) Pig Iron: India is also an important producer of pig iron, and has turned out to be a net exporter. The private sector accounted for 89% of total production of pig iron (5.507mt) in the country in 2019-20 (prov.). (iii) Sponge Iron: India, world’s largest producer of sponge iron (2019), has a host of coal based units located in the mineral-rich states of the country. Over the years, the coal based route has emerged as a key contributor and accounted for 86% of total Sponge Iron production in the country during 2019-20 (prov.). Capacity in Sponge Iron making too has increased over the years and stood at 37.143 mt (2019-20) (prov.). Source : WSA Crude Steel Production in million tonne (April and March 2020 ) Country April Country March World 137.098 World 147.281 China 85.033 China 78.975 Japan 6.617 India 8.038 South Korea 5.500 Japan 7.950 United States 4.968 United States 6.995 Russia 4.700 Russia 6.109 India 3.137 South Korea 5.776 Germany 3.000 Germany 3.287 Turkey 2.245 Turkey 3.110 Vietnam 1.946 Brazil 2.692 Brazil 1.811 Iran 2.300 Iran 1.790 Vietnam 2.114 Taiwan, China 1.650 Ukraine 1.765 Mexico 1.450 Taiwan, China 1.731 Italy 1.350 Mexico 1.612 Ukraine 1.339 Italy 1.367 France 0.800 Spain 1.170 Canada 0.750 Canada 1.021
Increase in World Crude Steel Production from 1950 to 2019, million tonne Year World Year World Year World 1950 189 2000 850 2010 1433 1955 270 2001 852 2011 1538 1960 347 2002 905 2012 1560 1965 456 2003 971 2013 1650 1970 595 2004 1063 2014 1671 1975 644 2005 1148 2015 1621 1980 717 2006 1250 2016 1629 1985 719 2007 1348 2017 1732 1990 770 2008 1343 2018 1814 1995 753 2009 1239 2019 1870 Source : WSA
IIM METAL NEWS 34 Vol.23 No.4 & 5 APRIL & MAY 2020 35 Rs. 18/- (Notional) RNI Regn No. 69992/98
Long Service life Medium service life Short service life
Building and infrastructure
Electrical equipment Other transport Steel use
Metal products Domestic appliances
Mechanical equipment Automotive
Source : WSA
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