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MBE’s activities in the Steel Sector is being expanded with technology tie-ups with several world leaders like TPE (Russia), DMT (Germany), Siemens Vai (France) and MCC (China) to offer the Indian steel sector, for expansion and/or new ventures, the latest in Steel manufacturing technology in the following areas:

  • Sintering Plant of size 400 Sq.m. and above.
  • Coke Oven Batteries upto 5.5 m height with stamp charging / top charging facility.
  • Continuous Casting Machines, both for bloom and billet and also for other units in the Steel Melting Shop.
This SBU is also responsible for setting up iron ore pelletisation plants on a turnkey basis.

MBE has commissioned the following prestigious projects :

  • Sinter Plant 3 at Rashtriya Ispat Nigam Ltd, Vizag in association with TPE Russia
  • By -Products separation plant at SAIL- IISCO unit, Burnpur in association with DMT, Germany
  • Pickling Lime and Tandem Cold Mill Plant at SAIL, Bokaro
  • We are setting up a second By Products recovery plant for SAIL - Bhilai steel plant

 

Sinter Plant

In a sintering plant raw materials like fine grain iron ore is processed into coarse grained sinter for charging the blast furnace. MBE has the experience of executing EPC contract of a complete Sinter Plant at RINL, Vizag, conforming to latest pollution control norms. Technical associates include Tyazhpromexport (TPE), Russia and China Metallurgical Group Corporation (MCC)-China. The maximum capacity of sinter plant that MBE can construct is 460 square meters.

Aerial view of Sinter Plant, Vizag Steel
Aerial view of Sinter Plant, Vizag Steel

 

Blast Furnace

The function of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called "hot metal". The blast furnace is a huge, steel stack lined with refractory brick, where iron ore, coke and limestone are dumped from the top and pre-heated air is blown from the bottom. MBE has the capability of executing turnkey blast furnace projects in technical association with Tyazhpromexport (TPE) Russia. The maximum capacity of blast furnace that MBE can execute is upto 4600 m3. MBE scope of supply covers four post tower structure for the blast furnace, pulverized coal injection system, pig casting machine, slag granulation plant and hot metal handling system.

 

By- Products Recovery Plants

Heating of coal in absence of air to produce coke is called carburization or destructive distillation. Apart from production of coke, the co-product produced is coke oven gas from which various liquid products like tar, benzol, napthalene, phenol etc can be recovered. Coke oven gas is treated in the By-Product Plant to recover these chemicals and then the coke oven gas is used as a gaseous fuel in the furnaces of the steel plant. Coke oven gas comes out at about 800˚C from the coke oven. It is cooled to 80˚C with ammoniacal liquor (NH4OH) by spraying it at the goose neck. This cooled COG is fed to the By-Product Recovery Plant unit for recovery of various by-products. MBE has the experience in construction of turnkey By-Products Recovery Plant at the IISCO, Burnpur unit of SAIL in technical tie-up with DMT, Germany. MBE can execute such plants in technical association with either DMT, Germany or ACRE Coking & Refractory Engineering Consulting Corporation, MCC-China. The maximum capacity of the plant that MBE can construct is 70,000 Nm3/hour.

Primary Gas Cooler, By Products, SAIL-IISCO
Primary Gas Cooler, By Products,
SAIL-IISCO
Scrubber - By Products Plant, IISCO, Burnpur
Scrubber - By Products Plant, IISCO, Burnpur

 

Coke Oven Battery

Coal is converted to coke in large coke oven batteries. The coking process consists of heating coal in the absence of air to drive off the volatile compounds; the resulting coke is a hard, but porous carbon material that is used for reducing the iron in the blast furnace. MBE has the experience of constructing coke oven battery plant at SAIL IISCO, Burnpur (in consortium with Gipro Kocks, Russia and Bhilai Engineering Corp.). MBE can execute such plants on a turnkey basis in technical association with ACRE Coking & Refractory Engineering Consulting Corporation, MCC, China, having upto 7 meter tall ovens, both top charging and stamp charging , conforming to latest pollution control norms .

 

Pickling Lime and Tandem Cold Mill Plant

In the Pickling area of the continuous pickling cum tandem cold mill, the rust layer on the surface of hot rolled steel coil is removed by treating the coil with acid solution in consecutive acid tanks in a precisely controlled environment. The coil is washed further in the rinse section to remove the traces of acid on the coil surface. In the tandem cold mill section the pickled coil is cold rolled to reduce the thickness of the coil to as low as 0.25 mm to 2.0 mm from input thickness of 1.6 mm to 5.0 mm. Currently one PLTCM project is being executed at SAIL, Bokaro plant with Siemens VAI, who are the technology providers. Some of the major equipment of the line will be supplied by MBE along with the entire erection of the line (around 7500 MT). The project is the first of its kind being executed by MBE, in line with the company’s vision of venturing into new areas of business as a process of expansion.

 

Steel Melting Shop

 
The oxygen steelmaking process converts the molten iron from the blast furnace, with up to 30% steel scrap, into refined steel. High purity oxygen is blown through the molten bath to lessen the carbon, silicon, manganese and phosphorous content of the iron, while various fluxes are used to reduce the sulfur and phosphorous levels. The impurities and a small amount of oxidized iron are carried off in the molten slag that floats on the surface of the hot metal. MBE has the ability to execute steel melting shop projects on turnkey basis in technical association with Capital Engineering & Research Incorporation Limited (CERI), China. MBE has the capability to construct Basic Oxygen Furnace of capacity upto 2 X 175 tonnes. MBE offers proven technology for hot metal desulphurization, basic oxygen furnace and suppressed combustion gas cleaning and recovery system with dog house, ladle furnace and RH Degasser of steel.

 

Hot and Cold Rolling Mills

A slab, billet, or ingot is passed or deformed between a set of work rolls revolving at the same speed, but in opposite directions. The distance between the work rolls is slightly less than that of the passing metal which allows for thinning. The temperature of the metal is generally above its recrystallization temperature, as opposed to cold rolling, which takes place below this temperature. Hot rolling permits large deformations of the metal to be achieved with a low number of rolling cycles. As the rolling process breaks up the grains, they recrystallize maintaining an equiaxed structure, preventing the metal from hardening. Hot rolled material typically does not require annealing and the high temperature will prevent residual stress from accumulating in the material resulting in better dimensional stability than cold worked materials.

Hot rolling is primarily concerned with manipulating material shape and geometry rather than mechanical properties. In Hot Rolling Mill the shape of the slab, billet or ingot is thus transformed by reduction in thickness and increase in width. The end product of Hot Rolling Mill comes out in the coil form and is referred to as Hot Rolled Coil.

The HR Coil from the Hot Rolling Mill is further rolled in the Cold Rolling Mill to achieve lower thickness, better surface finish and flatness. Often the Hot Rolled Coil is pickled prior to cold rolling to remove the rust / scale generated on the surface of the coil due to oxidation at high temperature during Hot Rolling. The scale is removed to avoid any damage to precision rolls / equipment of the CR mill and to achieve quality surface finish of the Cold Rolled Coil which is an important parameter for the CR coil as it is used in critical applications in auto, white goods and other home appliances. Often the CR coils are annealed prior to downstream work in order to remove the residual stresses that generate during the cold rolling process.

MBE is capable of executing on a turnkey basis, Hot & Cold Rolling Mills in association with leading Global Technology suppliers.

 

Continuous Casting Machine

 
In continuous casting, the molten steel from the steelmaking operation or ladle metallurgy step is cast directly into semifinished shapes (slabs, blooms and billets). Continuous casting represents tremendous savings in time, labour, energy and capital. By casting the steel directly into semifinished shapes, the following steps are eliminated : ingot teeming, stripping and transfer, soaking pits and primary rolling. Continuous casting also increases yield and product quality. MBE has technical tie-up with some of the world's leading Technology providers for setting up state-of-the-art Continuous Casting Plants, both Bloom and Billet casters on turn key basis. MBE also manufactures equipment for continuous casting machines viz, Tundish, Tundish cars, Roller Tables etc. The salient features of MBE’s continuous casting machine are sequence casting and composite casting with the aid of turret, protection of pouring stream between ladle and tundish as well as tundish and mould, automated addition of casting fluxes, constant casting temperature and electromagnetic stirring.