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JSW STEEL COATED PRODUCT Ltd

A-10/1, MIDC Industrial Area,
SH265, Kalmeshwar, Maharashtra 441501

REPORT ON

MEASUREMENT SYSTEAM ANALYSIS

FOR DROSS GENERATION AND
DEFECT ANALYSIS

Guided By
Mr. Nilesh Mahakalkar

SUBMITTED BY

Vrushabh M. Pannase 141611009

Sourabh Chahande 141611003
Jitendra R. Raut 141611013
Gourav K. Behune 141611001

COLLEGE OF ENGINEERING PUNE

DEPARTMENT OF METALLURGY AND MATERIAL SCIENCE
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COLLEGE OF ENGINEERING PUNE

(An Autonomous Institute of Government of Maharashtra)

CERTIFICATE
This is to certify that, Student of second year metallurgical engineering
have submitted their report of 21 Days training session on
“Measurement System Analysis for Dross Generation and Defect
Analysis” during the period of 9/6/2017 to 30/6/2017 as a part of work
described by collage of Engineering, Pune for keeping its student
updated regarding the recent development in various fields so as to
strengthen their basic knowledge and also enhanced practical
knowledge.
This report work is the record of student own work under my
guidance and to my satisfaction.

Signature of GUIDE
Mr. Nilesh Mahakalkar
3|Page

Content
 Acknowledgement
 Abstract
 About JSW
 History
Company profile
 About kalmeshwar work
Plant layout
Benchmarking
 Manufacturing processes
CRM
CGL/CAL
CCL
 Dross overview
 Minitab software analysis
 Case study
To study the microstructural defect
on the product of
Galvalume (gsm150)
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ACKNOWLEDGEMENT
It is genuine pleasure to express our deep sense of thanks to our
mentor and project guide Mr. Nilesh mahakalkar for believing in our
efforts and giving us a chance to prove our sincerity.

We extend our deep gratitude toward Mr. Nilesh mahakalkar for their
prompt inspiration and timely suggestion with kindness which made
our project possible.

Our sincere thanks to Mr. Damodhar Thakre for his valuable

information, meticulous scrutiny, Analytical and scientific approach
which helped us to complete the project.

It is privilege to take this opportunity to thank JSW group to give us

opportunity to carry out this project and prove ourselves.

We are also like to thanks to all the employees of JSW who have been
very cooperative to us throughout the project.

We have come out as a successful team of four, cheer to us.

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ABSTRACT
The main objective of this project is to know about measurement
system analysis of dross generation. During the study of continuous
galvanizing line, large amount of waste material is observed near the
surface of bath. The main object is to kept dross as minimum as
possible Dross is formed due to reaction between aluminum, iron and
zinc in the zinc bath. The coupled phenomena of aluminum, strip
temperature and iron dissolution were simulated in order to predict
and to better understand the generation and movement of inter
metallic dross particles within certain region of a typical galvanizing
bath. Solution for the temperature and aluminum concentration can be
correlated with the solubity limit of aluminum (Al) and iron (Fe) to
determine the amount of precipitated aluminum in the form dross.
MATLAB software is used to developed a simulation program to find
the total dross. The program is flexible to calculate the optimum
parameter and per shift data.

The result and conclusion of our project mentioned at the end of the
report.

Case study
Galvalume sample(gsm150) was provided to us by JSW for detail study
on microstructural defect effect
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ABOUT JSW
The JSW Group is amongst the leading conglomerates in India, with
presence across the vital sectors of the Indian economy. We are an $11
billion conglomerate, with presence across India, USA, South America &
Africa; the JSW group is a part of the O.P. Jindal Group with strong
footprints across viz Steel, Energy, Infrastructure, Cement, Ventures
and Sports.
With a diverse workforce of over 40,000 individuals, JSW is known to be
the “strategic first mover” to venture away from status quo, have the
conviction to make fundamental changes and drive operational
excellence. Built on a strong foundation of core values i.e.
Transparency, Excellence, Dynamism and Passion for Learning, in a
short span, JSW group has grown multifold. Technological innovations,
a strong focus on sustainability and a philosophy to give back to the
communities at large set each JSW Company apart.
JSW Steel is India’s leading private sector steel producer and amongst
the world’s most illustrious steel companies with an installed capacity
of 18 MTPA. JSW Steel boasts of one of the largest blast furnace with a
capacity of 3.3 MTPA, taking JSW’s overall capacity to 12 MTPA at
Vijayanagar, Karnataka, and its flagship steel plant. With its plants
located across 6 strategic locations in South and West India, JSW Steel
will continue to raise the bar with its high quality & diverse product
range.
Sustainability powers JSW Steel’s business vision. We realize that only
by creating a sustainable future can we pave the way for our goal of a
self-reliant India. Our strategy of always staying on the leading edge of
technical advancement has led to partnerships with global sector
leaders such as JFE Steel, Marubeni Itochu Steel, Praxair and Severfield
Rowen Plc. This technological edge has helped our plants rank among
7|Page

the lowest-cost steel producers in the world and differentiated us

from our competitors.

The strong focus on innovation and R&D has led to JSW Steel being
recognized worldwide as a purveyor of high-end, value-added steel.
Nearly 40 percent of our products today are high value steels; we
intend to take this figure up to 50 percent. Nearly one fifth of our
products are exported and we are India’s largest exporter of steel with
a presence in over 140 countries.
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History

The JSW Group’s foray into steel manufacturing began in 1982, when it
set up the Jindal Iron and Steel Company with its first steel plant at
Vasind near Mumbai. In 1994, Jindal Vijayanagar Steel (JVSL) was set
up with its plant located at Toranagallu in the Bellary-Hospet area in the
State of Karnataka, the heart of the high-grade iron ore belt and spread
over 10,000 acres of land. In next two decades saw significant
expansion and several acquisitions, following the merger of Jindal
Iron and Steel Co (JISCO) and Jindal Vijayanagar Steel Ltd (JVSL) in 2005.
It also set up a plant at Salem with an annual capacity of 1 million
tonne. It is on the threshold of a major expansion plan of adding 3.2
million tons per annum to it’s at Vijayanagar Plant to achieve 11 MTPA
by 2011. It has established a strong presence in the global value added
steel segment with the acquisition of a steel mill in US and a Service
Center in United Kingdom. JSW Steel has also formed a joint venture for
setting up a steel plant in Georgia. Today JSW Steel has plants in six
locations in India Vijayanagar in Karnataka, Salem in Tamil Nadu, and
Tarapur, Vasind, Kalmeshwar and Dolvi Maharashtra.
The Company has further acquired iron ore mines in Chile and coal
mines in USA & Mozambique. The current manufacturing capacity of
company is 18 MTPA. In Aug 2014, it acquired Welspun Maxsteel Ltd in
a deal valued at around 1,000 Crores. JSW has already acquired 3
MTPA Hot Rolling Plant in Dolvi Maharashtra
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Company Profile
JSW Steel
Parent Company JSW Group
Type Public Company
BSE : 500228
Traded as
NSE : JSWSTEEL
Category Iron & Steel
Founded 1982
Founder Sajjan Jindal (Chairman)
Headquarters Mumbai, Maharashtra, India
Area Served World wide
Revenue $ 7.2 billion (2013-2014)
Profit $200 million (2013-2014)
Number of employees 11103
Sector Industrial Products
Tagline/ slogan No Limits
The largest private sector steel manufacturer
USP
in terms of installed capacity
STP
Steel, Flat steel products, long steel products,
Segment
wire products, Plates
Infrastructure, oil industry, automobile and
Target
construction sectors
One of the key and strategic steel producer in
Positioning the country cantering to almost all segments
with the range of steel products
Competition
Tata Steel
Competitors SAIL
ArcelorMittal
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About Kalmeshwar Work

One of the downstream operations of JSW steel is executed from
Kalmeshwar. The kalmeshwar plant has a pickling line, two rolling mills,
two galvanizing lines, two rolling mills, two galvanizing lines, two colour
coating lines, a Galvalume line, six Slitting and 7 Cut to length lines, two
profiling lines and a tile profiling line.

Unique Features:

 Zero Liquid Discharge facility .

Company Profile
JSW ISPAT Steel
Parent Company JSW Group
Type Public Company
BSE : 500305
Traded as
NSE : ISPATIND
Category Steel
Founded 1984
Founder Mr. M.L.Mittal
Headquarters Kalmeshwar, Dist: Nagpur India
Key People Sajjan Jindal (Chairman), B.K. Singh
Sponge iron, Hot Rolled Coils, Cold Rolled
Products Coils, Galvanized sheet/coils, colour coated
sheets
Revenue $ 7.2 billion (2013-2014)
Net Income $-48 million (2013-2014)
Number of
3000
employees
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PLANT LAYOUT OF JSW STEEL COATED PRODUCT Ltd.

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Benchmarking

 First Continuous annealing line in India.

 Widest Cold Rolling Mill [up to 1870 mm width]

 India’s Largest Coated Steel Producer

 First Licensee Galvalume producer in India

 JSW Steel Salem Works in the Largest integrated alloy and special
Steel Plant in India

 Widest Hot strip mill in India : 25.4 x 2150mm

 India’s Most modern and Largest Vertical Caster – 300/260/220 x

2200mm

 India’s Only Multi – Radii Bloom Caster [12/16/30 m] operational at

Salem works.

 ZERO EFFLUENT discharge for greener & cleaner environment

1.5 Million trees planted at Vijayanagar works, transforming the area in

to a green Oasis
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MANUFACTURING LINES

1. Cold Rolling mill - CRM SECTION (0.65MT)

2. Continuous Galvanizing/Galvalume lines – CGL/CAL (0.7MT)
3. Continuous colour coating lines – CTL (0.2MT)
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Cold Rolling Lines

JSW has established India's first Continuous Annealing Line (CAL) in
technological collaboration with JFE Steel Corp, Japan to manufacture
high strength and advanced high strength steel for automobile sector.
This is the widest Cold Rolling Mill (upto 1870 mm width) in India.
JSW’s CRCA is manufactured in Deep Drawing, Extra Deep Drawing,
Interstitial Free Steels and High Strength grades conforming to JIS, EN,
ASTMA and IS standards. Dimensional accuracy is guaranteed by an
automatic thickness control system using advanced numerical models.
Easy formability, high-quality surface finish, consistent surface texture
with the optimum balance between texture (for paint keying) and
smoothness (for image distinction) makes JSW’s CRCA the product of
choice for automobiles, appliances, furniture and many other
applications.
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Key Features

 Widest Cold Rolling Mill for automotive steel in India

 First Continuous Annealing Line in India
 State of the art continous galvanising line with dual pot system for
GI and GA production
 Higher Strength (Upto TS 980 MPa) and SEDDQ Grade
 Seamless automatic material storage, tracking, retrieval and
transfer system
 Proven overseas technology from SMS Siemag for PLTCM and JP
Steel Plantech for CAL and CGL
 Continous pickling line (Capacity:1.3 MTPA) ; Supplier - Flat
Products India Limited
 Twin Stand 6-High Reversing Mill (Capacity - 0.850 MTPA) ;
Supplier - SMS Demag, Germany
 Electrolytic Cleaning Line (Capacity - 0.6 MTPA); Supplier - Flat
Products India Limited, India Automation by ABB
 Batch Annealing Furnaces; Supplier - Ebner, Austria
 4-High single stand skin pass (Capacity- 0.875 MTPA); Supplier-
SMS Demag, Germany
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Continues Galvanizing lines

JSW Steel is the largest manufacturer and exporter of Galvanised Steel
in India and the first supplier of higher coating (550 gsm) to the Solar
sector in the country. Our world-class galvanising facilities are located
at Vasind, Tarapur and Kalmeshwar in Maharashtra. Galvanised
products from JSW Steel are trusted the world over for their
impeccable quality.

Galvanised steel from JSW Steel is corrosion resistant, eco-friendly,

durable, light weight and high in strength. During the process of
galvanising, zinc reacts with steel and forms zinc-iron alloy layers. These
layers are bonded metallurgically to the base steel, with the relatively
pure zinc layer on the outer surface to act as a protective coat. It
creates an impervious barrier on the steel, thus preventing it from
coming in contact with moisture and preventing corrosion.

Additionally, galvanizing enables the sheet to achieve excellent

adhesion and abrasion resistance. Another shielding mechanism is
zinc’s property to galvanically protect steel. When base steel is exposed
to cuts, edges or scratches, the zinc coat’s corrosion protects the steel.
Zinc’s electronegative properties when compared to steel in the
galvanic series help achieve this protection.
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Key Features

 Wide thickness range for varied applications

 Manufactured in Commercial, Forming, Drawing and Structural
grades
 Continuous annealing at the Galvanizing Line renders customised
hardness
 Computer controlled processes ensure perfect zinc coating on the
strips which further helps in effective prevention of rust and in
lengthening the product life
 The sheets are made in different surface finishes, such as bright,
dull or matte as per customer requirements. Spangles can be
regular or minimum as specified by the buyer.
 JSW’s Galvanized sheets can be subjected to bending and forming
without the flaking of zinc.

Applications & Grades

 Roofing and Cladding
 Commercial, Forming & Drawing Grades
 Furniture
 Heat Plates
 Solar Heating Panels
 Electrical and Light Fittings
 Agricultural Equipments
 Sandwich panels
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Continues Galvalume lines

JSW Steel is the first Licensee GALVALUME producer in India that uses
technology from BIEC International Inc, USA. The technology license
qualifies JSW Steel to continually access the latest product innovations
and process refinements through BIEC and the ZAC Association.
GALVALUME is a superior product renowned for its excellent corrosion
resistance and heat reflectivity.

The alloy coated product nominally contains 55% aluminum, 43.5% zinc
and 1.5% silicon by weight. Applied by the traditional hot-dipping
process, the product is ideal for applications that require superior
corrosion resistance and heat reflectivity. GALVALUME is typically
required for building construction, appliances, agricultural equipment
and several non-exposed automotive components.

The product’s shiny spangled appearance is attractive enough to be

used without painting. The GALVALUME sheet is a unique product
which is suitable for heating and ventilation applications. It has better
resistance towards oxidation and can withstand temperatures up to
315°C without discoloration.

Key Features
 Smooth Surface and uniform spangled appearance
 Excellent quoting with anti-fingerprint to ensure better
appearance and longer life
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Continues colour coating lines

JSW Steel Color coated products offer a unique blend of advantages –

the strength of steel, enhanced corrosion resistance and the aesthetic
appeal of paint. For the retail segment, the pre-painted corrugated
sheets and profiles are branded as JSW Colouron (Colour Coated
Galvanised Sheets) and JSW Colouron+ (55% Aluminum-Zinc Alloy
Colour Coated Steel Sheets)

JSW Steel pre-painted products are available in a variety of paint

systems like Regular Modified Polyester (RMP), Silicon Modified
Polyester (SMP), Super Durable Polyester (SDP), Poly Vinyldene Fluoride
(PVDF) and Vinyl Coated Metal (VCM). The base metal has the first layer
of primer coating on both, top and bottom surface for superior
adhesion with the paint system. The final paint coating provides
additional protection to withstand harsh weather conditions and other
factors affecting longer life. The superior coating technology resists
cracking and peeling even during heavy forming operations.

JSW Colouron and JSW Colouron+ have a long life and if eventually
replaced, are recyclable. The paint used to coat the base metal is also
toxin free.

Key Features
 Impeccable range of thickness, width, colours and profiles
 A precision finish that is uniform in colour, gloss, texture and film
thickness
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DROSS OVERVIEW

 Definition of dross
 Why dross formation matters.
 How dross forms.
 To reduce dross formation and its negative effects on the finished
product.

Definition of Dross:
 Byproduct of the galvanizing process which consists of loose iron
particles (iron salts) that have metallurgically reacted with zinc in
the galvanizing kettle
 Dross can contain more than 94% zinc (6% iron).

Why Dross Formation Matter:

 Aesthetic concerns from dross pimples.
 Steel can be rejected for gross dross inclusions.
 Dross formation accounts for approximately 15% of the zinc usage
in the galvanizing process.
 Dross formation can be reduced.

How Dross Forms:

 Free iron particles in the galvanizing kettle metallurgically react
with zinc to create dross particles rather than the zinc reacting
with the steel to create a galvanized coating.
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Types of Dross:
 Floating Dross: free particles of dross that can float throughout
the kettle and usually consist of long intermetallic spikes
interwoven in clumps; hollow-like structures.
 Bottom Dross: dross particles that aggregate (settle) to the
bottom of the galvanizing kettle.

Reducing Dross Formation:

 Limiting formation of iron salts during pickling operation.
 Adequately rinsing iron salts after pickling operation.
 Monitoring iron levels in pickling and flux baths, and galvanizing
kettle.
 Elemental additions to galvanizing kettle.
 Avoiding large temperature swings in galvanizing kettle.

Limiting Iron Salt Formation During Pickling :

 Inhibitors can be used which limit the attack of the acid on the
steel while not affecting dissolving action of the iron oxide and
mill scale on the steel.
 Monitor pickling time to ensure steel is not over pickled.

Adequate Rinsing of Pickling Salts:

 Allow enough time for pickling salts to drain before transferring
the steel to the rinse tank
 Allow enough time in rinse tank.
 Implement a second rinse tank when possible/practical
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Monitoring Iron Levels in Pickling and Flux Solutions:

 Frequently check iron levels and pH in pickling tank and rinse
tanks.*Frequently check iron levels in flux (should be no greater
than 0.5%)
 Aim for an iron level of about 0.1% in the galvanizing kettle (iron
solubility will vary with kettle temperature).

Properly Maintain Flux Solutions:

 Dross formation can be higher in wet flux method than dry
method.
 Agitation of the flux in the dry process can help to convert excess
iron to sludge.
 Work with flux supplier to find optimal chemical levels and
filtering strategies.

Elemental Additions to the Galvanizing Kettle:

 Small additions lead (1%) can reduce dross formation, but the
industry is moving away from lead use in kettles.
 Nickel additions (0.04 to 0.09%) can reduce floating dross
(however, nickel decreases the solubility of iron and can increase
bottom dross formation).
 Adding elements to kettle in smaller quantities more frequently is
preferred over bigger quantities less frequently.

Maintaining Temperatures in the Galvanizing Kettle:

 Iron solubility increases with increases in kettle temperature .
 When temperature drops, the iron precipitates out of solution
which is then available to form dross. Uppermost level of zinc can
be cooler than lower levels of zinc and have lower iron solubility.
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Removing Dross from Kettle:

 Bottom dross should be removed on a scheduled basis, whether
by time or steel volume throughput.Nitrogen can be bubbled in
zinc (ensure bottom dross is not disturbed) to float dross to the
surface where it can then be scooped outRemoving Dross from
Kettle

Where the Free Iron Particles Come From:

 Iron salts formed by a reaction between pickling agents and steel.
 Iron salts formed by reaction between flux and steel.
 Zinc/iron alloys formed by a direct reaction between steel and
molten zinc (loose iron particles on the steel).

Iron Salts from Pickling Agents:

 Pickling agents react with iron oxide and the steel to create iron
salts.
 Creates loose iron salts that can then be transferred to
subsequent tanks if not rinsed properly.

Iron Salts from Reactions with Flux:

 Fluxing agents such as ammonium chloride and zinc chloride can
form iron salts when reacting with the steel which can then be
carried over to the galvanizing kettle.

Free Iron from Zinc/Steel Reaction:

 Particles of iron from the iron or steel that comes off while in the
kettle can go on to create dross particles.Reactive steels can
develop excess zeta layer formation which can flake off crystals
that create free iron particles.
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CONCLUSION

There are many factors on which the dross formation is mainly depends
upon which are listed below,
A) Zinc coating
As the coating thickness increases, less amount of coating material is air
wiped in the zinc bath as a result of less amount of dross is formed.

B) Aluminum content in zinc bath

Aluminium Is used (0.18%) to enhanced the bonding property in
between zinc and iron. However aluminum should not exceed above
0.18% otherwise it promotes the dross generation which is undesirable.

c) Bath temperature
As a bath temperature increases more amount of dross will form. The
minimum bath temperature for keeping less amount of dross is about
465Oc.

D) Line Speed
As speed of operation increases the more amount of coating material is
drawn from the bath as a result of less amount of material is remain in
the bath to react and form dross.

E) Surface area
As a surface area increases dross formation decreases.

F) Fe content
As a fe content increases dross will increases
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E) GSM (Gram/m2)
There are various product with varying GSM
90gsm
120gsm
150gsm
200gsm
Dross formation is decreases as the gsm increases

F) Dross composition
It form due to reaction between zinc and iron
Zinc = 94%
Iron = 6%.
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DATA ANALYSIS IN
MINITAB SOFTWARE
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DROSS % TEMP(Ċ)

5.7675 0.228 0.07 0.014 0.033 464

18.6916 0.2 0.06 0.013 0.035 463
7.3058 0.2 0.061 0.013 0.022 464
9.2661 0.109 0.06 0.013 0.035 463
8.3977 0.2 0.061 0.013 0.022 464
48.288 0.21 0.056 0.013 0.025 464
10.5495 0.21 0.053 0.013 0.033 464
8.4446 0.192 0.058 0.013 0.035 463
13.6301 0.2 0.063 0.013 0.022 463
6.2103 0.2 0.06 0.014 0.017 464
8.2299 0.209 0.054 0.014 0.02 464
20.1465 0.22 0.052 0.014 0.022 463
11.8394 0.21 0.056 0.013 0.021 463
9.8724 0.192 0.072 0.013 0.02 463
12.8382 0.2 0.077 0.014 0.026 464
10.9781 0.21 0.073 0.011 0.021 463
14.9702 0.2 0.068 0.013 0.02 462
8.8263 0.21 0.076 0.013 0.02 463
16.571 0.22 0.071 0.013 0.017 464
1.8769 0.217 0.073 0.013 0.022 463
14.9155 0.22 0.071 0.012 0.022 463
6.7911 0.25 0.076 0.012 0.018 462
12.7045 0.21 0.076 0.012 0.022 463
5.4269 0.21 0.07 0.012 0.025 463
7.3083 0.21 0.066 0.012 0.023 464
3.0288 0.22 0.062 0.012 0.032 463
6.0025 0.22 0.07 0.012 0.027 463
7.32 0.19 0.073 0.012 0.013 463
10.4779 0.2 0.076 0.013 0.025 463
6.2652 0.2 0.072 0.012 0.023 463
2.3703 0.22 0.079 0.012 0.025 464
10.7727 0.209 0.073 0.013 0.029 463
21.7352 0.21 0.061 0.012 0.045 463
19.8843 0.21 0.075 0.012 0.023 463
5.5301 0.23 0.077 0.012 0.026 464
10.3263 0.209 0.074 0.012 0.027 463
2.5447 0.22 0.075 0.013 0.029 464
3.3662 0.211 0.069 0.013 0.021 463
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MINITAB SOFTWARE ANALYSIS

RESULT

Correlations: Dross%, Fe%

Pearson correlation of Dross% and Fe% = 0.104

P-Value = 0.5

ACCORDING TO MINITAB SOFTWARE FOR STRONG CORELATION

 P Value must be less than 0.5

 Pearson correlation of Dross%,Fe% Zn%,Sb%
And zinc bath temp must be positive.
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CASE STUDY ON GALVALUME

SAMPLE (150GSM)
THE SAMPLE OF GALVALUME (150GSM)WAS PROVIDED US
BY JSW FOR,

1. DEFECT ANALYSIS
2. PHASE DETECTION
3. PHASE COMPOSITION
4. DENDRITIC ARM SPACING
5. MICROSTRUCTURAL EFFECT