Procured scrap and return scrap will be charged into the furnace to ensure optimum utilization. Carbon in the form of petroleum coke, breeze coke, will be charged in to the furnace for attaining necessary level of carbon in the process. Once the minimum temperature of the furnace is reached, sponge iron will be charged in small batches and the slag formed in the process will be removed from time to time. Required amount of Ferro Alloys will be added after raising the temperature to maintain the desired quality and composition of the molten metal.
The continuous casting machine will be equipped with moulds, secondary cooling segments, withdrawal and gas cutting units, dummy bar insertion system, run out roller table and cooling bed. During casting operation, the metal level in the mould will be maintained within predetermined limits by adjusting the flow of metal in to the mould or by withdrawal speed. The partially solidified billets leaving the mould will pass through strand guide roller segment where intensive but controlled cooling of the billets will occur by spraying of water. The solidified billets will be guided through withdrawal and straightening units before entering the gas cutting zone. The dummy bar will be removed from the billet after the gas-cutting unit and will be stored till its introduction is required for start of the next heat. The cast billet will be cut to the predetermined length by oxy-acetylene gas cutting torches. The sized billets will be delivered to the cooling bed through run out roller table and cross transfer mechanism. The billets will be marked on cooling bed by marking unit for identification.
For chemical analysis of liquid steel, the samples will be taken from the tundish. Samples will also be cut from cast billets and sent to the laboratory for macro etching, sulphur prints & other quality parameter testing.