Skip to main content

Process

From Raw to Refined Steel

Smelting

In the upper furnace zone the particulates are present as “loose charge” and product gas from the lower furnace consisting of principally CO and CO2 passes through this packed bed. Reactions between the gases and the solid ores result in the partial reduction of the ores and the formation of iron and alloy, and in some cases metal carbides resulting Decomposition of limestone fluxes e.g. CaCO3, and other minerals, Gasification of carbon; reaction with air and CO2, Gaseous reduction of ores and partial metallization of iron and oxides.

In the lower furnace zones, a series of reaction steps take place involving the slag phase; Dissolution of ores spinel in slag, Reduction of the slag phase to form alloy, Alloy/slag separation.

Although the overall reaction is described by the removal of oxygen by solid carbon, this reaction can take place through a number of pathways involving; carbon monoxide formation from solid carbon or carbon dissolved in alloy; reaction of CO gas with slag; metal on diffusion in the slag phase.

Each of these mechanisms contributes to the overall recovery of desired alloy. Optimization of the process to enhance the rates and extent to which these reactions proceed, and to maximize recovery. Production rate and energy efficiency is assisted by improved understanding of the various reactions and reaction mechanisms operative in the process, and by taking action through feed selection and preparation, and adjustment of process conditions.

Mughal Iron and Steel Industries Limited (MISIL) utilizes the renowned MCC-SERIES (one of the largest equipment manufacturers in China) for smelting process. Chorme One, Manganese One and Silica Manganese are used as raw materials to produce Ferro Chrome, Ferro Manganese, Ferro Silicomanganese and Ferro Silicon at Mughal Steel.

Melting

The principle of induction melting is that a high voltage electrical source from a primary coil induces a low voltage, high current in the metal or secondary coil. Induction heating is simply a method of transferring heat energy.

Induction furnaces are ideal for melting and alloying a wide variety of metals with minimum melt losses, however, little refining of the metal is possible until sequenced with “ladle refining furnace”. The advantage of the induction furnace is a clean, energy-efficient and well-controllable melting process compared to most other means of metal melting.

There are fewer chemical reactions to manage in induction furnaces, making it easier to achieve melt composition. However, its sensitivity to quality of charge materials when compared to other melting processes restricts the types of scrap that can be melted. The inherent induction stirring provides excellent metal homogeneity.

Mughal Iron and Steel Industries Limited (MISIL) imports high quality scrap, Direct-Reduced Iron [DRI], Shredded and HMS low-carbon scrap in accordance with ISRI standards, which in turn is sorted and separated. Electric Induction Furnaces (EIFs), ideal for melting and alloying a wide variety of metals from world’s most known manufacturers Electrother, Megatherm, are used to produce molten metal at 1600 -1700 °C. This infrastructure has optimized the production capacity of MISIL for making steel, around 200,000 tons of Mild Steel and Carbon Steel Billets annually.

The liquid steel is then poured from the electric furnace into a ladle, while at the same time eliminating impurities and making a first time adjustment to the chemical composition by way of adding alloys containing the necessary elements for the optimum quality of the steel.

Refining

In pursuit of making the finest grade of steel, refining process is carried out through LRF (ladle refining furnace). The molten material is refined in a manner unique to MISIL through alloy addition and nitrogen purging process. Further alloys such as Manganese, Nickel, Chrome, Vanadium, Molybdenum etc. are added to make special steel, spring steel, auto motive steel, stainless steel and low alloy steel. The two elements that can be mostly responsible for affecting the characteristics and properties of the steel, carbon and sulphur, are controlled additionally by LECO combustion apparatus. The chemical composition of the steel is analyzed by emission spectrometry and complete adjustment of the temperature and chemical analysis is carried out in the ladle furnace, together with the total elimination of impurities (non-metallic inclusions and sulphur) by injection of argon, via the bottom of the ladle.

A secondary steelmaking process is carried out during which oxygen and argon are blown into the molten steel. This method enables carbon to be removed without oxidising chromium for refining stainless steel. Molten metal is stirred and homogenized to achieve the perfect level of alloying. At MISIL, special stainless steel grades are made through AOD process. The only plant in Pakistan capable of manufacturing 60,000 tons per annum of stainless steel billets in conformance with 200, 300 and 400 series, through AOD (Argon Oxygen Decarburizer) converter having capacity of 18 tons per heat.

MISIL’s range of casting facilities provides the optimum metallurgical process route for demanding steel types. Billet, the raw material of constructional steel, is produced in appropriate quantities for hot and thermodynamic rolling during continuous casting. A highly specialized three-strand continuous caster, engineered and supplied by Concast, is used by MISIL for the production of 80 x 80 mm, 100 x 100 mm, 130 x 130 mm, and 150 x 150 mm billets of steel in a highly synergized manner. The liquid steel is discharged into a distributor unit, which has several holes at the bottom through which the liquid steel can flow into various casting lines or moulds, where the solidification of the steel takes place and semi-products (billets) are obtained. Later, a cooling system is applied—first by cold water jets and then by air. The billet is cut to the desired lengths using blowtorches that move with the billet during the cut.

Re-Rolling

In 1994 the group made capital investments to measure up clientele trust in industrial and residential structural sections like I. beam, H. beam, C.section, L.Section, T-bar etc. These are manufactured at the most modern re-rolling facilities with 100 % factory automation and a capacity to produce 200,000 tons of steel per year. Today, the facilities stand alone and high in pride while producing quality structural steels in Pakistan.

Mughal Steel’s fully automatic rolling mills are equipped with auto-control reheating furnaces; facilitating further to produce the required section of any kind. Above all, our clientele enjoys the facility of customized dimensions and sizes as per their own requirements or designs.

The Tandem Section Mills have been introduced for the first time in Pakistan by MISIL in line with Universal Stand (the ultimate re-rolling technology). Unlike the conventional cross county mills, the tandem mill does continuous rolling through DC motors providing electrical power. This is the best suitable technological solution accompanied with various advantages like; highest production rates, optimized yield, reduced roll consumption, flexible production, tight tolerances for web & flange thickness, shape, and high surface quality, low costs for operation, maintenance, and minimum down times . In addition to this, the European technology, state of the art Italian design by ABB, AMB, SCADA follows the procedure of four-dimensional rolling, whereby, uniform rolling and quality is ensure, making, the re-rolling technology at MISIL energy efficient and cost effective.

This is the only straight and continuous mill available in Pakistan. High speed computerized shearing machines cut customized lengths from a single bar of 1300 ft (approximately). These re-bar and de-bar re-rolling mills started producing bars in 1986 through prime quality billets procured from PSMCK and internationally renowned producers worldwide. These mills have an installed capacity of 180,000 tons annually to produce deformed and reinforced bar in conformance with ASTM A 615 G-40 and G-60, BS 4449 and other international standards of BS ASHTO and DIN.

Labs

Mughal steel has embraced the philosophy of Total Quality Assurance. Therefore, the quality of all products is ensured at all stages of the steel making process. This quality control process involves monitoring the quality throughout the whole production process. Invariable standard compliance could not have been possible without an unmatched source of reliability and particularly quality control trained personnel. Unrelenting efforts towards quality products have always received appreciation, accreditation and recommendation by national and international engineers. Mughal Labs are equipped with traditional chemical and mechanical analytical machines besides the world’s renowned OPTICAL EMISSION SPECTOMETER of M8 series. The machine is capable of analyzing 43 metal cannels within 3 minutes from sample preparation to complete detail analysis. We have two Universal Testing Machine units (100 tons & 200 tons) to carry mechanical tests such as yield, tensile strength and bend tests on various bars and sections.

Quality control and quality assurance are two separate departments directly reporting to Director Production in the organizational set up to avoid and production influence. The management is dedicated to winning Mughal Labs as a status of independent source for metal testing nationally and internationally by achieving accreditation with the world renowned labs.

Energy

Mughal steel has always readily adopted to energy management technologies as it is resolved to increase energy efficiency and maximize use of waste fuels, reducing emissions as well as reliance on purchased fuels. The comprehensive energy management plan has reduced powerhouse energy consumption by three to five percent and has helped MISIL to achieve its vision of becoming energy self-sufficient. In this regard, gas and electricity is being produced at Mughal industries. The company decided to go on captive power generation in 2005. The 20 MW captive power house in collaboration with GE Jenbacher was designed to be completed in two phases, of which the first phase started generating 9 MW power in 2006. The next phase was completed in 2007 with total investment of PKRs 630 million.

The production of steel is grossly dependent on large amount of coal feedstock that releases clouds of carbon dioxide emissions in the atmosphere. Clean coal technology is an efficient technology which reduces the emissions of Sulfur Dioxide and Nitrogen Dioxide resulting in plant efficiency. During 2014, MISIL met another milestone through the induction of clean coal technology. Mughal Steel is the pioneer in augmenting the utilization of coal gasification also known as the clean coal technology introduced in the industrial sector of Pakistan. The coal gasification not only yields efficiency in production and reduces the operating cost, but also accredits the company in fulfilling its strong commitment towards environmental sustainability. This has further strengthened the image of Mughal steel as an environmental sensitive company that operates in compliance to the international health and environmental standards which has encouraged the company to invest in the clean coal technology. Moreover, by adopting energy efficient measures, Mughal Steel has already stepped forward and extended its contribution in combating the global Carbon Dioxide emission levels.

Keep Up To Date – Get Emails Update

Stay tuned with latest company news.

Hidden

Next Steps: Sync an Email Add-On

To get the most out of your form, we suggest that you sync this form with an email add-on. To learn more about your email add-on options, visit the following page (https://www.gravityforms.com/the-8-best-email-plugins-for-wordpress-in-2020/). Important: Delete this tip before you publish the form.