Iron and Steel Making Machines

Product Details:

Backed by the skilled team of professionals, we are engaged in offering of supreme quality Modular Billet Caster. This caster is suitable for existing ingot making plants. Owing to its unique features like substantial saving due to reduced scale generation, Flexibility of operating each strand independently, the provided caster is highly admired by our clients in the market. The provided caster is precisely manufactured making use of high-grade components and cutting-edge techniques. Our clients can avail this caster at a reasonable price.

Features:

• High operational fluency
• Complete support for direct rolling
• Easy to operate

Product Details:

We are the leading manufacturers and suppliers of the Induction Melting Furnace.

Product Details:

We offer the Air Pollution Control System. Air pollution is defined as the addition of various hazardous chemicals, particulate matter, toxic substances and biological organisms into the earth’s atmosphere. In view of the several factors that attribute to air pollution, what comes from industries and factories is often considered the prime contributor to air pollution. According to a study conducted by the Environmental Protection Agency (a.k.a. EPA), it has been found that industrial pollution accounts for approximately 50 to 70 percent of the pollution. There are several serious ecological implications and health risks associated with industrial air pollution. Electrotherm clean air solutions offers pollution control systems for Induction furnace, AOD & LRF.

Government Norms & Regulations:

• Pollution Norms are becoming more and more stringent for steel plants/ Foundries.
• Installation of Air pollution control system will become mandatory.
• Presently in Goa, Chhattisgarh & west Bengal the norms is < 50mg/Nm³ and in other states it is less then < 100mg/Nm³. But it is expected that all will go to < 50mg/Nm³.
• Benefits to Customer & Operating Staff:
• Accident cases may reduce. The cost of the system will be very less in comparison to savings in the operating expenses of bigger range furnaces. Workers working efficiency will improve.

Fume Gas Systems:

• Fume Capturing Hood – Catch it before it runs out!
• Electrotherm’s specially designed fume capture hood capture the fume gas before it expands into the atmosphere.

Unique Features:

• This is the type of fume capturing hood which will capture at least 85% of the fumes, where conventional feeding methods and Hanuman is used Common hood for two crucibles
• Double Action Fume Hood

Product Details:

Keeping the track of latest happening of this domain, we present clients with the premium quality of Electric Arc Furnace. The special coil insulation of electric arc furnace prevents inter turn sparking. Furthermore, the insulated furnace lid presents heat loss through radiation. For the purpose of capturing smoke and fumes, the electric arc furnace is provided with fume extraction ring.

Features:

• Fume extraction hood provided to capture smoke and fumes
• The higher coil efficiency ensures energy savings and higher productivity
• To reduce heat loss through radiation, Insulated furnace lid is provided

Other Details:

• Electrotherm offers a complete range of melting units -high-impedance EAFs with the capacity for producing heat sizes from 3 Ton to 200 t in technical collaboration with Vitkovice Heavy Machinery, Czech Republic. Raw material may be up to 100% scrap or various mixes of hot metal, pig iron, DRI (hot and/or cold) and HBI, utilizing electrical and chemical energy, according to unit costs and power grid characteristics.
• The EAF operation can be made fully automatic by applying a series of technological packages to optimize the process, to be selected on a case-by-case basis depending on the performance figures to be achieved.

Product Details:

Understanding the demands of customers as a reliable organization, we are engaged in offering Vibro Feeder. This feeder moves on rails to feed the furnace and is kept on a trolley. The offered feeder has strong built hopper that receives and stores the charge material to be fed in the furnace. In order to ensure the feeder vibration ensures well spread charge in the feeder and uniform movement into the furnace.

Features:

• Feeder vibration at a suitable frequency is achieved by unbalanced motors
• The design ensures minimal noise level during the charging process
• The feeder movement from charge loading point to melt furnace is smooth
• Power cable drag is strong and well designed to achieve longer life

Other Details:

• A vibratory feeder is mounted on a trolley which moves on rails to feed the furnace.
• A sturdily built hopper receives and stores the charge material to be fed to furnace
• The feeder vibration ensures that the charge is well spread in the feeder and moves uniformly and smoothly into the furnace
• Feeder vibration at a suitable frequency is achieved by unbalanced motors.
• The design ensures minimal noise level during the charging process.
• The feeder movement from charge loading point to melt furnace is smooth.
• Power cable drag is strong and well designed to achieve longer life.

Product Details:

Owing to our vast industry experience and expertise, we have been able to offer Ladle Refining Furnaces. This system is specially designed to remove slag with phosphorus to make the steel clean. To control electrode consumption as low as 0.3 -0.4 kg/ ton, servo valves and hydraulic cylinders are used for electrode regulation.

Features:

• Removal of metallic inclusions to make clean steel
• Reduction of gas content by feeding Aluminium / CaSi wire to produce “killed” steel. Oxygen level of 30 ppm can be obtained
• Homogenization of temperature and composition of molten steel by gentle stirring
• Degassing treatment of steel to achieve low gas content (oxygen, nitrogen and hydrogen)
• Holding of molten steel while sustaining temperature/superheating for sequencing on the CCM

Refining Steel:

• Traditional Ladle Refining Furnace (LRF) is used to de-sulphurize steel, adjust its chemical composition and raise the temperature of molten metal besides as a buffer between the melting and casting equipment. Electrotherm Refining Furnace (ERF™) is specially designed metallurgical equipment to de-phosphorize steel besides preforming other processes as done by LRF.
• It facilitates tapping at lower temperature, which in turn increases production and refractory life of melting equipment and reduces power consumption, thereby reducing the cost of steel making. ERF provides greater flexibility to steel maker in overall plant operation. The concept is user-friendly and can produce high-quality structural steel, low alloy steel and other value added steels through Induction Furnace – ERF route using an even very high percentage of sponge Iron / DRI as raw material.

Product Details:

We are instrumental in providing our clients a comprehensive range of Rotary Kiln Coal Based DRI Plant. This kiln is used to raise materials to a high temperature (calcination) in a continuous process. The offered kiln is manufactured using quality tested components and advanced technology according to set industry standards and norms by our diligent professionals. Also, before delivering at clients'' end, our experts examine this kiln on predefined quality parameters to ensure its flawless nature.

Solid state reduction of Iron Ore using either coal/gas as a medium of reduction to produce a substitute raw material for steel making is termed as Direct Reduced Iron (DRI). Since DRI is produced by removing oxygen from iron ore, its structure is just like sponge with a network of connecting pores. These pores results in a large internal surface area which is about 10,000 times greater than the internal surface area of solid iron. Due to this, DRI is also known as Sponge Iron.

Sponge Iron is gaining more popularity because of the following reasons:

• Scrap is getting scarcer by the day
• Quality and composition variations are compelling
• Tramp elements coupled with Sulphur and Phosphorus hamper the end product quality of sale-able steel
• Uniform known composition, size and high bulk density compared to scrap
• Low Capex and gestation period compared to Gas based DRI plant
• It can be produced with non-coking coal and poor quality of coal that is available in abundance
• Capability of forming protective layer of foamy slag in the bath
• Potential of sensible heat recovery from waste gases
• Maintenance of Sulphur level in steel by its removal during Sponge iron production**
• Lower refining requirements of steel produced
• It allows steelmaking to dilute metallic residuals in scrap

Product Details:

Aiming to attain maximum client satisfaction in this cutting-edge competition as a reliable firm, we are engaged in offering Metal Refining Converters. These machines are used in decarburization, which is used to make stainless Steel grades and alloy steel. This process is done by using high carbon alloy and mild steel scrap/sponge iron. More to this, in this machine boiler quality MS plates are used that are demanded in the manufacturing process of MRK vessel.

Features:

• Decarburization
• To make Stainless Steel grades, Alloy Steel Economically by using High Carbon Fe Alloy and Mild Steel Scrap/Sponge Iron.
• This process is Air – Oxygen – Inert gas Decarburization (AOD) process, for Stainless Steel out of mild steel, Mild Steel out of high Cast Iron Melt, and alloy steel economically
• PLC based Gas Mixing Station of MRK gives flow measurements compensated for pressure and temperature variation. This avoids, “over oxidation” of liquid metal
• Imported Transducer used for accurate flow and pressure measurement in Gas Mixing Station of MRK enables high turn down ratio which results in low process gas and refractory consumption and high recovery of alloying elements
• Use of dry air (-80 degree C dew point) as process gas reducing the cost of production.

Product Details:

We are counted amongst the foremost suppliers of a broad range of Tunnel Kiln Coal Based DRI plant. The offered kiln is engineered under the guidance of our adroit professionals with utmost precision using optimum class components in tune with the set industry standards. Additionally, this kiln is rigorously inspected on numerous parameters to ensure its functioning as both Hematite & Magnetite can be converted to sponge iron using Tunnel Kilns. This kiln is offered in different technical specifications to the clients at an affordable price.

Features:

• Extremely low on environmental pollution
• Comfortable with coal fines and mill scale
• Negligible maintenance

Some of the key attributes of the Tunnel Kiln are:

• Tunnel Kilns can use soft ore
• Tunnel Kilns can comfortably work with Iron Ore fines (
• Both Haematite & Magnetite can be converted to sponge iron using Tunnel Kilns
• Tunnel Kilns are comfortable with coal fines and mill scale
• Uniform product quality
• Production cost from Tunnel Kilns is lower than that from rotary kilns
• Extremely low on environmental pollution

Other Details:

• The Research & Development team of Electrotherm has extensively worked upon this process of Sponge Iron making and we have successfully produced sponge iron from our 25TPD Tunnel Kiln at our steel making complex at Samakhyali, Kutch. A sample of the product from our Tunnel Kiln is shown here
• We had successfully experimented with a variety of raw materials like iron ore fines from Bellary and Barbil (in India), iron ore pellets from Bahrain, domestic and imported varieties of coal, self-developed and imported varieties of saggers etc. and our R&;D team has developed a software whereby we can support any combination of raw materials to produce quality sponge iron from a supposedly waste material.
• Quality of sponge iron made by the Tunnel Kiln technology is superior as compared to that made from the rotary kilns because, while the input raw material gets just about 24hours for the reaction, the figures almost reverse in case of the Tunnel Kiln. Reaction time of 42 hours in the Tunnel Kiln provides ample opportunity for the raw material to completely react and this results into superior Fe metallic from the end product
• Flow chart of the Tunnel Kiln process is as under
• Tunnel Kiln history dates back to 1807 when Hoganas first used this process to produce iron powder of 99.9% purity.
• When iron ore is mined or processed (in a crusher), lots of fines are generated. Quantity of fines generation is a function of the quality of ore i.e. whether it is hard or soft. Iron ore fines are usually subject to beneficiation and/or pelletisation thereby converting them back into hard rock-like shapes (pellets) with a proper tumbler index
• These pellets are then used for making sponge iron. Rotary kilns have a drawback upon the size and quality of iron ore that can be used. Initially, when the process was first introduced, the ore with an iron content >/= 65% was preferred and the preferred size of ore was 5-18mm. And coal of minimum “B” grade was required to be used for the solid state reduction or DRI making process
• With the passage in time, quality of both iron ore and coal declined and still DRI was being produced. However, the only solution for iron ore fines was beneficiation, if required, and pelletization
• And coal fines virtually lost their commercial value
• While both of the key materials are available in abundance, one of the best means of utilising them is the Tunnel Kiln.
  
  

Product Details:

Backed by a team of dedicated professionals, we have been able to offer Lining Vibrator. Pollution-free lining and smooth operation are some of the features of these vibrators. Ensures compactness of lining, the offered vibrator has high strength of lining throughout the furnace.

Product Details:

With the firm commitment towards quality, we are engrossed in offering Programmable Dynamic Load Manager. These machines are widely demanded to maintain the constant actual power demand of plant and to maximize sanctioned KVA, which optimizes the overall load factor. With optimum use of available power, we ensure that the overall productivity of plant is increased.

Features:

• PDLM is used to maintain the constant actual power demand of plant from supply line. If actual KVA tends to exceed the sanctioned KVA, the PDLM reduces the power of induction furnace. By using PDLM, maximum sanctioned KVA can be utilized, which optimizes the overall load factor of the plant.
• When more than one furnace is in operation on a single grid, PDLM can work still more effectively by sharing the total available power.
• Power to the furnace can be shared through priority selection switches wherein one furnace can be provided full power while other runs at reduced power.
• Overall productivity of plant will increase because of optimum use of available power. No human intervention is required for monitoring and controlling furnace load.
• CT & PT failure protection is provided in the system which reduces power to a minimum with an alarm indication.

Product Details:

Moving ahead in this cutting-edge competition as a reliable organization, we are providing Hydraulic Grab. Provided with simple electrical RDOL starter circuit, our offered machine reduces operations of EOT cranes and has no risk of insulation failure. In addition to this, these machines ensure no electricity failure, owing to which demanded in various industries.