INDUSTRIAL TRAINING REPORT

AT
ESSAR STEEL INDIA LTD, HAZIRA-SURAT.

PRESENTED BY

Raj Sudani

Faculty Of Technology & Engineering (KALABHAVAN).

The Maharaja Sayajirao University Of Baroda,

Vadodara, Gujarat.
 ACKNOWLEDGEMENT

It is always a pleasure to remind the fine people in the Engineering Workshops

for their sincere guidance we received to uphold our practical as well as
theoretical skills in engineering.

Firstly, we would like to thank Mr. Gopalji Sinha (Head-ELC) and Mr. Nirali
Purohit and Ms. Shweta Yemdey and Mr. Nilesh Hirpara(Manager-EOL) for
providing us with the golden opportunity for training at CRM(Cold Rolling Mill) in
ESSAR STEEL INDIA LTD -Hazira.

We express our deepest gratitude to Mr. Nitin Kulkarni(Head-CRM), Mr.Sushil

Jamkhedkar, Mr. Anil Godhishala, Mr. Indraneel Sinha, Mr. Aditya
Chaturvedi for their help and guidance and for giving prompt replies for our
uncertainties regarding the plant.

Finally we express our sincere regards to all other unnamed who helped us in
various ways to have an interesting and fruitful training.
 CONTENTS
I. Essar Profile

II. Introduction to Essar Steel

III. Process Flow Chart at Essar Steel Hazira.

IV. Process Flow Chart at Cold Rolling Mill

V. Cold Rolling Mill(CRM):

1. Pickling Process

2. Acid Regeneration Plant (ARP)

3. Roll shop

4. Continuous tandem cold mill (CTCM)

5. Six high reversible mill (CRM-1)

6. Electrolytic clean line (ECL)

7. Batch annealed furnace (BAF)

8. Cold skin pass mill (CSPM)

9. Continuous galvanizing line (CGL)

10.Cold Rolled Closed Annealed(CRCA)

Essar Profile
  History
The Ruia family has been in business and in trading since the 1800s, when the
family first moved to Mumbai from Rajasthan in western India. In 1956, Nand
Kishore Ruia, the group founder, moved south to Chennai to begin independent
business activities. In 1969 following the untimely demise of Nand Kishore Ruia,
his sons Shashi and Ravi Ruia took over the group.

The name of company of "ESSAR" is getting from the first letter of two brothers
"Shashi" and "Ravi" S as ESS and R as AR.

 Overview
Essar is a multinational corporation with investments in Steel, Energy,
Infrastructure and Services. With operations in more than 29 countries, it
employs over 60,000 people.

- STEEL 

Essar has a significant global presence in steel and an international portfolio of

iron ore and coal mines.

Essar Steel is a fully integrated flat carbon steel manufacturer – from iron ore to
ready-to-market products – with a current capacity of 14 million tonnes per
annum (MTPA) and a footprint in India, Canada, USA, the Middle East and Asia.

- ENERGY

Essar Energy is a world-class, low-cost, integrated energy company focused on

India and positioned to capitalize on India's rapidly growing energy demand. The
combined assets of Essar Power and Essar Oil constitute Essar Energy.

Essar Oil is a fully integrated oil and gas company of international scale with a
strong presence across the hydrocarbon value chain – from exploration and
production to oil retail.
Currently, Essar Oil India has over 700,000 barrels per stream day (bpsd) of
global crude refining capacity at Vadinar, Gujarat, India and Stanlow, UK.

Essar Power is among India's top private sector power producers with a current
generation capacity of 6700MW spread across eight power plants in India and
Canada. 
 - INFRASTRUCTURE 

Essar Ports is one of India’s largest owners and operators of ports in India and
provides port & terminal services for liquid, dry bulk, break bulk and general
cargo.

Essar Projects is a class-leading Engineering, Procurement and Construction

(EPC) contractor offering innovative execution and delivery solutions.

Introduction to Essar Steel

Essar Steel is a global integrated steel producer with an annual capacity of 14
million tonnes with a strong presence in intensive steel consuming markets of
Asia and North America. It has operations in four countries

 A 10 MTPA integrated facilities in India.

 A 4 MTPA steel plant in Canada.

 A 7 MTPA Taconite plant under execution in USA.

 A 0.4 MTPA downstream complex in Indonesia.

Essar Steel India is an integrated steel producer with an annual production

capacity of 10 million tonnes. Essar Steel’s manufacturing facility comprises ore
beneficiation, pellet making, iron making, steel making, and downstream facilities
including cold rolling mill, galvanising, pre-coated facility, steel processing facility,
extra wide plate mill and a pipe mill.

Essar Steel has set up a 1.5 MTPA plate mill and a 0.6 MTPA pipe mill at Hazira
to add further value to its product portfolio. With one of India’s largest steel
processing and distribution network with a capacity of 4 MTPA located at several
industrial hubs.

DETAILS OF VARIOUS ESSAR STEEL PLANTS IN INDIA

Vizag  8.0 MMTPA beneficiation plant at Kirandul
 267 km slurry pipeline
 Port based 8.0 MMTPA pellet plant

Paradip  12.0 MMTPA beneficiation plant at Dabuna

 253 km slurry pipeline
 Port based 12.0 MMTPA pellet plant
 Hazira  10 MMTPA steelmaking capacity; 3 distinct iron making units (DRI,
BF & Corex)
 Port based plant
 Steel Making Technologies:
- 4.6 MMTPA Electric Arc Furnaces (4 units)
- 5.0 MMTPA CONARC Furnaces (2 units)
 Product capacities
- 7.1 MMTPA of Hot Rolled
- 1.4 MMTPA of Cold Rolled
- 0.5 MMTPA of Galvanized
- 1.5 MMTPA Plate Mill
- 0.6 MMTPA Pipe Mill

Pune 0.6 MMTPA Cold Rolling, 0.5 MMTPA Galvanizing & 0.4 MMTPA Color
Coating facility

Process Flow Chart at Essar Steel Hazira

HBI + DRI H.M From Steel Scrap

From MIDREX COREX & BF
Process
 vvvc

CONARC EAF

LF
LF

VD/VCD/RH
Degasser
CSP INI caste

CONCAST

PLATE MILLPL HSM

PIPE MILL CRM

 Process Flow Chart at Cold Rolling Mill Complex(CRM)
Hot rolled coil from HSM (Hot strip mill)

Pickling line - 1 Pickling line -2

HRPO

Six high cold rolling mills(CRM- CTCM (Tandem mill)

1)

Cold rolled full hard (CRFH)

Continuous galvanizing line-1 Continuous galvanizing line-2

GAL product
Electrolytic Cleaning Line (ECL)

Roll Forming line-1 Roll Forming line-2 Auto CTL

Batch Annealed Furnace (BAF)

GAL Finishing Line

Cold Skin Pass mill (CSPM)

Packing

CRCA product

Corrugation Line
FIMI LIR DMS ICTL
 Pickling Process

Pickling is the chemical removal of oxide layer (scale) from metal by immersion in
acid solution The hot rolled strip or sheet has surface oxidation or iron oxide
which is very brittle, hard and has coefficient of friction. The surface of the strip is
objectionable when they are to be further process.
Pickling is performed to remove hot rolled mill scales before any Cold rolling,
Galvanizing or Painting operation.
In Pickling process HCL, H2SO4,and HNO3 used as pickling solution

Advantage of Hcl over H2so4:

1. Considerably produce a uniform surface characteristics.
2. Pickling rate is faster.
3. It is cleaner to use and because if can be used at lower temperature due to
less fumes are evolved.
4. Cost of heating bath is less because of lower operating temperature.
5. Easily to handle as it available in 36% concentration.
6. Rinsing is very easy because of high solubility of chlorides

Factor affecting rate of Pickling;

 1. Acid bath concentration
2. Temp. of the acid bath
3. Time in acid bath (line speed)
4. Iron concentration in bath
5. Agitation in bath
6. Presence of inhibitor
7. Chemical composition of steel

Scale formation in hot rolling;

In the hot rolling of carbon steel a layer of oxides forms on the surface of hot strip
when the product leaves the mill typically at high temperature between 550.C
and 900.C that forces oxidation and is coiled.
Steel coiled at a high temperature has thicker scale is layer (750.C=12 microns
whereas 570.c = 6 microns) and composition of scale is largely influenced by
cooling rate after cooling the faster cooling the higher proportion of wustite The
scale on steel comprises three oxide of iron that differ proportion of oxygen.

Oxide layer of metal surface:

Fe2o3
Fe3o4
feo

Base metal

Oxide layer Percentage of iron Percentage of oxygen

Fe2o3(hematite) 69.9 38.1
Fe3o4(magnetite) 72.4 27.6
Feo(wustite) 77.7 22.3

Reaction occurrence in pickling:

The purpose of pickling is remove scale from the metal surface The strip of plain
carbon steel passed from the hydrochloric acid and then rinse with hot water.
After rinsing dryer is carried out. In this process reaction carried out which
describe below:
Fe2o3 + 2HCl = Fecl2 + H2O
Fe3o4 + 8HCl = 2Fecl3 + Fecl2 +4H2O
Fe2O3 + 6HCl = 2Fecl3 + 3H2O
In most of cases Fecl3 is reduced by metallic Fe and hydrogen to Fecl2
Fecl3 + H = Fecl2 + HCL
Fecl3 + Fe = 3Fecl2

Pickling line specifications:

Properties Line-1 Line-2
Capacity type 0.60 MTPA 0.80 MTPA
Type Pull and semi Continuous
continuous shallow type
Width 850-1025 (mm) 850-1550(mm)
Thickness 1.60-6.00(mm) 1.60-5.00(mm)
Coil inner diameter 610mm 610mm
Coil outer diameter 1000mm Max. 2020mm
Line speed 170mpm 150mpm
Pickling agent HCL HCL
Coil width 28 ton. Max. 28 ton. Max.

Defects after pickling;

Defects Corrective action
Over pickling Decrease bat concentration, reduce
line speed, reduce bath temp.
Under pickling Decease line speed, increase acid bath
concentration
Yellow patches Check rinse spray action, check pH
value of the water
Roll marks Check i/p quality, tensioned roll
Scratches Check roll rotating, check scratches
input head
Telescopicity Check EPC, check dust on EPC tube
Handling Damage Check strapping coil, proper storage of
coils
 Acid Regeneration plant(ARP)
In acid regeneration plant mainly regeneration of hydrochloric acid from liquid
product of pickling process. Liquid of pickling process mainly comprises Fecl3,
Fecl2 and H2O. After process Fe particle and HCL are obtained Fe particle send
for charging in blast furnace in iron making process and HCL send for pickling
process. Chemical Reaction is carried as described below:
2Fecl2 + 2H2O + 1/2O2 = Fe2O3 + 4Hcl
In this plant heating done by combustion engine. Storage tank material is
FRP(fiber resistance plastic)

Roll shop
In roll shop various type of process is take place such as grinding, overhauling,
texturing, chocking-dechocking, lekage testing sand etc.
Roll material is forge steel which harden done by induction hardening so, outer
layer of roll material is martensite which is very hard and inner layer of roll
material is pearlite which is soft Roll mainly used for rolling operation

Roll grinder;
ESSAR steel in CRM department mainly four grinder machine available which
details as bellow;
Specification of roll Grinder-1:
Make - Herkules Franz Thomo
Max. roll diameter ]= - 640mm
Minimum roll diameter - 300mm
Roll speed - 120RPM
Grinding wheel speed - 1300RPM
Grinding wheel size - 750mm
Specification of roll grinder-2:
Make – Herkules Franz Thoma
Maximum roll diameter – 640mm
Minimum roll diameter – 380mm
Roll speed – 120rpm
Grinding wheel speed – 1300rpm
Grinding wheel size – 750mm
Specification of roll grinder – 3:
Make – Arrel Guist
Maximum roll diameter – 1500mm
Minimum roll diameter – 480mm
Roll speed – 26rpm
Grinding wheel speed – 1300rpm
Grinding wheel size - 915mm

Specification of roll grinder – 4:

Make – Waldrich Siegen
Maximum roll diameter – 1600mm
Minimum roll diameter – 380mm
Roll speed – 100rpm
Grinding wheel speed – 1600rpm
Grinding wheel size - 915mm

Specification of EDT Machine:

Make – Waldrich Siegen
Maximum roll diameter – 5500mm
Minimum roll diameter – 380mm
Roll speed – 35rpm

Overhauling:
Taper roller bearing – for CRM-1, CTCM & CSPM (work roll/IMR)
Cylindrical roller bearing – CRM-1, & CSPM (backup roll)
Margolis bearing – CTCM (Backup roll)
Ball bearing – CSPM Thrust Bearing
Leveler Table for bearing inspection
Large over hauling stand
Plunger leakage testing stand
Puller and tackles for different bearing

Chocking and Dechocking:

CTCM - Work roll
CRM-1 – Work roll
CRM-1 – intermediate roll
CSPM – Work roll

Six High Rolling Mill(CRM-1)

Mill specifications as given bellow:
1.Pay of Reel:
Material – Hot rolled and pickled low carbon steel
Thickness – 1.20mm to 4.50mm
Width – 700mm to 1270mm
Coil inner diameter – 508mm & 610mm
Coil outer diameter – 850mm & 2000mm
Unwinding speed – maximum 450 m/min.
Coil maximum weight – maximum 25T
Back tension – 500-5000kg
2. Three roll feeder:
Top Roll – 280mm*1400mm driven by A.C. motor
Bottom Roll – 280mm*1420mm fixed free roll
Bending Roll – 160mm*1420mm up down by hydraulic force
3. Mill Stand:
Finishing product thickness – 0.15mm to 1.60mm
Width – 700mm to 1270mm
Rolling speed – 1200mpm Max. at 400diameter work roll
Spindle Torque – 6046knm
4. Roll dimension:
Work roll – 400mm
Intermediate roll – 490mm
Backup roll – 1170mm
Purpose of 6 high rolling mill is reduction of thickness, finshing, and shape
correction etc. During process for coolant oil and water mix use It is cold working
process so, due to strain hardening steel become harden. Reason for strain
hardening is interstitial atom, lower temperature etc. In this mill one stand for
passing stand so, many time passing of sheet for rolling due to frequently
passing of mill production of mill is very low as compare to tandem mill But
advantage of this mill is that no require any lopper system, welding system etc.
and require low working space.
In this mill width of sheet is not increase due to tension force which is given by
DTR(delivery tension reel) and ETR(Entry tension reel) although width is
increase in micron size but length of sheet is increase much more time as
compare to original length. It is based on the plain stress and strain condition
force applied on the roll it is done by hydraulic mechanism. Roll gap between two
roll is depend on thickness sheet mainly 15% of thickness of sheet.

Continues Tandem Cold Mill(CTCM)

In CTCM(continues tandem cold mill) five stand and four high mill is available
main advantage of tandem mill is high production as compare to six high
reversible mill
Special future of tandem mill as given bellow:
1. Flush butt welder
2. 90 degree turning point
3. 6 stands 600 mts. Lopper
4. L-2 automation
5. Mill cleaning system
6. Automatic flatness control
7. Automatic thickness control
8. DSR(Dynamic Shape Roll) in stand-5 better shape control
9. Flying shear to cut sheet at 200mpm
Specification of tandem mill as given bellow:
1. Production capacity – 1.2MTPA
2. Mill speed maximum – 1000max.
3. Entry thickness of sheet – 1.55mm to 5mm
4. Exit thickness of sheet – 0.2mm to 3mm
5. Coil maximum weight – 28MT
6. Coil width - 650mm (min.)&1625mm (max.)
In tandem mill starting portion is flash butt welder which is used for joining of tail
of one coil and head of another coil. After welding head and tail of coil fill material
to each other after welding lopper portion is start. In lopper sheet turn at 90
degree. It is done by two roll which put at 45 degree mainly lopper fill 90%
material at the end of coil
In lopper portion also put the bridle roll and steering unit work of bridle roll is
creating tension in the sheet while steering unit control sheet at center line
After lopping mill portion is start. Initial thickness of sheet measured by x-ray
gauge 1 and then one stand pass sheet and reduced thickness of sheet. In this
mill only one time pass of mill. And then once again measure thickness of sheet.
In this mill force is given to roll by using of hydraulic mechanism. The diameter of
backup roll is 1350mm to 1500mm and work roll is 480mm to 560mm. Working
temperature of this mill is around 50degree Celsius so, strain hardening
phenomena occur and material become hard and dislocation produce. So,
increase force of roll at further process. For cooling oil and water use.
In stand 5 roll put bright and matt surface that depend on further process. Final
measurement of thickness also put x-ray gauge after completing cold rolling.
End of mill two tension reel which recoil of sheet. Mill cleaning done by hydraulic
pump. After cleaning of surface strip measure the Ra value. It should be within
0.6 to 1.8 micron. If the Ra value below 0.6 than increase unit roll force for last
stand while Ra value below the 1.8 reduced unit force for last stand

Thickness(mm) Rolling Mode Unit roll force

0.3-0.5 Sheet thin 650+/-50
0.5-0.8 Sheet 650+/-50
0.8-1.0 Sheet 700+/-50
1.0-1.2 Sheet 700+/-50
1.2-1.5 Sheet 700+/-50
1.5-2.0 Sheet 750+/-25
2.0-2.5 Sheet 800+/-25

For work roll diameter variation with crown as given bellow:

Stand Max. dia.(mm) Min. dia.(mm) crown Roughness(Ra)

1 530 480 140+/-10 0.9+/-0.1

 2 540 490 110+/-10 0.9+/-0.1
3 550 510 80+/-5 0.6+/-0.1
4 560 520 80+/-5 0.6+/-0.1
5 560 520 80+/-5 0.6+/-0.1for
GAL & 3+/-0.2
for CRCA

For back up roll diameter variation with crown as given bellow:

Stand Diameter(mm) Cycle over Crown Roughness(Ra)
tonnage
1 1350-1500 75000T 160+/-180 1+/-0.2
2 1350-1500 75000T 160+/-180 1+/-0.2
3 1350-1500 75000T 140+/-160 1+/-0.2
4 1350-1500 75000T 140+/-160 1+/-0.2
5 1450-1500 75000T 140+/-160 1+/-0.2

Cycle over Tenure for work roll:

Stand-1 Stand-2 Stand-3 Stand-4 Stand-5
90KMS 300KMS 350KMS 450KMS 200KMS
(plain roll)
0.6-0.7 Ra on
strip surface
for matte roll
or 200KMS
ever earlier

Electrolytic Cleaning Line(ECL)

The purpose of this line is to remove the residual oil and iron fines present of cold
rolled strip This required to avoid carbon shoots and hydrogen shoots on the strip
after annealing It requirement for auto and white good product
Specification of this line as given below:
Thickness – 0.25 to 3 mm
Width – 600 to 1625mm
Line speed – 270mpm
Strip tension - 12N/nm2
Oil & dirt (input) – 300mg/m2/face
Iron fines – 70mg/m2/face
Residual oil on strip:
Input – 250mg/m2/side
Output – 50mg/m2/side
Residual iron fines on strip:
Input – 50mg/m2/side
Output – 25mg/m2/side
To avoid the formation of insoluble cracking product during the annealing
process The cold roll strip has following process will not be disturbed
This soiling can be rolling oils, rolling emulsions (natural synthesis, corrosion,
additives etc.)
Sometimes also called tramp oils (hydraulic oil other oil during cold rolling
process ) can be found
Furthermore iron fines and chemical reaction product as iron scale remove
This line based on the three law saponification, emulsification, deflocculating.
In saponification more particle concern fatty matters such as fatty acid exist on
the strip. soda or potash saponifies the ester to form soaps that will be soluble in
alkaline solution.
An emulsion is a mixture of two or more liquids that are
normally immiscible (unmixable or unblendable). Emulsions are part of a more
general class of two-phase systems of matter called colloids. Although the
terms colloid and emulsion are sometimes used interchangeably,emulsion should
be used when both phases, dispersed and continuous, are liquids. In an
emulsion, one liquid (the dispersed phase) is dispersed in the other (the
continuous phase). Examples of emulsions
include vinaigrettes, milk, mayonnaise, and some cutting fluids for metal working.
Flocculation, in the field of chemistry, is a process wherein colloids come out of
suspension in the form of flake; either spontaneously or due to the addition of
a clarifying agent. The action differs from precipitation in that, prior to flocculation,
colloids are merely suspended in a liquid and not actually dissolved in a solution.
In the flocculated system, there is no formation of a cake, since all the flocs are in
the suspension.
In this line alkali tank available which remove the iron fines and oil gets lessened
at 85 degree Celsius and then brush scrubber remove the iron fines and then
pass through ECL tank. In this tank strip become anode and cathode remove oil
and then flow of water spray remove the solution of iron fine as well as oil and
then passed for drying (hot air).

Batch annealed furnace(BAF)

It receive coil from the electrolytic cleaning line which material is very hard due to
cold working process.
Purpose of this line is to relive internal stress produce during cold working
process and the material is subjected to only recrystalise annealing temperature
In general material heated up to predetermined temp. it is known as
recrystalisation temperature. And finally cool down slowly and we achieved
desire property. The various property of treatment are to:
1. Relive internal stress
2. Improve restore ductility and toughness
3. Enhance machinability
4. Refine grain size and orientation
5. Reduce gas content in steel
6. Improve formability related property
Start process with charging in charging of coil put in the form of stack and final
shape of stack of coil is kept cone, cylinder type. When different diameter of coil
is available that time higher cross section are must kept at lower portion and
lower cross section area of coil must kept at upper portion. This plate separated
by diffuser plate for better convection process. This coil loaded on annealing
bases after charge coil placed shell which is made by stainless steel. This shape
is cylinder type it also called inner cover.
After clamping the inner cover ready for leak test. In this test find out leakage in
the bases inner cover purge out of inert gas i.e. N2 gas which drive the O2
The base ensure free of any leakage and then ready for heating sequence. In
heating sequence heating bell is enter on the inner cover furnace inert
atmosphere should be H2 it reduce oxidation of the steel after heating complete
for cooling another bell is entered. Which is called cooling bell in this bell hot air
is removed and cold air enter
Heating of coil done by natural gas and air mixture. This mixture ready for
combustion in 2 step high velocity burner here heating bell heat the inner cover
by using of burner
During process recovery, recrystalisation, grain growth is occur after annealing
grain become big grain so mechanical properties are recovered.
Process sequence in batch annealed furnace:
Heating cold roll strip recrystallisation temp. in inert atmosphere
soaking at this temp. for sufficient homogenization and necessary changes
Cooling at predetermine zone
Here pure H2 is used because
1. Very high conductivity
2. Low viscosity
3. High reducing potential
4. Smaller molecular size
5. High decarburizing power
Conduction, convection and radiation occur in furnace for heat transfer
Grain before annealing:
Cold Skin Passing Mill(CSPM)
Purpose of cold skin passing mill is
1. To suppress the yield point phenomena,
2. To increase roughness of the material,
3. Shape correction of sheet
4. Cleaning of sheet
In cold skin pass mill thickness reduction of sheet occur in micron range which
is negligible. Yield stress represent that deformation of material is gone elastic
to plastic The reason of suppress the yield point is that coil will go for deep
drawing process in automobile industries that time deep drawing not occur and
wrinkle produce. Also elongation of sheet is increase.
Roughness of sheet is also improve due roughness of roll is high. Here matt
surface roll is used. So impression of roll put on the sheet. It is carried out
because this coil will go for automobile industry which doing paint on the sheet.
If roughness is low than sheet can not be old down the paint so, roughness
impart is necessary.
Cleaning of sheet is done because rust resistance is increase.
Shape correction also take place on this mill. Shape defect produce during
backward process of coil such as waviness, center braking, quarter etc.
Raw material of this process is low carbon steel which emerge in batch
annealing furnace. In this type mill comprises mainly 4- roll for process such as
two backup roll and two work roll, anti crimping roll, wet temper unit, pay of reel,
tension reel, various type of gauge.
First of coil is entered in mandrel of pay of reel. Then bridle work for increase in
tension then gauge measure the dimensions of sheet. Then wet temper nozzle
start to flow of cooling media(oil and water). Then sheet pass from the roll air
wiper flow of air to remove cooling media and then tension reel uncoil the sheet.
Benefits of Wet temper unit:
1. Prevention of iron fines on work roll
2. Good corrosion preventing properties
3. Lubricant properties
4. Good staining preventing properties
Rust preventive unit:
Type of oiler – Electrostatic high tension
No. of coil reservoir – 3
Oil used – FUCHS 4107-S
Temperature reservoir – 65-75degree Celsius
Temperature spray bar – 70-80degree Celsius
Benefits of electrostatic unit:
1. Uniform coating
2. Significant oil saving
 3. Coating weight flexibility
4. No mechanical contact
5. Coating material transfer efficient
Here mainly low carbon material is used for this mill so in microstructure in ferrite
and pearlite is available. Grain size of material is high after passing material in
mill grain size become elongated in elliptical shape.

Continuous Galvanizing Line(CGL)

After rolling under cold roll mill then coil will go for coating in galvanizing plant.
Here zinc coating take place on the coil. For galvanizing two line is available.
GAL-1 and GAL-2
Specification of Gal-1 line:
1. Input material – cold rolled/hot rolled low carbon including structural steel
2. Strip thickness – 0.30mm to 3.25mm
3. Strip width – 800mm to 1370mm
4. Coil inner diameter – 508/610mm
5. Coil outer diameter – 1800mm
6. Line speed – 180mpm
Specification of Gal-2 line:
 1. Input material – cold rolled/hot rolled low carbon including structural steel
2. Strip thickness – 0.12mm to 0.60mm
3. Strip width – 700mm to 1250mm
4. Coil inner diameter – 508/610mm
5. Coil outer diameter – 1800mm
6. Line speed – 150mpm
7. Coil weight – 22T(max.)

Here two uncoiler for process after uncoil the coil is gone for welding. GAL line
type of welding is seam welding which is high frequency resistance and it is
operated by electric current. And then coil pass through bridle which create
tension in the sheet. Here lopper also available in GAL-1 lopper is horizontal
while in GAL-2 lopper is vertical. After lopping coil go for process section.
In process section first coil heated in the furnace. Five zone in furnce is available
just like
1. Preheating zone
2. Direct fired furnace
3. Radiantive furnace
4. Soaking zone
5. Jet cooling furnce
In preheating zone mainly coil heated up to 400 to 500 degree Celsius. for
combustion natural gas and air is mixed. In direct fired furnce have also sub
zone in zone 1, 2, 3 eight burner is available and in zone 4 64 burner is available
for heating. In radiative furnace strip heated by radiation of heat. In this zone
tube for heating is available which is made up of copper. In soaking zone 48
burner is available. In last zone five blower for GAL-1 and 3 GAL-2.
Heated strip pass in zinc bath. Chemistry of zinc bath is
Al – 0.143 to 0.030%
Pb – 0.05 to 0.15%
Zn – balanced zinc
Working of al is control the reaction of the Zn and steel strip because this
reaction between Zn and steel is high diffusion occur. Charging of bath is Zn
ingot. High grade zinc, prime western zinc and al alloy. In bath three roll also
available such as sink roll, seal roll and stabilizer roll. Sink roll give tension to
strip for going in upward direction. Seal roll seal the zinc coating. And stabilizer
roll maintain excess zinc coating. Mainly two type dross is obtained 1. Bottom
dross and 2. First dross
After coating strip go for pot cooling. In cooling done by water quench. And then
coated zinc strip pass through chromic acid at high temperature. Chromic acid
increase life of zinc coated strip.
And then coil is again recoiled. And go for finishing line.
microstructure of Zn coated material:

In GAL finishing line two lines available:

1. Corrugation
2. Cut to length
In corrugation line roll forming line which produce corrugated shape in strip.
In figure one is represent the trapezoidal shape while in figure two is sinusoidal

CRCA Finishing Line

The CRCA finishing Line is last unit of CRM plant where various type coil
finished such as HRPO, CRFH, GAL, CRCA. After passing this line coil pack
and go to costumer.
CRCA finishing line is four which describe as bellow:
1. DMS(Dujardin Montbard Somenor) line
2. LIR line
3. .FIMI line
4. ICTL(inspection cum trimming line) line
Various Processes are take place:
1. Shearing
2. Trimming
3. Parting
4. Slitting
5. Inspection
Specification of DMS line:
1. Make – D.M.S. France
2. Capacity – 69900MT/Annum
3. Strip Thickness – 0.3 to 3 mm
4. Strip width - 500 to 1300mm
 5. Slit Width – 250mm min. 5 pieces max.
6. Yield Strength – 42kg/mm2 max. up to 3 mm

Specification of FIMI line:

1. Make – FIMI Italy
2. Capacity – 140000 MT/Annum
3. Strip Thickness – 0.3 to 3 mm
4. Strip Width – 400 to 1600mm
5. Shear Length – 1000mm to 3500mm
6. Yield Strength – 42N/sq.mm
Specification of LIR line
1. Make – D.M.S. France
2. Capacity – 180000MT/Annum
3. Strip Thickness – 180000 MT/Annum
4. Strip Width - 0.4 to 2.5 mm
5. Slit Width – 300mm min. – 3pieces max.
6. Yield Strength – 45kg/mm2 max. up to 3mm thick
Specification of ICTL line:
1. Make – Dong Bang Korea
2. Capacity – 300000MT/ANNUM
3. Strip Width – 600 to 1650 mm
4. Strip Thickness – 0.3 to 3mm
5. Trim Width – 1000mm min. – 1 pieces
6. Yield Strength – 45kg/mm2 max. up to 3mm thick