Production Process

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Production Process

zsrm-production-process

Process Flow

Raw Materials

  • Two types of Raw Materials
    • Direct Raw Materials
      • Scraps
      • DRI/ Sponge Iron
      • Ferro Alloys
    • Indirect Raw Materials
      • Mainly Refractories.
      • Quartzite Powder
      • Other Refractories for Casting Process.
      • Source – Import.
Raw-Materials

Scraps

  • Recycling of Scraps from different sources ensure environmental well being and less use of Ores.
  • Scrap Types-
    • HMS-1
    • HMS-2
    • PNS
    • Bundles
    • Shredded Scrap
    • Other Fe-Based Scrap.
  • Source –
    • Local
    • Import

DRI and Ferro Alloys

  •  Direct Reduced Iron – Sponge Iron.
    • Iron percentage 90-94%
      • Source- Import.
  • Ferro Alloys
    • Silico Manganese- Consists Mainly Fe, Si and Mn
    • Ferro Manganese- Consists Mainly Fe and Mn
    • Ferro Silicon- Consists Mainly Fe and Si.
      • Source- Local and import.
DRI-and-Ferro-Alloys
Sponge Iron
DRI-and-Ferro-Alloys2
Ferro Alloy

Melting

Melting
  • Furnace
    • 03 Furnaces – 15 Ton and 02 Nos 20 Ton.
    • 6 Crucibles.
    • Electrotherm- India
    • DIFOC Technology.
    • Electricity Powered. Medium frequency.
    • Efficient Quick Melting.
    • Benefits of IMF-
      • High Efficiency
      • Low Cost of Operation
      • Electromagnetic Stirring
      • Lower oxidation losses
      • Cleaner Operations

Furnace Preparation

  • Quartzite powder used for lining.
  • Separation between liquid metal and coil.
  • Prevention of erosion from agitation process.
  • High Temperature Sustainability.
    • Source- Local and Import.
Furnace Preparation

Melting Process

  • Charging-
    • Charging is done Via EOT Crane.
    • Requires less manpower and ensures safety.
  • Slag Removal is necessary for IF-
    • Undesirable compounds.
    • Crucial for removing impurities.
    • To prevent gas entrapment in liquid metal.
    • Slag Type- Acidic.
    • Slag removal improves casting process and refines the quality as per required standard.
  • Sample Collection-
    • Bath sample Collection.

Optical Emission Spectrometer

  • Quartzite powder used for lining.
  • Separation between liquid metal and coil.
  • Prevention of erosion from agitation process.
  • High Temperature Sustainability.
    • Source- Local and Import.
Furnace Preparation