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How to Reduce the Operating Cost of Rolling Mills

 

India has been growing rapidly when it comes to the steel industry. In comparison to other countries, India rightfully caters to the world’s needs with its high-quality steel solutions. Nowadays, manufacturers have only one goal in mind, which is to provide only superior quality products to their customers.

But how can one achieve that level of quality? It is simply to install state-of-the-art machinery to give attention to detail and produce better quality products. However, what often stops multiple companies from doing so is the cost of operation. Let us find out how we can reduce the operating cost of rolling mills.

What is the main purpose of a rolling mill? It is to form metal. Depending on the client’s demands and the goal they want to achieve, the thickness will vary. Now there are various categories of rolling mills, and they are differentiated based on the temperature. For instance, if the temperature is above the level of recrystallisation, i.e., hot, then it will be considered hot rolling but if it remains below the recrystallisation temperature, then it shall be regarded as cold rolling. 

One of the biggest concerns of manufacturers worldwide is the operating cost. Luckily, with a few alterations to the operating process, the manufacturers can drastically decrease the cost without altering the end product. 

Here are a few steps with which you can reduce rolling mill costs-

1. Energy Consumption 

The first thing that needs to be done is the reduction of energy consumption. On a daily basis, there is a lot of energy waste during operation, and there is no track of it. Our priority is to reduce the energy cost of the unit. How should we do that?

  • There is a dire need for high-quality machinery in daily operation. The main reason is that advanced machinery and its mechanism will reduce rejects. If there is a reduction of rejects from 1.5% to 2%, this small shift can decrease fuel use up to 9%. 
  • The electricity used during the rolling process can also be decreased significantly if motors are used in conjunction. This process is highly efficient and reduces nearly 1%-2% energy consumption. 
  • A decrease in oxygen levels by even 1.5% in the heating furnace effectively reduces the cost. Energy consumption reduces down to 2.4% once the oxygen reduction is implemented. 

2. Process Optimization

Process optimisation is a key way to control and reduce the operating costs of rolling mills. Multiple components work in sync to utilise state of the art rolling mill. There needs to be constant analysis, evaluation, and improvisation for the best output. The most essential is to reduce downtime and accurate interconnection of the production stages. 

This method effectively increases the productivity of the operation. One can also accurately measure the energy used per unit. In general, optimisation reduces the risk of scale loss and heightens efficiency. This is a practice that can be adopted by steel plant consultants and multiple different metal manufacturers.

3. The Right Equipment 

High-quality rolling mill equipment plays a major role in the operating cost and impacts the overall value in many ways. Good quality equipment reduces maintenance costs as you will omit the need for regular maintenance as these are much more reliable.

It also reduces system downtime significantly and improves operation costs. High-quality equipment also has replacement parts readily available, making replacing much smoother. 

4. Leverage Automation

When it comes to reducing the cost of the rolling mill, leveraging automation can be incredibly useful. Making any production process efficient requires advanced mechanical equipment, process technology, and automation functions. These three together can transform the overall cost of operation.

The more suitable software and electrical equipment used will allow more accurate information to be received by mill operators to automate and unify mill setup. This process improves overall operating practices and reduces costs. 

Find The Most Reliable Partner in Steel Forming

The Steefo Group is your reliable partner in steel forming when it comes to steel forming. They provide the most high-quality products and turnkey solutions from concept to commissioning. Advanced machinery, highly skilled engineers, state-of-the-art manufacturing facilities, and undisputed quality make the Steefo Group an eminent steel rolling mill manufacturing company in India. 

To learn how you can reduce your operating costs and improve profits with the products and solutions of The Steefo Group, contact +91 98240 76873 or drop a mail at marketing@thesteefogroup.com.  

 

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How to Select The Most Suitable Rolling Mill Equipment

 

When it comes to metal rolling and deformation, the critical component essential to the operation is the steel rolling machine that determines the level of production and technology. Therefore, it is crucial to select the best rolling mill equipment suitable for all your needs and positively impacts the mill’s functioning.

How to Select Steel Rolling Mill Machines?

Several factors come into play when selecting the perfect rolling mill machine. Some of them are: 

  • The steel grade
  • The production scale 
  • The product variety 
  • The production process and more. 

When it comes to the process design of the rolling mill, we also consider numerous components such as- 

  • The structural type of the rolling mill 
  • Choosing the number of rolling mills 
  • Laying method
  • Technical parameters 

Now that it is time to pick the steel rolling machine, one should always remember that the rolling mill should have a reasonable composition and compact arrangement. It should also have a high equipment utilization and impressive production efficiency. Another important aspect is to guarantee that the product quality is up to the mark, not only for current production but also for new production capabilities. 

Apart from that, a suitable rolling mill should facilitate the scope of automation and mechanization to significantly upgrade the working conditions of the employees and be advanced enough to be easy to operate and maintain. Speaking of maintenance, this includes having an easy availability of spare parts that facilitate long-lasting usage. A green flag to consider is the availability of good economic and technical indicators. 

Rolling products and rolling mills come in an exhaustive assortment. Due to the plethora of products, the characteristics of the products differ significantly during rolling. That is why various products have various requirements for rolling mills. 

For example, what is the number one priority for large-scale blanking machines heavy plate rolling mills and more? Well, apart from the required precision? The most crucial thing is the ample strength that allows the large deformation of rolled products. Similarly, plate steel mills, wire mills, and more require substantial and sufficient rigidity; a degree of strength is needed to operate smoothly. 

Why Rely On The Steefo Group For The Best Rolling Mill Equipment?

So you are looking for suitable rolling mill equipment. Look no further as The Steefo Group can provide you with everything your rolling mill will ever need.  For almost four decades, we have been the ultimate and the most favoured integrated rolling mill manufacturer.  The Government of India also acknowledges us as the Star Export House, and we adhere to our reputation. With over 100+ establishments, we are a prominent name worldwide and in the country. 

Understanding The Steefo Group’s Products 

When you choose products from The Steefo group, you are getting guaranteed quality. You also  get your hands on the most innovative and futuristic products that will help you transform the face of your business.  The Steefo Group specializes in everything,  from turnkey projects to single modular projects, depending on the needs of your business. From TMT bar rolling mills and wire rod mills to products such as mill stand, rolling mill gearboxes, reheating furnaces and more. 

Our projects and products also undergo rigorous testing and quality checks to supply the best-in-class products. Our focus on technology and innovation also provides you with the most up-to-date products for your rolling mill.

To learn more about the Steefo Group and their products and how they can improve your productivity and profits, contact +91 98240 76873 or drop a mail at marketing@thesteefogroup.com.

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The Steefo Group: Innovating Rolling Mill Solutions Around the World

When we talk about reliable experts in steel forming, the only name that comes to the forefront is The Steefo Group. Our reputation stems from the word steel forming. Our origins are rooted in excellence and superior production, both in national and international export markets. 

The Origins of The Steefo Group 

The Steefo Group has humble beginnings; we started our journey four decades ago in 1976.  With Mr K.K Agarwal laying the foundation of the  Steefo Industries in 1976, starting our first order in 1979 to achieving our first export order in 1991, we have always had an upwards trajectory. The only goal that we had in mind was to provide precision in design and manufacturing and produce superior quality products and turnkey solutions that fit our clients’ expectations and standards. 

We aimed to become the one-stop shop for all steel rolling and melting industries. We have expanded our services and products since 1976, and now we have a group of expert engineers catering to numerous sections of this ever-demanding industry.

The Steefo Group Quality

One thing that we have pledged to maintain and have never compromised on is quality. The name of The Steefo Group is recognised worldwide today because we are consistent in provisioning high-quality products. We hold ourselves to the strictest standard and norms possible to ensure that only products of the highest grade products to our clients. 

We have a dedicated quality assurance team that performs quality checks and rigorous testing from raw materials to the finished products. This is done to ensure that we stay true to the promise of being your reliable steel forming partners. We take a quality-based approach to quality commitment.  

Our Commitment To Innovation 

From its very inception, Steefo has been dedicated to growth and innovation.  We believe that innovation can transform change into new beginnings and fruitful opportunities. Innovation is more than just developing new products but rather producing cohesive design and technology that comply with the constant evolution. Our team of dedicated and experienced design engineers have the vision and talent to delve into undiscovered and uncertain aspects of the world of steel forming to discover and develop new processes, systems, and management methods to positively impact the growth, productivity, and profitability of our clients. 

When you partner with us, you invest in premium grade products and are consistently provided with a workforce that offers the skill to produce the best output in the competitive steel forming market. 

Research and Development

The Steefo Group is known worldwide because of our drive toward developing and improving our R&D and design capabilities. We invest our resources in technical improvements because we know that only development in the field of technology guarantees consistent improvement in our manufacturing speed and product quality. Only the most advanced technology can cater to and match the demands of our varied clients. We utilise software such as CAD and Kissoft and more to procure future-ready equipment that complies with industry 4.0. 

How Has The Steefo Group Solutions Transformed the Steel Rolling Industry?

The Steefo Industry has become synonymous with innovative and unique turnkey solutions that transform rolling mill solutions worldwide. From concept to commissioning of rolling mills and integrated steel plant, we have complete expertise in all aspects of the field. Multiple turnkey projects are supplied with plant equipment and execution, including erection and commissioning to obtain the maximum desired production value. 

1. TMT Bar Rolling Mill 

Steefo Group - TMT bar rolling mill

For The Steefo Group, TMT bar rolling mills have been ingrained in our DNA. Being your one-stop-shop for all your rolling mill solutions, we ensure that we provide our clients with innovative and modern designs in our turnkey solutions. Our expert engineers can handle these projects from concept to commissioning. We constantly customize our products according to the demands and needs of our clients and have production capabilities ranging from 80 TPH to 100 TPH. We ensure that productivity is boosted and ensure faster ROI.

2. Structural Rolling Mill 

The production process in the rolling mill

The Steefo Group is a front runner amongst companies known to produce end-to-end solutions for structural rolling mills. We guarantee that our structural rolling mills have the most incredible performance capacity and shortest downtimes.

3. Wire Rod Mill

Wire rod mill solutions

We have mastered wire rod mills over four decades and have become a trusted name in this industry when it comes to the production of wire rod mills. From cost-effectiveness to flexibility, the growing demand for wire rods is being matched by our support in creating impeccable wire rod mills to allow large production capacities. The Steefo Group creates wire rod mills that are not only high speed but are also capable of rolling themselves into the smaller dimension to increase production rates.

The Services of The Steefo Group That Sets Them Apart

For anything related to steel, you can trust The Steefo Group. From process analysis to optimization and up-gradation, our skilled engineers are here to help you from start to finish. Our end goal is to drive our clients towards success and profitability.

1. Product Design and Engineering

As your reliable steel-forming partner, you can trust us as we are equipped with worldwide experience in implementing turnkey solutions. Our technical departments come together to customise the project to your exact requirements. From individual to products to complete solutions, we provide it with all to ensure that our clients do not face any disadvantage in any step of the process.

2. Spares and Consumables 

We have provided superior customer support and client satisfaction throughout the project lifecycle. We understand how demanding the process is, and that is why we are there every step of the way. We are not only involved in turnkey projects; we also offer spare parts and consumable products to our customers to ensure prolonged service and consistent performance and endurance.

3. Technical Support and Repairs

The Steefo Group always ensures that the steel plants are always equipped with advanced technology to maintain and raise the bar in terms of quality and production. Our team of engineers works closely to keep an eye on the project until the output production stage to prevent downtime and cost overruns.

4. Service Agreement Program

Surviving the rapidly evolving steel market is not an easy task. We meet the demands of the evolving market and rapidly proceed to optimise and improve the efficiency and quality of the plant. It includes adopting the best practices and maintaining equipment and machinery pristine and well maintained. Our company provides a complete service program to ensure that your products reach peak performance levels. The entire process involves evaluating equipment and improving them whenever deemed necessary.

Why Work With The Steefo Group?

Today, The Steefo Group has reached this level of success due to its relentless drive toward excellence and an uncompromising attitude towards quality. We are constantly evolving and trying to improve our current products and solutions, and therefore, we have transformed into the leading innovation in the world of rolling mills.

When you work with us, you get high-quality products and receive constant support from our team of professionals. Join the world of success. To learn more, call us at +91 98240 76873 or drop us a mail at marketing@thesteefogroup.com.

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The Dramatic Rise in demand for TMT Steel Bars in India

The introduction of Thermo Mechanically Treated (TMT) steel bars began a new era in the Indian construction industry. Round plain steel reigned supreme until the sixties but was then ousted by TOR steel in the seventies and maintained dominance until the nineties came into the picture. In the late nineties, TMT steel and corrosion resistance steel made their grand debut, transforming the face of RCC structure by making them more resilient and long-lasting. 

What Makes TMT Bars Stand Apart?

The term TMT bars has become the industry staple for constructing any structure, starting from bridges, flyovers, dams, hydel power plants, industrial structures, high-rise buildings, rapid transport systems, and more. TMT or Thermo Mechanically Treated bars uses Quenching and Tempering technology during production, obtaining their unique strength from that process. There is no chemical treatment involved in the manufacturing of TMT bars. 

But what gives TMT bar the unique edge that allows them to conquer the construction industry? 

Here are some of the attributes:

  • TMT bars’ carbon content is limited to 0.2% to achieve weldability and suffers no strength loss. 
  • Ordinary electrodes have the ability to weld joints without any extra precaution.
  • Due to their tough exterior and soft interiors, they have incredible ductility.

TMT bars tick all the three crucial boxes, strength, weldability and ductility, making them economical and safe for usage. A bonus is the corrosion resistance that TMT bars obtain since the cooling process avoids the formation of coarse carbide. The soft ferrite pearlite increases seismic loading. TMT bars are usually produced in Fe- 415, Fe – 500,  Fe – 550, Fe 500D, Fe 550D grades with diameter starting from 8,10,12,16,20,25, 28, 32, 36, 40 MM, with a standard length anywhere from 5.5 -13 metres.

TMT Bars and the Indian Market 

India’s iron and steel industry has come to occupy a dominant place in the country’s socio-economic development. India also ranks seventh as the largest crude steel-producing nation in the world. The Indian steel industry has gone through tumultuous business cycles, with several ups and downs. Today the industry is on the cusp of a significant change as it gears toward an expansion of ambitious standards. 

The secondary producers of the Indian steel industry are joining forces with the main producers. The emergence of the secondary producers has initially been modest in the post-liberalized decade in the steel scene. Still, it steadily contributes to the development of the domestic steel and iron industry in aspects of capacity, production, spread,  necessitation and commodity basket. 

Steel production in India received a massive boost with the introduction of the Industrial Policy Resolution of 1956. This is where the public sector saw three SAIL plants being set up in the late 1950s and the fourth one in the early !970s. These plants, along with VISL, TISCO and IISCO(now a part of SAIL), were the sole producers of integrated steel till the eighties (RINL came into production in the early nineties)  

There was a rising demand for the secondary sector for smaller-scale steel producers in the seventies. Specifically for those who had opted for induction furnace routes or the scrap-DRI based electric arc furnace, particularly for meeting local demands. 

Semi-finished billets and ingots manufactured by this part led to the commissioning of considerable re-rolling units to transform semi-finished steel into rods and bars that can be utilised mainly in the construction industry. 

The re-rolling part faced several market challenges, especially in high energy consumption and prices. However, there is a bright prospect of future growth, given the pace of construction and infrastructure activities. Experts estimate that the secondary producers in total crude steel production will increase from the current under -50% mark to at least 53%. 

We are also seeing an increase of foreign steel plants setting up steel plants in India, gearing up to venture into their dream project as the steel industry of India prepares for a new era. An era that will include the dominance of the Indian iron and steel industry. The steady growth of the Indian economy because of the steel industry has also increased infrastructure from township complexes to roads, bridges, and civil construction projects, which guarantees the continuous demand for TMT bars. 

Find the best TMT Bar Rolling Mill

We at the Steefo group understand the importance of TMT bars; therefore, we are the number one producer of TMT bar rolling mills. These TMT bar rolling mills are a part of Steefo’s DNA. We are the creators of ultra-modern, integrated automation solutions, developed to increase productivity and decrease manpower, guaranteeing a faster return on investment. 

For queries related to TMT bar rolling mills, you can reach out to us by calling us at +919824076873 or write to us at marketing@thesteefogroup.com.

You can also check with our experts to understand TMT rolling mill project costs! We would be happy to help!

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5 Best Reasons Why TMT Bar is the Future of the Steel and Construction Industry

The Indian construction industry has gone through a transformative phase since the late 1990s, both in technology and research. The proof of this rapid developmental stride is in the steel industry’s products- most of today’s products did not exist a decade ago. The industry has also made its presence in India’s numerous developmental plans in rural, urban and metropolitan areas. With the introduction of robust technological advancements, the popularity of steel products has also increased in the nation. 

But to be the future of any industry, products must meet the growing consumer demands and address the environmental factors. Historically, the steel industry has always been associated with ecological deterioration and destruction. To improve upon that aspect, the steel and construction industry worldwide has advanced into more environmentally conscious modes of production. The goal is to become more sustainable and reduce the industry’s carbon footprint. 

Here is where products such as the TMT bars come into action. TMT bars have proven to be the solution as the bars have adapted to future demands. Let us find out how they have proven to be a massive asset to the construction industry. 

What are TMT Bars?

Before we delve into the benefits, let’s find out all about TMT bars? ‘Thermo Mechanical Treatment’ bars, better known as TMT bars, are among the most necessary construction materials worldwide. They are high-strength reinforcement bars manufactured using a distinctive technique that endows them with a rigid outer surface and a soft internal core, making them strong yet flexible.

TMT bars are steel bars of a new era, suited for concrete reinforcement. These bars are employed widely in modern-day construction work, emphasising quality, safety, and longevity. 

Before TMT Bars

Before TMT bars came into the industry, Cold Twisted Deformed Bars, also known as CTD bars and M.S or Mild Steel Bars, were used for Reinforced Cement Concrete work. These bars failed to deliver on ductility and corrosion resistance compromising structural integrity in the long run. Hence, TMT bars came into existence to combat the downsides of previous construction materials and have now evolved into the most commonly used material for long-lasting structure construction. 

Why is TMT Bar The Future of the Industry?

When we observe the construction industry’s economy, we can witness the advent of the TMT (Thermo mechanically treated) steel bars. These bars are paving a new epoch of advanced growth and demand graph in the steel market.

Here is the reason why we are seeing such growth: 

1. Recyclability and Waste Management

The steel industry is circular, meaning that the generated waste can be used as an input in further production without losing its core properties. Therefore a waste generated can easily be melted and reconstructed, raising the rates of recovery in comparison to other products. It is also relatively easy to recover steel from other waste materials. At present, recycled steel represents as much as thirty percent of the whole new production process of steel making.

2. Longevity 

A key reason why TMT bars are becoming the face of the future of construction is their longevity. TMT bars production takes place, keeping in mind durability. Before TMT bars, iron rods were used in construction, making them prone to corrosion. For example, during the CTD bar manufacturing process, the method of twisting the rods negatively affects the ductility of the bar. It also breaks the protective blue oxide, making the CTD bars susceptible to corrosion.

On the other hand, TMT bars obtain anti-rust properties during the manufacturing process. Due to the intense cooling, coarse carbide, which is the foremost cause of the corrosion, does not get a chance to build up, creating the most durable bars. 

3. Strength 

Compared to ordinary reinforcement bars, the strength of TMT bars sets them apart and makes them the most suitable choice for any construction. The reason behind their strength and ductility is the extreme cooling it receives. The manufacturing process passes through a water cooling system which causes the outer surface to toughen. The ribbed texture of the TMT bar also allows better adhesion with the concrete, offering it more strength, while the flexibility makes it easier to work with. 

4. Disaster Resistant 

All scenarios are considered during construction, even the possibility of man-made or natural disasters. TMT bars are known to be earthquake and fire-resistant, making them a safer choice than other bars. 

The advantage of using TMT bars is their high thermal stability. Because of this property, they can tolerate severe temperatures varying from 400 to 600 degrees Celsius and maintain more than 80% of their ambient temperature yield strength at 300°.

TMT bars are a staple in earthquake-prone zones due to their ability to withstand high levels of stress and pressure because of their fatigue-resistant properties. The soft inner core and the rigid exterior make the bars very ductile, which permits them to absorb shock causing minimal damage to the structure.

5. Weldability 

Architects and engineers are looking to create more unorthodox and unique designs in this modern era without compromising basic structural integrity. TMT bars have high weldability because of the low carbon content. Also, since there is no pre or post-welding treatment, the process is more efficient for the workers.

The Future of TMT Bars

The growth potential of TMT bars is very promising, mainly because of the speed and scale of the infrastructure and the construction activities. Since India is still a budding market, construction-related works have a tremendous scope, which can pump the demand potential in the steel and TMT industry markets. 

Reach out for High-Quality and High-Performance Products

The Steefo Group has been the most trusted name in precision designing, manufacturing, and providing top-notch products and solutions in the field of steel rolling for four decades. They are also pioneers in providing consultancy and manufacturing of rolling mill plants. 

For queries related to TMT bar rolling mills, you can reach out to us by calling us at +919824076873 or write to us at marketing@thesteefogroup.com. You can also check with our consultants to understand TMT rolling mill project costs! We would be happy to help!

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Energy Saving Technology of Rolling Mill System

The steel industry often earns itself a reputation for being energy-intensive. But with recent developments, there has been an opportunity to transform and walk toward the path of energy efficiency. 

In rolling mills, during the production process, intermediate steel products obtain their shape and dimension because of an array of shaping and finishing techniques. To get their shape, slabs are heated to an extreme temperature in the reheating furnace and are then rolled into shape with hot or cold rolling or in finishing mills. Some products specifically require hot rolling, such as reinforcement bars, steel plates, etc. Some products like steel for cars and white goods require both hot and cold rolling. 

But the energy needs and costs for both hot and cold rolling can be significantly high. Due to the cold rolling process, the mechanical forces create much more force and increase the energy needed. In the hot rolling process, the execution is faster as it consumes less force, but substantial energy costs are incurred to heat the metal to near eutectic temperatures. Data accumulated from large integrated plants show that the hot strip rolling process is the third-largest energy user apart from iron and steel making. 

Reheating Furnaces

Reheating furnaces is critical in determining end-product cost and quality in any hot rolling operation. The energy use in a reheating furnace is determined by several production factors such as stock, steel type, etc., and operational factors such as scheduling and design features. 

Globally, the total primary energy requirement for hot rolling was reported at 2 – 2.4 GJ/t, and global average energy needs in cold rolling are between 1 – 1.4 GJ/t. (IEA 2007). The way to harvest energy savings could be via upgrading existing furnaces.

Rolling Mills Technology And Measures To Be Energy Efficient  

1. Process Control in Hot Strip Mill

To improve indirect energy savings through reduced oxygen rejects, we require improved hot strip mill process control. The main objective is to control and monitor oxygen levels to optimise the combustion rate in the furnace. It also enhances productivity and reduces downtime. We can see results from a system installed at a mill in Belgium, which reduced rejects from 1.5% to 0.2%and decreased downtime from more than 50% of the time to 6%. It also leads to a reduction in CO2 emissions by 15.1kg of CO2/t-rolled steel.

2. Oxygen Level Control and VSDs on Combustion Fans

To optimise combustion in the furnace, controlling oxygen levels and using Variable Speed Drives (VSDs) on combustion air fans on the reheating furnace helps significantly. There is a substantial drop in combustion efficiency with excessive air as it leads to unnecessary waste gases. The fuel to air ratio, therefore, should be monitored regularly. The usage of VSDs on combustion air fans also helps keep the oxygen levels on the reheating furnace under check. 

This process has the potential to reduce emissions by 16.6kg CO2/t-rolled steel. It also calculates energy savings to be around 10% or 0.33 GJ/t-rolled steel by a conservative estimate.

3. Pressure Control for Furnace

There are multiple apertures that heating furnaces have, such as extraction ports, raw material charging ports, cracks in the furnace ceiling, and sidewalls. There can be unnecessary heat losses if the pressure in the furnace is too high, causing the heat to be forced out of the furnace.

Due to this, if the internal pressure drops, cold air will be sucked into the furnace, spiking up the fuel consumption. The furnace pressure control technology’s objective is to maintain a constant optimum pressure level to minimise energy consumption.  It is primarily applicable in cases of industrial furnaces, including rolling mill reheating furnaces. 

4. Regenerative Burners for Reheating Furnace

A regenerative burner is a heat recovery system that recovers the furnace exhaust gas’s waste heat to heat the furnace’s combustion air. Heat reservoirs and dual heat-recovering generators of the regenerative burner are utilised. One side of a burner combusts fuel during combustion while the other accumulates the exhaust heat into the heat-recovering generator. 

The burners then switch so that the one collecting the heat combusts the fuel while the other gathers exhaust heat. The usage of regenerative burners for reheating furnaces can deliver significant energy savings. According to NEDO, using regenerative burners on a 110 t/h capacity billet reheating furnace (operating at 1050 oC) can reduce the energy consumption by 0.18 to 0.21 GJ/t-steel in comparison to a conventional furnace.  Annual energy savings are reported to be 9.3 to 11.6 GWh. There is a scope of up to 50% NOx reduction in high-temperature combustion.  CO2 emissions will also be reduced according to the reduced fuel consumption. 

5. Walking Beam Furnace

If you are looking for state-of-the-art efficient reheating furnaces, you will have to look towards a walking beam furnace. In a walking beam furnace, the stock is located on the stationary ridges. The revolving beams walk the product through the furnace till it reaches the exit, where the beam returns to the entrance.

Compared to the three-pusher-styled furnace, installing a walking beam furnace and an efficient control system reduced energy and fuel consumption by 25% and 37.5%. It also provides lower operational costs compared to alternative transmission systems.

Bottom Line

Energy efficiency is a goal that many industries, including the steel industry. Investing into methods reduces exorbitant energy consumption and saves you from facing cost overruns due to lack of optimization. This step toward energy efficiency is also a step toward a better and greener future as many methods cut down on CO2 emissions and improve productivity.

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How Quality TMT Bar Adds Strength & Longevity to Construction

No matter how much you paint the walls or furnish the interiors, a weak structural foundation of any building can be detrimental to its strength and longevity. The only thing that guarantees your construction will survive the test of time is using good quality materials that make your base strong such as TMT bars.

What is a TMT Bar?

Before we delve into why and how quality TMT bars are crucial for your construction project, we need to learn all about TMT bars. 

TMT bars, also known as ‘Thermo Mechanical Treatment’ bars, is one of the most indispensable construction material worldwide. They are high-strength reinforcement bars manufactured using a unique technique that leaves them with a rigid outer surface and a soft inner core, making them strong yet flexible.

6 Advantages of Using Quality TMT Bars 

TMT bars are called the backbone of every RCC (Reinforced Cement Concrete) structure, but why? Let’s find out how these bars enhance a building’s longevity and strength.

1. Ductility and Strength 

Compared to regular reinforcement bars, the strength of TMT bars is what sets them apart and makes them the best choice for any structure. The reason for their strength and ductility is the intense cooling it receives. During the manufacturing process passes through a water cooling system which causes the outer surface to harden. The ribbed texture of the TMT bar also allows better bonding with the concrete giving it more strength, while the flexibility makes the bars easier to work with.

2. Corrosion Resistance

Based on the manufacturing process, the TMT bars anti-rust properties. Due to the intense colling, coarse carbide, which is the leading cause of the corrosion, does not get an opportunity to build up, making the bars more durable.

3. Fire Resistance

For a structure to have longevity, fire safety is a necessity. The perk of using TMT bars is their high thermal stability. Due to this, they can tolerate extreme temperatures ranging from 400 to 600 degrees Celsius and can retain more than 80% of their ambient temperature yield strength at 300°.

4. Weldability

TMT bars have high weldability; because of this quality, TMT is an exceptional choice for architects who intend to innovate and create unorthodox designs without compromising on the structural integrity of the building. The low carbon content not only makes weldability easier, but since there is no pre or post-welding treatment, it makes the process easier for the workers.

5. Earthquake Proof

TMT bars are favourite during construction projects is due to their ability to withstand high levels of stress and pressure because of their fatigue-resistant properties. One natural calamity that causes the most property damage is an earthquake. The soft inner core and the hard exterior make the bars very ductile, which allows them to absorb shock causing minimal damage to the property.

6. Cost-Effective

Because of its tensile strength, high elongation value, and uniform sectional weight per unit, using TMT bars in your construction project saves up to 20% steel, in turn saving money. Its high structural strength also reduces the cost of production. On top of that, these bars are easier to manage on-site, reducing the construction and fabrication costs.

The search for a quality TMT bar starts from its very inception. Known for its soft inner core and hard exterior, it will have no value if it is not manufactured correctly. TMT bars have an advanced manufacturing technique that includes three essential components: Quenching, Self-tempering, and Atmospheric cooling.

Why Choose The Steefo Group for TMT Bar Rolling Mills

The Steefo Group strives to be your reliable partner for all your steel forming needs, from turnkey solutions to best-in-class products. To manufacture superior quality TMT bars, you will need machinery that will aid you in attaining that goal. Look no further than our TMT bar rolling mills which are a part of our DNA. Whether you require a production capacity of 10 TPH TO 100 TPH, we can help you. With our design expertise and experience in producing turnkey projects, you will not have to worry about anything, from conception to commission.

Our ultimate goal is to be a creator and provider of innovative, integrated automation solutions that boost productivity, reduce workforce needs, and ensure faster returns on your investment. Our TMT bar rolling mill will enhance your production and help you stand apart from the rest.

To learn more, contact us at marketing@thesteefogroup.com or call us at +919824076873.

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Hot Rolling vs Cold Rolling

 

In the metalworking industry, rolling is a crucial process. The metal stock passes through a pair of heavy rolls in this process. This gives it the desired shape and thickness and imparts desired geometrical dimensions and mechanical properties. The idea is similar to rolling dough with a rolling pin. 

What is Hot Rolling?

Hot Rolling is a process in metalworking during which the metal is rolled above the recrystallisation temperature. The minimum temperature at which metal is recrystallised is 1700 degrees Fahrenheit. The hot rolling process makes the metal more malleable and easier to shape into desired geometrical dimensions and material properties while maintaining the same volume. 

During this process, as the name suggests, a billet of metal is heated and passed between two rolls to flatten and lengthen it. This process helps the metal obtain uniform thickness and reduces the cross-sectional area.  

What are the Advantages of Hot Rolling? 

1. Improvement in Mechanical Properties

When metal is heated and rolled above the high temperature of 1700 degrees Fahrenheit, the metal gains a lot of new properties due to the hot rolling process. Some of the changes include toughness, resistance to shock, ductility, elongation percentage, and more. 

2. Elimination of Porosity and Refined Grain Structure

A significant advantage of the hot rolling process is the removal of defects which include welding pores, coarse grains, and more. During the recrystallisation process, the coarse grain converts into refined grains, causing changes in the properties of the metal. 

The pores are also removed during this time, causing a strong and uniform structure.

3. Uniform Distribution of Impurities  

During the hot rolling process, any impurities that might be present gets removed from the metal, such as slag and others. The removal of such impurities makes the metal more durable. Had there been impurities, it would have made certain sections weaker. 

4. High Production Rate 

When the metal is heated at a high temperature, the raw material’s deformation resistance is lowered, and thermoplasticity increases. This process increases the production rate as the machinery and motor get less worn out due to the malleability of the metal at that given point. 

What are the Disadvantages of Hot Rolling?

1. High Cost of Equipment

The process of hot rolling might increase the production rate but does raise the cost of production, from expensive tools to trained professionals who need years of experience to operate the machinery properly. 

2. Maintaining Accurate Temperature

The majority of the hot rolling process depends on the correct temperature. Maintaining 1,700 Fahrenheit can be a challenging task. If the right temperature is not maintained, it might cause damage to the metal being produced. 

3. Surface Finish And Texture 

The high temperature causes the surface to have a poor finish as the high temperature increases the oxidation and scaling process. 

What is Cold Rolling?

The alternative to hot rolling is known as the process of cold rolling. Metal passes through the roller below the recrystallisation temperature in the cold rolling process. This process increases the strength and durability of the metal. The metal is less malleable because it remains at room temperature than the recrystallisation temperature, but this labour-intensive process reduces the grain size of the metal. 

What are the Advantages of Cold Rolling?

1. Surface Finish 

Due to the absence of high temperatures, the metal coating of the metal is not damaged. It also has a flat and smooth surface with fewer deformations. 

2. Lower Cost 

For cold rolling, there is no requirement for expensive tools and machinery. Since the cold rolling process doesn’t need to maintain a specific temperature, the expertise required is also significantly reduced. 

3. High Yield Point 

Due to the cold rolling process, metal can produce large plastic deformation, which increases the yield of the metal.

4. Close Tolerance Point 

With the cold rolling process, the tolerance point of the metal can go as close as  0.025 mm.

5. Strength 

Since the cold rolling process does not require high temperatures, the metal maintains its structural integrity and doesn’t turn weak. 

What are the Disadvantages of Cold Rolling?

1. High Cost 

The cold rolling process takes longer to produce than the hot-rolling process. The metal is more difficult to manipulate and takes longer to process. That is why the price increases. 

2. No Distribution of Impurities 

When the metal is heated for the hot rolling process, impurities get the chance to distribute evenly. In the cold rolling process, impurities don’t get the opportunity to redistribute. 

3. Grain Size

The reduction size of the grain is necessary to obtain strength and durability. During the hot rolling process, metal receives a refined grain structure, but in the cold rolling process, there is no significant reduction in the size of grain due to the lack of high temperature. 

4. Width 

The cold rolling process provides minimal leeway to correct things post-production. Width is one of the primary examples of it. In the case of rolled metal, you can shave down unnecessary portions easily. You need to begin with the correct measurement for cold-rolled metal, as customising it might be problematic later. 

Which One is Better: Hot Rolling or Cold Rolling?

The question of which process is better is a question that does not have a definite answer. As we discussed, the hot rolling and the cold rolling process both have their advantages and disadvantages. To obtain the answer of which process is better, you need to know what you intend to manufacture in the first place. 

The metal we get during the hot rolling process is necessary for railroads, construction steel bars, beams, and more. Due to its appearance, the hot-rolled metal is used more for structural works. 

On the other hand, cold-rolled metal would be too brittle for railroads. Instead, due to the close tolerance point, the sheets are thinner. This process creates metal sheets appropriate for furniture, household appliances, cabinets, beverage cans and more. 

Why Choose The Steefo Group?

The name of The Steefo Group has become synonymous with premium quality in rolling mill services. With its foundation going back around four decades, we have built our reputation based on our quality. Recognized by the Government of India as the Star Export House and international clientele, we intend to be your reliable partner for all your steel-forming needs. To enquire more about our products and services, contact marketing@thesteefogroup.com or give us a call at +919824076873. 

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Blogs
5 Benefits of Rolling Mills for Small Manufacturers

 

Rolling mills come with various constructions and are an integral part of any small industry in India. No matter the size of the rolling mill machinery, their performance remains the same in handling heavy metals. You might wonder what a rolling mill is and how it is profitable for small manufacturers? Read on to learn more so that you can make an informed decision.

What Are Rolling Mills?

Rolling mills are a type of metal forming machinery. They help process various metals through one or more rolls to reduce or create uniform thickness or imprint a design.

All rolling mills have at least one pair of heavy rollers. Depending upon your use and requirement, you can opt for mills with more than one pair of rollers that are also heavier to mould high-density metals. The range of sizes the rolling mills offer makes them profitable for small manufacturers.

How Does a Rolling Mill Work for Manufacturing Units?

Rolling mills can help alter the physical properties of a metal sheet. The purpose of a rolling mill is to provide a uniform thickness and consistency. These rollers are constructed with a strength that can easily squeeze and compress hardened pieces of metal as they are passed through a pair of adjoining rollers. 

No matter the initial shape of the metal, once they are squeezed out of the rollers, they acquire a uniform flattened shape ready to be used in various spheres of small-scale and large-scale manufacturing facilities.

Advantages of Installing Rolling Mill Machinery 

Rolling mills come with many advantages for both large-scale and small-scale manufacturers, catering separately to varied needs.

1. Ideal for Processing Metal

For ages, rolling mills have served as the perfect machinery for processing metals of varying densities. Not only do they save time in beating and flattening the metals into sheets, but they are convenient to small-scale manufacturers who place the utmost importance on efficiency and perfection in their work.

2. Good Consistency

Small manufacturers need the highest accuracy in their products because they produce metal sheets of comparatively smaller sizes and less in numbers than large-scale manufacturers. It is only through rolling mills that such constant uniformity is maintained throughout the long material length.

3. Easy to Use

Being able to use good quality rolling mills is no rocket science if you learn the basics of the machine. You can also get a test run to learn how to operate the mills efficiently.

4. High Productivity Rate 

For a manufacturing unit, large-scale or smaller production facility, a high productivity rate in minimal time is the goal of all. With a one-time investment in rolling mills, you can boost the production rate. These machines can help you save time, ensure accuracy and time efficiency, and are a wise investment overall.

5. Lower Operating Cost

Rolling Mills primarily come in two categories: Hand-powered and Electric rolling mills. Hand-powered rolling mills are cost-effective for a firm and preferable for small-scale manufacturers. Electric rolling mills are known to save power, ultimately reducing costs in the long run.

Choose Us for Reliable Rolling Mills for Your Needs 

Reliable rolling mill plants hire well-trained engineers who cater to all the requirements of a high-functioning rolling mill mentioned above. The various parts of a rolling mill are put through a series of tests by professionals before they are assembled and sent to factories.

Steefo Industries is now a part of the Steefo Group. We only sell tried and tested products to ensure a promising result to our buyers. As a leader in the rolling mill industry, we believe in providing the highest quality and manufacturing standards while verily complying with ISO 9001:2015 certification. We have strived hard to create a name in the industry as the leading and most preferred Rolling Mill Manufacturers since 1976.

Our services include project design and engineering, spares and consumables, technical support and repairs, service agreement program, and revamping & productivity enhancement.

You can reach out to us at marketing@thesteefogroup.com or call and schedule an appointment at +919824076873. It would be our pleasure to be of service to you!

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Blogs Rolling Mill
TMT Bars Rolling Mills Reduce Manufacturing Costs

Rolling mills are critical products for the manufacturing industry. So if you have been searching the web to find all you can about TMT bar rolling mills, their applications in the manufacturing industry and the benefits they offer, read on. Here we bring to you everything you should know about TMT rolling mills – particularly about how they can help you reduce manufacturing costs.

What is a Rolling Mill and What is it used for?

In simple words, TMT rolling bars are used in the metal forming process. They are primarily responsible for reducing the thickness of metal and making it uniform across the length and breadth of metal, using a process called rolling. The rolling process also adds strength and durability to the steel. TMT bars that you see around you at construction sites are a product of this rolling process.

Rolling is of two types – Hot Rolling Process and Cold Rolling Process. Both processes are equally rewarding, and they, in their capacities, process more tonnage than any other manufacturing process.

However, there are distinct differences in metals that have been hot rolled or cold rolled. The hot rolling process makes the product more pliable and the surface of the metal, post-treatment, is not shiny. On the other hand, cold rolling yields a harder finished product with a distinct shine on the surface.

What are the Benefits of Rolling Mills?

The rolling aspect in the TMT manufacturing process offers several benefits – the most critical of them being the reduction in material wastage. Here is a glance at the general benefits of rolling:

  1. Rolling ensures that the metal has uniform thickness across its length and breadth
  2. A rolling mill saves you the cost of purchasing different and separate equipment. The same rollers can be used for the production of a wide range of components
  3. Close tolerance is possible for components in the rolling
  4. Saves time as high-speed production takes place in the rolling

How Can Rolling Reduce Costs?

Now that you have understood the generic benefits of using TMT rolling mills and the rolling process, here is the information you have been looking for all this while. Can rolling reduce costs? How?

Yes, rolling can save you a lot of money and here is how:

One of the most important products that come out of the rolling process is TMT Bars. These TMT bars are a preferred choice for most builders because of the strength, flexibility and durability it offers. So in a way, rolling mills can serve you a great deal by saving loads of money. Here is how:

1. Lesser quantity: 

TMT bar manufacturing machines lend TMT bars high tensile strength, which means they are stronger than any other ordinary steel. So TMT rolling mills help you by causing a tremendous drop in the amount of steel required for production.

2. Reduced Labour: 

Through the rolling process, high-performance TMT bars are made. These bars are extremely malleable, which means that they are easier in terms of handling by construction labour and easily transportable. This, significantly, reduces labour and construction costs.

3. Maintenance Savings: 

TMT Bars made in TMT rolling mills are corrosion-resistant. As a result, they stay robust longer even in the face of seasonal wear and tear. Hence, they offer greater RoI and require less maintenance and repair.

4. Protection During Earthquakes

One of the major concerns that manufacturers have to address during the production of construction materials is to ensure that they are earthquake resistant. The TMT manufacturing process strengthens TMT bars to ensure that they can withstand earthquakes efficiently.

5. Flexibility/Usage Benefits

TMT bars are extremely strong, offer flexibility and weldability without compromising on the core strength. This allows builders to not only build stronger structures but also experiment with various designs.

6. Transportation Savings

TMT bars are extremely lightweight and flexible, hence their transportation is easy. As a result, there are lesser labour and transportation costs.

If you are looking for the top TMT manufacturers in India to explore products, you can check out the products by the Steefo Group – one of the top 10 TMT steel companies in India.

Reach out for High-Quality and High-Performance Products

The Steefo Group has been the most trusted name in precision designing, manufacturing and providing top-notch products and solutions in the field of steel rolling for four decades. They are also pioneers in providing consultancy and manufacturing of rolling mill plants. 

For queries related to TMT bar rolling bars, you can reach out to us by calling us at +919824076873 or write to us at marketing@thesteefogroup.com. You can also check with our consultants to understand TMT rolling mill project costs! We would be happy to help!