LEO WORKSHOP

JSW STEELS Ltd.

VIJAYANAGARA WORKS

MALLIKARJUNA G B

KARTHIKEYA NIKKAM

1
 PROCESS OVER VIEW OF JSW STEEL LTD
Toranagallu Bellary Karnataka

INPUT RAW
MATRIAL

Export slab & billets dispatch

WIRE &TMT RODS

HOT STRIP MILL

FINAL PRODUCT DISPATCH

COIL & Wire,TMT dispatch

2
STEEL COILS
SMS SHOP OVERVIEW

3
 DEFECTS IN SLAB

SLAB SURFACE DEFECTS SLAB INTERNAL DEFECTS:

Longitudinal cracks Inclusions
Transverse cracks Triple point cracks
Slag patch Edge cracks
Oscillation marks Internal cracks
Blow/Pin holes Centre line segregation

4
 SLAB SURFACE DEFECT

LONGITUDINAL CRACK
Longitudinal facial crack
Longitudinal corner crack

Longitudinal crack is a crack which occurs on the surface or the corner of slab parallel
to the casting direction.
The longitudinal crack Usually has on origin in the mould inside and is expanded in
the secondary cooling zone.
They are nearly parallel to the base of casting and are formed due to lateral tension
in skin

5
 TRANSVERSE CRACKS
Transverse Mid face crack
Transverse corner crack

1. Transverse crack can occurs on the surface or corner of slab along the valley of a
oscillation mark
2. The Transverse crack is caused by tensile stress applied on the cast slab at
straightening

SLAG PATCH
Slag powder entrapment

They are smooth entrapments or cavities on the upper surface of the casting and are
produced when slag tends to find its way into mould cavity along with the molten steel

6
 BLOW HOLES/PIN HOLES
Gas evaluation during solidification
They are smooth and round holes clearly perceptible on the surface of
defects. They may either in the form of a cluster of small holes or in the
form of large and smooth depression

TRIPLE POINT CRACKS

Triple point cracks occur near sides of the slab within the areas defined by the
three solidification fronts coming together.

Triple point cracking increases with decreasing manganese levels

Tensile forces due to bulging (Improper roll gap)

Low Mn/S ratio in steel

Steel grade with >0.15% of Carbon

High Super Heat

7
 INCLUSIONS
Inclusion not only play an important role in steel cleanliness but their presence is highly
deleterious in steel products as they contributes in the formation of slivers.

Inclusion are mainly oxide products, which will remain as mechanically entrapped
particles in steel.

Inclusions impair the mechanical property of steel depending on their size, shape
composition and distribution.

Types of Inclusions:

Indigenous: Those arising in the course of steel making, mainly comprises of deoxidation
products
Exogenous: Those arising from mechanical erosion of contacting refractory lining , mould
powder and tundish covering powder or slag in tundish

8
 CENTERLINE SEGREGATION

Causes:
Casting temperature is too high
Centerline Porosity due to Dendrite Bridging

Increase of local accumulation of segregation elements

such as C, Mn, S, P
Improper roll gaps at the solidification front.
Prevention:
Avoid high temperature casting
Frequent roll gap check
Use H S A

9
METHOD OF MONITORING STRAND CONDITION &
MONITORING OF MOULD & SEGMENT LIFE
Sarclad / Vatron (Roll gap checker)

Once in 15/days

Once in a week if time available

MONITORING OF MOULD & SEGMENT LIFE

10
 MOULD POWDER FEEDING SYSTEM
and
QUALITY OF POWDER AND PERFORMANCE

Manual feeding

Gravity feeder

Powder trail reports

SEN Erosion pattern study

11
Erosion Profile measurement equipment

MINIMIZATION OF SEN EROSION 12

MINIMIZATION OF SEN EROSION

13
 CURRENT GOOD PRACTICES
SLIVER STUDY EMS

GRADE MIXING Auto Scarfing

INTERNAL QUALITY SYMS (Slab yard Management system)

TCD Tundish Extended Shrouds

14
 SPRAY COOLING SYSTEM

Level 1

Dynamic Solidification Control

Spray Checking

Mould, bender, in every break

Other zone once in a week

15
16