PROJECT REPORT

ON

IMPROVING THE CRUSHING LIFE OF BULL HEAD HAMMERS (CRUSH-
ING HAMMERS USED IN SINTER PLANT) .

Project report during the project internship training at Visakhapatnam
Steel Plant, Visakhapatnam Under the esteemed guidance of

B.R.JENA
Manager (Metallurgy) ES&F Dept. VSP.

SUBMITTED BY

G.LALITHA DEVI 105
K.NAGAMBICA 106
E.LAKSHMI PARVATHI DEVI 107
P.DEVI DURGA 108




Department of
Metallurgical & Materials Engineering
RGUKT IIIT
NUZVID-521201
VISAKHAPATNAM STEEL PLANT



CERTIFICATE

This is to certify that this project entitled TO IMPROVE THE
CRUSHING LIFE OF BULL HEAD HAMMERS (CRUSHING HAMMERS) USED
IN SINTER PLANT is a Bonafide work


NAME OF THE STUDENT

ADMISSION NUMBER
G.LALITHA DEVI 105

K.NAGAMBICA 106

E.LAKSHMI PARVATHI DEVI 107

P.DEVI DURGA 108

Done under the guidance of Sri B.R.JENA, Manager (CMS), ES&F, Visakhapatnam
Steel Plant , Visakhapatnam. The project report is done during the period from
15-04-2013 to 08-06-2013.

Project Guide

Sri. B.R. JENA

RAJIV GANDHI UNIVERSITY OF KNOWLEDGE TECHNOLOGIES
(AP Government Act 18 of 2008)
Mylavaram Road ,Nuzvid,Krishna District -521202

Department of Metallurgical & Materials Engineering

CERTIFICATE

This is to certify that the Dissertation entitled Improving Crushing life of Bull Head
Hammers is a bonafide record work done by the students
E.L.P.DEVI(N081195),G.LALITHADEVI(N081263),P.DEVIDURGA(N081974),K.NA-
GAMBICA(N081187) Of 3rd year engineering in the year 2013 submitted in partial
Fulfillment of the requirements of B.Tech in Metallurgical & Materials Enginnering
Of Rajiv Gandhi University of Knowledge Technologies has been carried out our su-
pervision and embodies original work.


HEAD OF THE DEPARTMENT (MME)
Dr. A. Raja Annamalai

ACKNOWLEDGEMENT

We wish to express our sincere thanks to Mr. B.R.JENA, Manager
(Metallurgy) ES&F Dept. Visakhapatnam Steel Plant for his valuable guid-
ance in completing this project.


We wish to express our sincere thanks and deep sense of gratitude
to Mr. K.NAGABHUSHANAM, Senior Manager (ES&F-Forge Shop), Dept.
Visakhapatnam Steel Plant for his valuable guidance in completing this
project.


We wish to express our sincere thanks to Mr. RAJABABU ES&F Dept.
Visakhapatnam Steel Plant for his valuable guidance in completing this
project.

We also express our sincere thanks to each and every one of ES&F
Dept. for their valuable support during the completion of our project.




ABSTRACT

Sinter plant needs bull head hammers at the rate of 700 numbers per
month, which is to cater their requirement for the crushing of dolomite
and limestone. Any variation of the metallurgical or mechanical proper-
ties makes a huge difference as compared to its performance and the
total down line stream of production gets affected. Hence our project
deals with IMPROVING THE CRUSHING LIFE OF BULL HEAD HAMMERS
of Sinter plant in VSP.

Out of the spares supplying by ES&F, bull head hammer is one of the
important spares, which is used in hammer crusher of sinter plant for
crushing dolomite and limestone.

This project deals with the preparation specifications of the bull head
hammer followed by manufacturing of the same from raw material. For
this raw material is obtained from SAIL with material composition of
50CrMo4 and of sizes of 100mm square. With the help of manipulator it
is cut to specified sizes & then forged to form into bull head hammers. It
is followed by heat treatment at CMS to achieve the required properties.
Here we be experimenting with the metallurgical properties to improve
the wear resistance and toughness so that we can improve the crushing
life and the break down time can be reduced.


CONTENTS:

1. ABSTRACT
2. INTRODUCTION (VSP)
a. Profile of VSP
b. Location
c. Major products
d. Minor products
e. Modern Technology
3. Engineering Shops and Foundry.
a. Central Machine Shop.
b. Forge Shop..
c. Steel and structural shop.
d. Foundry
e. Utility Equipment and Repair Shop.
4.BULL HEAD HAMMERS.
a. Introduction.
b. process for preparation of bull head hammers.
c. Process involved in the central machine shop.
D. dispatch to sinter plant
5.REASONS AND SUGGESIONS


INTRODUCTION

Visakhapatnam Steel Plant is the biggest project and most
modern steel plant in the country ,nesting in between the NH-5 and the Bay of Ben-
gal lays a stretch of land strewn with hillocks, valleys a natural creek and green for-
ests south west of Visakhapatnam harbor .Taking full advantage of the natural
bounty ,plans were drawn up for setting up Indias seventh integrated steel plant
in the government sector and the first shore based plant at Visakhapatnam .New
Technology ,large scale computerization ,and automation etc. Are incorporated in
design of the plant. The plant was registered under corporate name Rastriya Ispat
Nigam Limited, a holding company of Visakhapatnam steel plant on 18
th
February
1982.
It is the first coastal based steel plant of India located 16 K south
west city of destiny i.e. Visakhapatnam .Equipped with modern technologies, VSP
has installed capacity of 3 Million Tons per annum of Liquid Steel and 2.656Million
tons of saleable steel. At VSP there is emphasis on total automation seamless inte-
gration and efficient up gradation, which results in wide range of long and structural
within India and abroad. VSP products meet exalting international quality standards
such as JIS, DIN, BIS,BS etc.

VSP has the distinction to be the 1st integrated Steel plant in India to
become a fully ISO-9002 certified company .The certificate covers quality systems
of all operational. Maintenance, services units besides purchase systems, Training
and Marketing functions spreading over 4 Regional Marketing offices.20 branch of-
fices and 22 stock yards located all over the country .VSP by successfully installing
operating efficiently Rs.460 corers worth of pollution Control and Environment Con-
trol Equipments and barren landscape by planting more than 3 million plants has
made the steel plant, steel Township a greener ,cleaner and cooler place, which can
boast of 3 to 4c lesser temperature even in the peak summer compared to Visa-
khapatnam city. VSP exports quality pig Iron Steel products to srilanka , Myanmar,
Nepal, Middle East, USA&South East Asia(pig iron). RINL VSP was awarded "Star
Trading House "status during 1997-2000. Having established a fairly dependable ex-
port market.

VSP plans to make a continuous presence in the export market. Hav-
ing a total manpower of 17250 VSP has envisaged a labor productivity of not than
tones per man year of Steel which is the country and comparable with the interna-
tional levels.

MAJOR PLANT FACILITIES:

VSP has the following major production facilities:

4 coke oven batteries of 67 ovens each having 41.6 M3 Volume.
2 Sinter machines of 312 M3 area.
3 Blast furnace of 3200 M3 useful volume.
Steel Melts Shop with three L.D. converters of 150 Tons capacity each and 6
N0s.of 4 standard continuous bloom casters.
Light and Medium Merchant Mill of 710000 Tons per year capacity.
wire rod mill of 850,000 tons per year capacity.
Medium Merchant & Structural Mill of 850,000 tons per year capacity.

Besides these a capacity power plant site a capacity of 286.5 MW, Oxygen
plant, Acetylene plant with Air plant, extensive repair maintenance facilities form
part of the facilities available at VSP.
Number of ovens in series one after the other form a coke oven Battery. At
VSP there Coke oven Batteries , 7 Meter tall and having 67 Ovens each. Each oven
is having a volume of 41.6 m3 & can hold up 31.6 Tons of dry coal charge.
MINOR DEPARTMENTS:

Power generation and distribution.
Water management.
Traffic department.
Engineering shops and foundry.
Utilities department.
Quality assurance and technology development department
Calcining and refractory material plant.

MODERN TECHNOLOGY:

Visakhapatnam Steel plant is the most sophisticated and mod-
ern integrated steel plant in the country. Modern technology has been adopted in
many areas of production, some of them for the first time in the country. Among
these are:

Selective crushing of coal
7meter tall coke ovens.
Dry quenching of coke.
On ground blending of sinter base-mix.
Conveyor charging and bell less top for blast furnace,
cast house slag granulation for blast furnace,
100% continuous casting of liquid steel
Gas expansion turbine for power generation utilizing blast furnace top gas
pressure.
Hot metal de-sulphurisation .
Extensive treatment facilities of effluents for ensuring proper environmental
protection.
Computerization for process control.
Sophisticticated , high speed and high production rolling mills.
MAJOR DEPARTMENTS IN VSP:
1)RAW MATERIAL HANDLING PLANT(RMHP):



VSP annually requires quality raw materials which are iron ore,
fluxes, coking and non-coking coals etc. to tune of 12-13 million tons for producing
3million tons of liquid steel. To handle such a large volume of incoming raw materi-
als received from different sources and to ensure timely supply of consistent quality
of feed materials to different VSP consumers, raw materials handling plant serves a
vital function. This unit is provided with elaborate unloading, blending stacking and
reclaiming facilities which are Wagon Tipplers, Ground and Tank Hoppers ,Stock
yards Crushing Plants , vibrating Screens, Single or twin boom stackers, wheels on
boom and Blender Reclaimers .

Various raw materials in (RMHP) are Ore Fines, Iron Ore Lumps, Sized
Iron Ore, Limestone (BF and SMS grade), Dolomite (BF and SMS grades), Dole chips,
Sand, Quartzite , Manganese fines and Lumps and Fluorspar and Flux etc.

MAJOR SOURCES OF RAW MATERIAL
Raw Material S ource S ource
Iron Ore Lumps & Fines Ba iladilla, MP
BF Lime stone Jaggay yapeta, AP
SMS Lime Stone UAE
BF Dolomite Madharam, AP
SMS Dolomite Madharam, AP
Manganese Ore Chipurupalli, AP
Boiler Coal Talcher, Orissa
Coking Coal Australia
Medium Coking Coal (MCC) Gidi /
Swang /Rajarappa/Kargali

These raw materials are sent in different proportions to various depart-
ments as indicated below :
Coke Ovens: Imported Medium, Medium
Sinter Plant: Iron Ore Fines, Lime stone (BF), Dolomite, Sand and Manganese Fines.
Blast Furnace: Sized Iron Ore , Limestone(BF), Manganese Lump, Quartzite.
SMS: Dolomite (SMS), Fluorspar Sized Iron Ore
CRMP: Limestone (SMS), Dolomite (SMS), Dole Chips
TPP: Boiler Coal.
COCCP: Imported coaking coal, medium coaking coal.
The raw material handling plant is divided into two sections coal handling
plant and ore handling plant.



THE FACILITIES AVAILABLE IN TWO SECTIONS ARE AS FALLOWS:

COAL HANDLING PLANT ORE HANDLING PLANT

2 Wagon Tipplers . 3 Wagon Tipplers.

5 Ground & 10 Track Hopper. 10 Ground& 10 Track Hoppers.
Stock Yards (10 beds). Stock Yards(12 beds).

Boiler coal crushing plant. Lump ore crushing plant.
Stackers , Reclaimers and stacker Lump ore screening plant. Cum
Reclaimer.

Reclaiming Conveyors. Reclaiming Conveyors

Stacking Conveyors. Stacking Conveyors.


SALIENT FEATHERS OF RMHP:

Peripheral unloading system for railway wagons coming directly upto
pushers .
Blender reclaimers for blending of ores and fluxes in which the bucker
wheel has a lateral motions across the bed.
Wheel on boom reclaimers for reclaiming different materials from same
bed in ore and flux yard and same type coals in CHP.
Two ring granulators for crushing of boiler coal
Three blender reclaimers for blending of iron ore fines and fluxes
PLC control of all systems
Drier for drying SMS size ore
Preparations of sized iron ore for using BF to enable close size range of
raw materials
Dust extraction system is provided at various locations of RMHP to
absorbed the dust generated during the process.
RAW MATERIAL SPECIFICATIONS:
The iron bearing burden materials are Iron Ore fines
supplied from Bailadilla mines and manganese ore from the deposit in Viziana-
garam District.
The various raw materials handled in the OHP are as follows:

SI NO RAW MATERAIL
1 IRON ORE FINES
2 IRON ORE LUMPS
3 SIZED IRON ORE.
4 LIME STONE (BF grades)
5 LIME STONE (SMS grades)
6 Dolomite (BF grades)
7 Dolomite (SMS grades)

The various raw materials handled in the CHP are as follows:

SI NO RAW MATERIALS
1.
2.
3.
4.
5.
Imported coking coal
Imported soft coking coal
Medium coking coal
Prime coking coal
Boiler coal.

2.COKE OVENS AND COAL CHEMICAL PLANT(CO & CCP):



Blast Furnaces, the mother units of any steel plant requires huge
quantities of strong, hard and porous solid fuel in the form of hard metallurgical
coke for supplying necessary heat for carrying out the reduction and refining reac-
tion besides agent.
Coke is manufactured by heating of crushed coking in the absence of air at
a temperature of 1000
0
c and above for about 16 to 18 hours. The coal chemicals
such as Benzol, Ammonium sulphate etc. are extracted in coal chemicals the gas is
used as a product fuel by mixing it with gases such as BF gas , LD gas etc. A mechan-
ical , biological and chemical treatment plant takes care of the effluents.
A coke oven comprises of two hollow chambers namely coal
chamber and heating chamber. In the heating chamber a gaseous fuel such as blast
furnaces gas , coke oven gas , etc. is burnt .The heat so generated is conducted
through the common wall to heat and carbonize the coking coal placed in the adja-
cent coal oven battery.

At VSP there are three coke oven batteries, 7 meters tall and having
67 ovens each. Each oven is having a volume of 41.6 cubic meters and can hold up
to 31.6 tons of dry coal charge. The carbonization takes place at 1000
0
c to 1050
0
c
in the absence of air for 16 to 18 hours.

Red hot coke is pushed out of the ovens and sent to coke dry cooling
plants for cooling to avoid its combustion. The capacity of each cooling chambers is
50 to 52 TPH. Nitrogen gas is used as cooling medium. The heat recovery from ni-
trogen gas is done by generating steam and expanding in two back pressure tur-
bines to produce 7.5 MW power each.

The coal chemicals such as benzyl (and its products),tar (and its prod-
ucts)and ammonium sulphate , etc. are extracted in coal chemical plant from CO
gas. After recovering the coal chemicals , the gas is used as by- product fuel by mix-
ing it with gases such as BF gas, LD gas , etc. A mechanical, biological and chemical
treatment plant takes care of the effluents.

BATTERIES:

Oven charge weight (T)
Coaking time (hrs) 16
Heat consumption(x103 Kcal/NM3) 6.86 per ton of dry coal charged
C.V of mixed gas for heating (Kcal /NM3) 1000



COKE DRY COOLING PLANTS:

There are four coke dry cooling plants, each having four
chambers. Capacity of each chamber is 50-52 TPH. Each coke dry cooling plant con-
sists of cooling chambers with individual lifter and lifting shaft, waste heat boiler
,dust catching arrangements and mill fan.

The cooling chamber has two technological zones. Red hot
coke is charged into the upper zone while cooling takes place in lower zone by cir-
culating gases. Gas is forced by mill fan into distribution channels in the lower part
of the chamber and fed into the cooling zone. The gas flows upwards and gets
heated. Circulating gases enter boiler, cyclones and return to bottom part of cooling
chamber because of mill fan.
1) Temperature of coke charged in the chamber(
o
c) 950-1050
2) Temperature of cooled coke(
0
c) 200-250
3)Steam rising from one chamber(T/hr) 20-25

COKE STORING PLANT:


From the dry cooling plant, cooled coke is conveyed to a
dedusting unit by conveyor. From the dedusting unit, coke is conveyed to crushing
section. Here the incoming coke fractions are first separated into +70 mm and -70
mm fractions. The +70 mm fractions is fed into a roller toothed crusher .The crushed
product along with -70 mm fractions in conveyed to coke screening section where
25-70 mm and 0-25 mm fractions are separated using roller screens.25 to 70 mm
fractions are conveyed to blast furnace.Bunkers of 600 tonnes capacity are also pro-
vided for loading into wagons and dumpers for sending to coke yard.

0 to 25 mm fractions are fed to vibrating screens provided
to separate into nut coke and breeze coke .Nut coke is sent to blast furnace or yard
depending upon the requirement .Breeze coke is sent by conveyor to sinterplant.

CONVEYORS :

The following types of conveyors are used in coke ovens & coal chemi-
cal plant.

Width - 1600 1400 1200 1000 800 650 500

Quantity - 9 49 6 11 - 4 2

Total no of conveyors - 87

Total Length - 15000
3.SINTER PLANT (SP):




Sinter is a better-feed material to blast furnace in comparison to iron ore
lumps and its usage in blast furnace help in increase in productivity, decreasing the
coke rate and improving the quality of hot metal produced. Sinter is a hard and
porous ferrous material obtained by agglomeration of iron ore fines, coke breeze,
lime stone fines, Metallurgical wastes which are Flue dust, Mill scale, LD slag etc.
Sintering is done in 2 nos.of 312 square meter, sinter machines of
Dwight Lloyd type by heating the prepared feed on a continuous metallic belt made
of pallets at 1200
0
c-1300
0
c.

Hot sinter discharged from sintering machine is crushed to sizes be-
tween 5mm and 50mm size and cooled before dispatching to
blast furnaces.
SINTERING PROCESS:
Preparation of various raw material.
Mixing &Blending.
Mixing with sinter returns in presence fo water to form green
balls.
Charging on to the machine.
Ignition and suction.
FLUX CRUSHING PLANT:
Flux crushing plant consists of four reversible Hammer
crushers to crush Limestone and Dolomite to <3mm.Limestone of 6 to 40mm size
and Dolomite of 6 to 80mm size are received from raw material handling plant.
Crushers are fed with the help of vibro feeders.The crushed material is conveyed to
screening plant by a conveyor.
Coke crushing, Limestone and Dolomite Screening Plant:
The coke screenings are crushed in seven four-roll crushers
of 11 tons/hr capacity to a size of 0 to 3mm.The crushed limestone and dolomite
are fed to eight screens for separating the +3mm and -3mm fractions are sent to
raw material bins by means of inertia screens, 15 numbers of electrical vibro-feed-
ers, shuttle conveyors etc.

PARAMETERS OF SINTERING MACHINES:
Effective area : 312 sq.m
Sintering area : 276 sq.m
Sintered height : 300 mm
Capacity : 450 TPH each
No. of wind boxes :26

The dust laden air from the machines are cleaned in scrub-
bers and electrostatic precipitators to reduce the dust content to 100mg/m3 level
before allowing to escape into the atmosphere and thus helping in maintaining a
clean and dust free environment.

4.BLAST FURNACE(BF):




Hot metal is produced in blast furnaces, which are tall vertical furnaces. The furnace
is named as Blast Furnace as it is run with blast at high pressure and temperature.
Raw materials such as sinter, iron ore lumps, fluxes (limestone, dolomite) and coke
are charged from the top and hot blast at 1100
0
c to 1300
0
c and 5.75 KSCH pressure
is blown almost from the bottom through tuyers. The furnaces are designed for
80% sinter in the burden.
VSP has two 3200 cubic meters blast furnaces (largest in
India) equipped with Paul worth Bell less top equipment with conveyor charging.
Rightly named as Godavari and Krishna after the two rivers of A.P , the furnaces will
help in bringing prosperity to the state of Andhra Pradesh.
Provision exists for granulation of 100% liquid slag at blast
furnace cast house and utilization of blast furnace gas-top pressure (1.5 to 2 atmos-
pheric pressure) to generate 12 MW of power in each furnace by employing gas
expansion turbines.

The two furnaces with their novel circular cast house and four tap holes
each are capable of producing 9720 tons of metal daily or 3.4 MT of low Sulphur
hot metal annually.


5.STEEL MELTING SHOP(SMS):




steel is an alloy of iron with carbon up to 1.8%.Hot metal pro-
duced in blast furnace contains impurities such as Carbon (3.4 to 4.25%) ,silicon(0.4
to0.5%) Manganese(0.3 to 0.4%),sulphur (0.04% maximum) and phosphorous
(0.04% maximum) is not suitable as a common Engineering Material.To improve the
quality,the impurities are to be eliminated or decrease by oxidation process.

Vsp produces steel employing three numbers of top blown oxygen convert-
ers called LD converters (L and D stands for Linz and Donawitz-two towns in Austria
where this process was first adopted )or Basic Oxygen Furnaces /Converters. each
converter is having 133 cu. mts volume capable of producing 3 MT of liquid steel
annually. Besides hot metal ,steel scrap ,fluxes such as calcinated lime or dolomite
from part of the charge to converters.

199.5% pure oxygen at 15-16 KSCG pressure is blown in the converter
through oxygen lance having convergent divergent copper nozzles at the blowing
end. oxygen oxidizes the impurities present in the hot metal which are fluxed as
slag with basic fluxes such as lime. During the process heat is generated by exother-
mic reactions of oxidation of metalloids viz. si,mn,p and Carbon and temperature
rises to 17000 c enabling refining and slag formation.

Different grades of steel of superior quality can be made by this
process by controlling the oxygen blow or addition of various ferro alloys or special
additives such as FeSi, FeMn , SiMn, coke breeze, AL etc. in requried quantities while
liquid steel is being tapped from the converter into a steel ladle. converter/LD gas
produced as by product is used as a secondary fuel.


CHARACTERISTICS OF VSP CONVERTERS:

Capacity -150 Tons per heat/blow
Volume -133 cubic meters
Converter sp.volume -0.886 meter cubic per ton
Tap to tap time -45 min to 60 min
Height to diameter ratio - 1.36
Lining - Tar Dolomite bricks


Liquid steel produce in LD Converters is solidified in the
form of blooms in continuous Bloom casters. However,to homogenize the steel and
to raise its temperature,if needed steel is first routed through, Argon rinsing station,
IRUT(Injection refining & up temperature)/Ladle Furnaces.



6.CONTINUOUS CASTING DEPARTMENT:





Continuous casting may be defined as teaming of liquid steel
in a mould with a false bottom through which partially solidified ingot/bar (Similar
to the shape & cross section of the mould) is continuously withdrawn at the rate
which liquid steel is teamed in the mould.

Facilities at a continuous casting machine include a lift and
turn for ladles, copper mould ,mould oscillating ,primary & secondary cooling ar-
rangement to cool the steel bloom, gas cutting machines for cutting the blooms in
required lengths(Avg.6meters long).

At VSP we have 6-4 strand continuous casting machines
capable of producing 2.82MT / year blooms of size 250X250 mm and
250X320mm.Entire quantity of molten steel produced(100%) is continuously cast-
ing radial bloom casters which help in energy conservation as well as production of
superior quality products.



7.ROLLING MILLS:

BLOOMS produced in SMS-CCD do not find much applications as such
and are required to be shaped into products such as billets, rounds, squares, an-
gles(equal &unequal), channels, I-PE b exams, HE BEAMS , wire rods and reinforce-
ments by rolling them in, there sophisticated high capacity,high speed, fully auto-
mated rolling mills, namely Light & Medium , Merchant Mills(LMMM), Wire Rod
Mills(WRM) and Medium Merchant and Structural Mill(MMSM).
(A)LIGHT AND MEDIUM MERCHANT MILL (LMMM):




Light and Medium Merchant Mill (LMMM) is designed with the
operation floor on a second storey elevation (+5.0 MTS).This arrangement provides
better drainages for both lubricants and water and mill scale.The oil sellers placed
at slightly below the ground level without deep excavations but ensuring adequate
drainage. the oil and water pipes and cable trenches are readily accessible .Blooms
per LMMM are placed on charging grids(3 nos )of 150 tones per hour capacity each
by 16 tones claw cranes (2 nos).An inclined elevator delivers the blooms to the fur-
nace approach roller table(+5.8 mts)from bloom storage roller table(+.8 mts).The
approach roller table is provided with a weighing scale, and then pushed by hydrau-
lic pushers onto the charging skits of the furnaces.The blooms can be discharged
from the furnaces in case of emergency.
Heated blooms are placed piece by piece by discharging
devices onto the furnaces delivery roller table. High pressure de-scalar descales the
blooms. Blooms are reduced to 125 mm square in the 7 stands , finishing speed will
be 1.3 to 1.6 mts/sec. Billets feeding the LMMM cropped at the front and back ends.
If one blooms is rolled for LMMM and the next one for the WRM
alternatively, The mill is designed to produce 710,000 tons per annum of various
finished products such as rounds, rebars, squares, flats, angles, channels besides
billets for sale.

(B).WIRE ROD MILL (WRM) :




Wire Rod Mill is a 4 strand, 25 stands fully automated and sophisticated
mill. The mill has a four zone combination type reheating furnace (walking beam
cum walking hearth) of 200 TPH capacity for heating the billets received from billet
mill of LMMM to rolling temperature of 1200 C. The heated billets are rolled in 4
strand. No twist continuous mill having a capacity of 8,50,000 tonnes of Wire Rod
coil and having the following configuration .
- 7 stand two high 4 strand horizontal roughing train
- 6 stand two high 4 strand horizontal intermediate mills
- 2 stand 4 strand pre finishing mill
- 1- stand 4 strand no twit finishing mill
The mill produces rounds in 5.5 12 mm range and rebars in 8
12 mm range.The mill is equipped with standard and retarded stelmore lines for pro-
ducing high quality Wire rods in low, medium and high carbon grade meeting the
stringent national and international standards viz., BIS, DIN, JIS, BS etc., and having
high ductility, uniform grain size excellent surface finish.

(C)MEDIUM MERCHANT AND STRUCLTURAL MILL (MMSM):



This mill is a high capacity continuous mill consisting of 20 stands arranged in 3
trains.
Roughing train having a 8 stands (4 two high horizontal stands, 2 vertical
stands and 2 combination stands).
Intermediate train has 6 mill stands as per details given below.
2 high horizontal stands.
2 combination stands.
2 horizontal stands/two universal stands.
finishing train consists of 6 stands.
2 combination stands.
4 horizontal stands/4 universal stand.
The feed material to the mill is 250 X 250 mm size blooms,
which is heated to rolling temperatures of 1200 C in two walking beam furnaces of
rounds, squares, flats, angles ,channls, having high strength and close tolerance.

ENGINEERING ENGINEERING ENGINEERING ENGINEERING

SHOPS SHOPS SHOPS SHOPS

& && &

FOUNDRY FOUNDRY FOUNDRY FOUNDRY
ENGINEERING SHOPS & FOUNDY:

Engineering shops & foundry is set up to meet the requirements of
Ferrous & non ferrous spares of different departments. Engineering shops &
Foundry is divided into 5 shops.
1. Central Machine Shop.
2. Forge Shop.
3. Steel Structural Shop.
4. Foundry.
5. Utility equipment repair shop.

DESCRIPTION OF SHOP FACILITIES:
Central Machine Shop:

Inputs: Iron &Steel castings .forgings, rolled sections, repair and rectifica-
tion parts, nonferrous castings, fabrication structures.

Products and Service: shafts , pinions ,Gears, crane Wheels, Rollers
Machining of various fabrication jobs done in SSS. Repair &reconditioning of vari-
ous assembly jobs like L&T housing, Tk stands, pulleys, revisioning facing and cen-
tering machines ,hacksaws, and gas cutting facilities are provided. The machining
section has over 100 major machine including lathes, milling, boring ,and planning
slotting, shaping ,grinding and other machines. The assembly section undertakes
medium repair and general overhauling of mechanical equipment. Horizontal and
vertical presses, washing tanks oil berths etc. are provided. The tool room has fa-
cillites for manufacture of special tools, jigs and fixtures, re-grinding of tools and
and brazing of tipped tools. The heat treatment section is provided with annealing,
normalizing , heat treatment furnaces, carbonizing furnaces, heat treatment fur-
nace with protective gas atmospheres, high frequency hardening machine, quench-
ing tanks with oil cooling arrangements, welding generator and transformers for
normal welding, sub-merged arc welding machine etc. Facilities for surface grind-
ing, pipe bending and threading are provided.

2.FORGE SHOP

Inputs: Ingots from foundry ,blooms from SMS, billets, rods from mills etc.

Production and Services: Raw material for shafts, coupling, gears, pin-
ions, flanges bull head hammers for plant hammer crusher, drill rods for blast
furnace, v-hooks for SMS, straightening of pallet frames of sinter plant.
The shop is designed for production of shafts, coupling:- flanges
etc. and also of forged shapes such as crusher hammer heads, special bolts, nuts,
etc. The repair and testing of chains are also carried out. The annual production
from the shop is about 2,400 tons based On 300 working days per year and two
shifts per day. These inputs consisting of ingots, billets, blooms and flats of var-
ious sizes.
In heavy forging section, open die forging of long shafts,
gear blanks, couplings etc.is made with the help of 2-ton bridge type pneumatic
hammers. Each hammer will be provided with thin chamber heating furnaces.
Floor type manipulator and jib Crane are provided for handling heavy jobs. In
general forging section, 1 ton, 500 Kg, and 200 Kg hammers with separate heat-
ing furnaces are provided. A 2 ton drop stamp hammer with a heating furnace
trimming press etc. is provided for stamping. For cutting them to size, a cold saw,
a billet shear and gas cutting facilities are provided. For stress relieving, a bogie
type-annealing furnace is provided.

3.STEEL STRUCTURAL SHOP:

Inputs: Sheets of various sizes, plates angles, channels, beams for fabrication
of jobs.

production & services : All types of fabrication jobs, repair of slag pots of
SMS, Mfg. And repair of tundishes for SMS, Mfg. Of scrap boxes for SMS for sin-
ter plant, hot metal ladle for SMS,500 meters launder for SMS, mfg. of KAMAG
body for FMD. Repairing of buckets for LMMM, WRM. The annual production of
fabricated structures are about 4,500 tones and the input consisting of sheets,
plates, channels, angles, beams, etc. are about 5,100 T.




For marking, cutting to size, forming and bending, guillo-
tine shear, circular saw plate bender, gas cutting unit etc. are provided, For weld-
ing transformer, automatic and semi-automatic machines and submerged arc
welding machines are provided. Painting is carried out partly with help of spray
guns and partly by hand .Wire brush, spray guns etc. are provided. A mainte-
nance section equipped with lathe, shaper, drill etc. are provided for running
repair of shop equipment.

4.FOUNDRY :

The iron and steel foundry at VSP produces metal castings
meant for internal uses at different departments like SMS, sinter plant, continuous
casting, blast furnace, coke ovens etc. The raw materials for the foundry are blast
furnace pig iron and steel scrap. This foundry has excellent facilities to produce
quality castings economically on a large scale. The VSP foundry is mainly a captive
foundry because the castings produced by it are used only in VSP and is jobbing in
nature as variety of castings varying in chemistry and weight are being made. Re-
cently started executing outside orders for special steel ingots.
As per the norms of requirement for cast spares, it was found
that 12000 Tons of castings will be required for the steel plant comprising of 5400
T of cast iron spares, 6240 T of steel spares and 360 T of non-ferrous spares. Keep-
ing the requirements in view various equipment were installed to meet the above
targets.
The capacities of the shop are:
The maximum weight of single casting in steel 10 T.
The maximum weight of single casting in iron 10 T.
The maximum weight of single casting in non-ferrous 1T.
Captive foundry was envisaged for the supply of consumables and spares for the
steel plant with an investment of 25 crores, followed with the man power of 160
people.
The foundry is divided into five bays
AB Bay : Raw materials section
BC Bay : Sand preparation, core making
CD Bay : Melting, mould making, casting
DE Bay : Fettling and cleaning
EF Bay : Heat treatment and non-ferrous section

5) UTILITY EQUIPMENT REPAIR SHOP (UERS):
INPUTS:
Sheets, Plates , Channels, Angles , Beams, Billets, Rounds from Forge
Shop for manufacturing Shafts, Steel & Iron castings.

PRODUCTS AND SERVICES:

Manufacturing of Impellers to various departments , repair of
GCP ID Fan, Repair of Steam exhausters for SMS, supply of Cones and Ducts of
various sizes, build up & machining of various components, reclamation jobs like
valve repairs, Conveyor Idlers, PCM Rollers etc.




CENTRAL PLANNING SECTION (CPS):

Central planning section of Engineering Shops & Foundry
plays an important role in coordinating various departments and the shops of ESF
for supply of spares, castings, fabricated structures. Duties of Central planning sec-
tion as follows Scrutiny of annual jobs, monthly jobs projected by customer dept.

Preparation of monthly plan based on annual, and MBC projection.
Preparation of material procurement plan based on annual requirement.
Issue of Break down (B/D), MBC and normal work orders to section.
Inspection of semi/finished jobs of 5 sections.
Daily monitoring of jobs progress and preparation of daily production report.
Weekly reviewing B/D jobs.
Monthly monitoring of MBC jobs.
Preparation of monthly progress.
Computerization of details of intershop and dispatch to depts.
Looking after excise formalities of ESF.
Attending MOU meetings of customer departments.







BULL HEAD BULL HEAD BULL HEAD BULL HEAD

HAMMERS HAMMERS HAMMERS HAMMERS

BULL HEAD HAMMERS

PROCESS INVOLVED IN PREPARATION OF BULLHEAD HAMMER:

To prepare the Bull Head Hammers, raw material is obtained from
SAIL with material composition of 50CrMo4 and of sizes of 6000x100x100 mm and
then these billets are cutting by Cold Shear Machine.

CUTTING OPERATION THROUGH COLD SHEAR MACHINE:
By using this Cold Shear Machine we can cut billets into required size(216mm) bars.

COLD SHEAR MACHINE



Cutting Machine Bars having 216mm length

PROCESS FOR PREPARATION OF BULL HEAD HAMMERS:
















DETAILS OF BULL HEAD HAMMER

BULL HEAD HAMMER DRAWING :
Material - 50 Cr M04
Weight - 17.5kg.
BILLET
COLD SHEAR
CUTTING MACHINE
BARS
FURNACE
(HEAT TREATMENT)
MANIPULATOR
(TO TRANSPORT THE BARS FOR
FORGING & TO HOLD WHILE FORGING)
BULL HEAD
HAMMERS
INSPECTION
ANNEALING
HEAT TREATMENT
DRILLING

Out of the spares supplying by ES&F Bull Head Hammer is
one of the important spares which is used in hammer crusher of sinter plant for
crushing of Dolomite and Limestone.

These Hammers are made in Forge Shop and Central Machine
Shop. In Forge shop ,raw material is forged to the required shape; stresses relieved
or annealed and send to CMS for further operations like drilling and heat treatment
.
The raw material for Bull Head Hammer is being procured from VSNL, BHADRAWA-
THI ,and the material specification is 50CrMo4.The weight of Bull Head Hammer is
17.5kg.Average life of bull head hammer is 60 hrs.

Technical specifications of BULL HEAD HAMMERS as per draw-
ing:
Hammer is to made by stamping.
Hammer should be weighed and weights. Punched on bull head
hammers.
Surface defects like laps and cracks are not allowed.
The compensation hole is to be drilled if the weight exceeds 17.6 kg
Hammer are to be heat treated up to 380-500 BHN.

QUALITIES REQUIRED BY BHH ARE :
a. Hardness
b. Toughness
c. Wear resistance
d. Ultimate tensile strength
HARDNESS: It is a fundamental property which is closely related to strength. It is
defined as a resistance to abrasion / penetration .It is also includes resistSance to
cutting and scratching .its unit is N/mm
2
.hardness of bull head hammer should be
380 t0 500 BHN range. It should not be less it should be increased.

TOUGHNESS: It is defined as amount of energy required for fracture.
The toughness of a material its ability to withstand both plastic and elastic defor-
mation. So it is a desirable quality of bull head hammer.

WEAR RESISTANCE: Bull head hammer should have sufficiently wear resistance
.if it is not there then it will be worn out faster. leading to the low life of BULL HEAD
hammer.



ULTIMATE TENSILE STRENGTH: The strength of material is its capacity to with-
stand destruction under the action of external load.The stronger the material the
greater the load it can withstand it. Therefore it determiones the ability of a mate-
rial to withstand stress without failure. The maximum stress that any material will
withstand before destruction is called its ultimate strength. This is the desired qual-
ity of BHH as it is under continuous stress while crushing of limestone and dolomite
in hammer crusher.

THE ABOVE QUALITIES CAN BE ACHIEVED BY THE FOLLOWING
HEAT TREATMENT PROCESSES:

HEAT TREATMENT : It is defined as an operation or combination of operation
involving the heating and cooling of metal alloy in the solid state to produce certain
desired properties. All heat treatment processes may be considered to consists of
three main stages.
1. The heating of the metal to predetermined temperature.
2. The soaking of metal at that temperature until the structure becomes uniform
throughout the mass.
3. The cooling of the metal at some predetermined rate to cause the formation of
desired structure within metal /alloy for desired purpose.

ANNEALING: The purpose of annealing is to soften the steel so that it may be
more easily machined and to relieve the internal stresses which may have been
caused by working the metals or by unequal contraction in causing. The process of
annealing involves heating the metals slowly to the required temp, then holding at
that temp for long enough to enable the internal changes to take place and finally
cooling slowly. Annealing reduces the hardness, increases ductility and usually re-
duces its strength.

HARDENING: Hardening is a heat treatment process. It is made to develop high
hardness to resist wear as well as to improve strength, elasticity, ductility and
toughness to the material. Hardening process consists of heating the steel to a
temperature above critical point, holding at this temp for considerable period and
finally quenching in water, oil or molten salt bath.

TEMPERING:

When a steel specimen has been fully hardened, it is very
hard and brittle and has high residual stresses. The steel is unstable and tends to
contract on aging . The internal stress can be relieved by an additional heating pro-
cess.This heating process is called tempering .

After specimen has been fully hardened by quenching
from above critical temp, it is reheated to some temp below the critical temp for a
certain period of time and then allowed to cool in still air. The temp to which it is
reheated depends upon the composition and the degree of hardness or toughness
desired. Tempering reduces the elastic limit and ultimate strength lightly but they
are still higher than they were before drawing . Hardening with subsequent tem-
pering serves the following purposes for bullhead hammer. It develops high hard-
ness to resist wear and to enable it to cut another metals. It also improves strength,
elasticity, and ductility.

Tempering is a term historically associate with the heat
treatment of martensite in steels. It describes how the microstructure and mechan-
ical properties change as the metastable sample is held isothermally at a tempera-
ture where austenite cannot form. The changes during the tempering of martensite
can be categorised in to stages. During the first stage, excess carbon in solid solution
segregates to defects or forms clusters within the solid solution. It then precipi-
tates, either as cementite in low-carbon steel, or as transition iron-carbides in high-
carbon alloys.

The carbon concentration that remain in solid solution
may be quite large if the precipitate is a transition carbide .Further annealing leads
to stage 2,In which almost all of the excess carbon is precipitated, and the carbides
all convert into more stable cementite. Any retained austenite may decompose dur-
ing this stage. Continued tempering the leads to the coarsening of carbides, exten-
sive recovery of the dislocation structure, and finally to the recrystallization of the
ferrite plates into equiaxed grains.



BASIS FOR SELECTING 50Cr Mo4 AS RAW MATERIAL FOR BULL HEAD
HAMMER:

COMPOSITION OF 50CrMo4:
C : 0.46-0.54
Si : 0.15-0.4
Mn : 0.5-0.8
P : 0.03 Max
S : 0.03 Max
Cr : 0.9-0.12
Mo : 0.25-0.3

CHROMIUM(Cr)- The addition of chromium results in the formation of various
carbides of chromium which are very hard, yet the resulting steel is more ductile
that a steel of same hardness produced by a small increase in carbon content. Chro-
mium also refines the gain structure so that these two combine effect results in
both increased toughness and hardness. The addition of Cr increases the critical
range of temperature and raises strength at the high temperature .Alloy of chro-
mium resists abrasion and wear.
MOLIBDNUM(Mo)- It acts very much like cr but is more powerful in action.
It also increase depth of hardness after heat treatment .Mo finds its greatest use
when combined with the alloying element like cr,Ni or both .Mo increases critical
range fo temp. Except for carbon it has the greatest hardening effect and results in
the retention of a great deal of toughness.
SILICON- It is added to all steels as deoxidizing agent. When added to very low
carbon steels it produces a brittle and high magnetic permeability .The principal use
of silicon is with other alloying element, such as manganese ,chromium and vana-
dium to stabilize carbides.
MANGANESE- it is added to all low and the manganese content is high over one
percent, then it is classified as a manganese alloy.it loweres the critical range of
temperature.
SPHERODOISED ANNEALING- The machinability of high carbon tool steel is at
its best condition when the structure is composed of grained or globular pearlite.
An alloy steels ,including those of the carbide class as well as ball bearing steels
should have a structure of globular pearlite in the deliverable state. The process of
producing a structure of globular pearlite is known as spheredoising or sphe-
rodoised annealing.



PROCESS FLOW FOR BHH:

Transportation
Shearing of Billets
Heating for forging upto 1250
0
c
Forging
Annealing for softening
Inspection for dimensional checking
Transportation to CMS
Drilling of 50mm hole
Hardening
Tempering
Sampling
Inspection for hardness checking
Transportation to customer

THE PROCESS INVOLVED IN FORGE SHOP: THE PROCESS INVOLVED IN FORGE SHOP: THE PROCESS INVOLVED IN FORGE SHOP: THE PROCESS INVOLVED IN FORGE SHOP:

Length is reduced to 3m by gas cutting.
Heat treatment is done in bogie type hearth furnace in order to reduce
hardness from range of (230 to 246) to 170 BHN.
Shearing of billet. size of the billet is reduced to 100x100x127 mm.
Heating is done up to 1250
0
c / hr heating is done then half an hour soaking
is done.



With the help of manipulator and open die hammer , manual forging is done.
Only 90 mm size is forged. Shank portion length is kept as per drawing equal
to 193.5 mm. for checking the size during the process template is used. After
this process the BHN of BHH is approx. 350 BHN.
Annealing is done after forging in order to reduce hardness from 350 to
220.So that drilling may take place successfully. Room temp loading is done
for annealing , it is heated at the same rate up to 850
0
c then one hr soaking.
Then furnace cooling is done for 38 hrs. Due to this annealing hardness come
down to 210-220 BHN.
Inspection is done with respect to shape and size of BHH.
BHH is sent to Central Machine Shop after inspection. They are sent in batch
as Batch size is 400 jobs per batch.

BOGIE HEARTH FURNACE :




This is a modification of the horizontal type furnace with a
movable hearth mounted on heels to facilitate loading and unloading of the
components. Before loading the bogie, the hearth is removed from the
furnace and the components are placed in it by means of an overhead crane.
The bogie is then pushed into the furnace, keeping the furnace
atmosphere airtight when required. After the treatment, the discharging of
the charge is done through the entrance only. These furnaces may also be
provided with loading and unloading it opposite ends to carry out quenching
operations in the case of hardening.
The bogie hearth furnace is mainly used for hardening large
components and for annealing alloy steel forging, stress relieving, etc.


Spheroidising Annealing :





Lamellar Pearlite Globular pearlite
Plates of Cementite Spheroids of Cementite
Improves machinability and ductility
Not adapted for low carbon steels
T= just above A1 temperature
T=Depends on several factors

T and t is decided by
Chemical composition/Alloying
1. Plain carbon Steels =700
0
C , 4-6 hrs.
2. Tool Steels =800
0
C , 10-15 hrs.

Previous Structure:
a. Fine pearlite responds better than coarser pearlite
Machinability high in FINE GRAINED STRUCTURE
b. Network form of cementite responds very poorly
c. Martensite , Troosite,Sorbite responds better.

Inspection procedure:

After completion of tempering BHH are offered for inspec-
tion for checking hardness in addition to dimensional checking. Inspection is carried
out by CPS. Inspection of BHH hammer is done by sampling as it is of mass produc-
tive nature.
In case of sampling inspection lot size is chosen to keep
the number of jobs between 50 to 70 and about 20% of jobs are inspected(next
higher integer if 20% of fraction(Lot is accepted only if the rejection rate is less than
or equal to 2% of the lot size (next lower integer in case of if 2% is fraction).100%
inspection is done if sampling inspection rejects the lot. On each job work order
number and date of inspection are marked to indicate that inspection is done. Ac-
cepted hammers whose hardness in between 380 to 550 BHN are marked OK.
Hammers which are of low hardness, consisting of cracks, dimensional inaccuracy
like drill hole position, are coming under rejected jobs which are marked REJ and
jobs for rework are marked R/W.

THE PROCESS INVOLVED IN CENTRAL MACHINE SHOP: THE PROCESS INVOLVED IN CENTRAL MACHINE SHOP: THE PROCESS INVOLVED IN CENTRAL MACHINE SHOP: THE PROCESS INVOLVED IN CENTRAL MACHINE SHOP:

(a) A hole of 50mm diameter is made in shank portion of BHH as per drawing. If
required another hole is also drilled in order to control the weight of BHH.

(b) Hardening heat treatment is done in CO gas fired fixed hearth type furnace. It
is twin chamber type. Heat treatment cycle for BHH is shown below.








HEAT TREATMENT CYCLE FOR HARDENING:


From Carbon equivalency formula :

= C + (Mn)/6 + (Cr+Mo +V)/5 + (Ni+Cu)/15

= 0.5+0.108+(0.51+0.275+0)/5 +(0+0)/15

= 0.760


We got 0.760 C %.From this if we plot straight line in Fe-Fe3C diagram it touches
around 768
0
c temperature.By considering heat losses we have to add +60
0
c, then
we will get around 828
0
c.
HARDENING OF CARBON STEELS:
The properties of all steels vary under definite conditions of heating and
cooling cycles called Heat treatment.
Heat treatment is to make this steel better suited, structurally and physically
for specific applications.
The most important heat treatment for steels is Hardening.

1.The Hammers upto 600
0
c+ at a constant rate of 150
0
c/hr.

We know that 600
0
c is a recrystallization temperature so we have to heat to
upto 600
0
c.

Purpose of Hardening:
To harden the steel to the maximum level by austenite to martensite
transformation (Due to increase in hardness, brittleness also increase).

To increase the wear resistance and cutting ability of steel.

Hardening process consists of heating the steel to above A3 (727-910
0
c)
temperature for hypo eutectoid steels.

Above A1(727
0
c) temperature for hyper eutectoid steels.

Principles involved in Hardening:

Hot- rolled or Forged Steel that has been slowly cooled from above
red hot condition consists structures of Pearlite with either free Ferrite depending
upon the carbon content. Also ,this slow cooled state of steel results in a relatively
soft and plastic conditions. If we want to increase the hardness of steel we have to
carry out three operations:

1. The first operation in the hardening of steel consists of heating the steel to a
temperature in excess of the critical temperature.

2.The second operation is the soaking

3. The third operation is the rapid cooling or quenching of the heated steel back to
room temperature.

2.Soaking at 600
0
c for 30mins.
soaking of the components at the austenizing temperature is
necessary to dissolve all the carbides into the austenite.
The time of soaking depends on the size of the component, type of
steel.
Soaking to sufficient time so as to obtain Homogeneous
austenite.
3.Raising the temperature from 600
0
c to 875
0
c at 100
0
c/hr.
We have to heat up to critical temperature 875
0
c because at that
temperature only phase changes occurs.We are heating at a rate of 100
0
c/hr to
avoid grain growth.
Why we are heating above A
3
?
Hyper eutectoid steels are not hardened from temperature between
A1 & A3, because the phases which exist at this temperature are Austenite and Pro-
eutectoid Ferrite and only Austenite gets transformed to Martensite with no change
in Ferrite. Such steels show free Ferrite in their microstructures, since ferrite is a
soft phase , the hardness of hardened steel get reduced.
4.Soaking 875+25
0
c for 2hrs.

We have to soak based on thickness of the component ,about
20 mins for cm thickness.
We have to soak the component for 2 hrs inorder to
homogenize the temperature inside the sample.

5.Quenching in water upto 100mm

Water and oils are the most common quenching mediums for
hardening of steels .

Why we are using water as quenching medium than oil ?

Rate of heat transformation is less when compared to
water.Our requirement is to get Martensite which is not possible with oil.And
water is not so expensive,less hazardous , and not a pollutant. Water remove
the heat from the component.















HEAT TREATMENT CYCLE FOR TEMPERING:
Why we need Tempering?
The high internal stresses produced due to hardening are likely to cause
cracking of components. Therefore, tempering should be immediately done
after hardening.
The retained austenite may be transformed to martensite by tempering
operation.

Tempering is done in carburising furnace.

1. Heating the job up to 350+25at a const rate of 100 1. Heating the job up to 350+25at a const rate of 100 1. Heating the job up to 350+25at a const rate of 100 1. Heating the job up to 350+25at a const rate of 100
0 00 0
c / hr . c / hr . c / hr . c / hr .

PURPOSE OF TEMPERING:
To relieve the internal stresses developed due to rapid cooling of steels
during hardening process(i.e Austenite to Martensitic transformation) and
due to volume changes occurring in the above transformation, to reduce
brittleness.
To reduce hardness, & to increase ductility and toughness.
To eliminate retained Austenite.`

Tempering Process:

Heating below A1.The process consists of heating the hard-
ened components to a temperature between 100 & 700
0
c. holding at this temper-
ature for specific period(1-2 hrs) and cooling to room temperature, usually in air.Af-
ter hardening heat treatment, steel combines Martensite and retained Austenite.

Martensite and Austenite are not stable phases and try to transform to
more stable phases during heating. Try to transform to more stable phases during
heating. Depend on the transformation behavior , tempering is classified in the fol-
lowing types:
a) Low temperature tempering 100-200
0
c
b) Medium temperature tempering 200-500
0
c
c) High temperature tempering 500-700
0
c


Medium Temperature Tempering:-
Due to heating in this temperature range, Cementite is formed
and a very fine distribution of cementite particles is observed in the matrix of fer-
rite.
1. The retained Austenite may get transformed to bainate or decompose and
form carbides & martensite. This transformation of Austenite to martensite
is due to increase in Ms Temperature because of decrease in carbon content
of Austenite. This freshly formed martensite also decomposes.
2. The low carbon Martensite and Delta-carbides transform to Ferrite and
Cementite. The particles of Fe3C are very fine and cannot be resolved by
optical microscopes.
3. These changes in microstructure result in decrease of hardness with
increasing tempering temperature. The decrease in hardness is gradual up to
350
0
c and rapid thereafter, reaching to almost a minimum value at about
500
0
c.These changes are accompanied by simultaneous increase in
toughness and ductility.


2.Soaking 350+25
0
c for 1hrs.

We have to soak based on thickness of the component ,about
20 mins for cm thickness.
We have to soak the component for 1 hrs inorder to
homogenize the temperature inside the sample.

3.Air cooling. 3.Air cooling. 3.Air cooling. 3.Air cooling.

Tempering is very successfully carried out in air tempering furnaces.
In these furnaces, air is heated by gas or electric means, and the hot
air is circulated around parts to be tempered. These furnaces are fully
austenite.


DISPATCH TO SINTER PLANT: DISPATCH TO SINTER PLANT: DISPATCH TO SINTER PLANT: DISPATCH TO SINTER PLANT:

Once production of Bull Head Hammers is completed then those are dispatch to
sinter plant. The bull head hammer as shown in this figure is fitted to rotor of ham-
mer crusher meant for crushing dolomite and lime stone.




This rotar contains five rows of nine hammers each axil.Total 45
number of Hammers are there in one Crusher to crush Limestone and Dolomite to
0-3 mm.Crushers are fed with the help of vibro feeders.The crushed material is con-
veyed to screening plant by a conveyor.


Problems are being faced by Sinter plant with respect to BHH:

Low life :
If the hammer is having low crushing life we need to manufacture more
number of hammers hence production cost will increases.
Fracture :
Because of low service life hammers will fracture before we are getting re
quired size. because of this we need to replace the hammers which will disturb the
work .
Increase in down time of crushers
Low production
High maintenance cost
REASONS AND SUGGESTIONS: REASONS AND SUGGESTIONS: REASONS AND SUGGESTIONS: REASONS AND SUGGESTIONS:

Hardness at different points has been done.From the figure
it is very clear that hardness at the side position ,which is directly exposed to water
quenching is more. As going at inside dimentions it is in the decreasing nature.
Hardness at the center of BHH head at three different thickness may also be com-
pared .It is 573 BHN at surface, 451 at the next 15mm thickness and after 30mm it
is 388 mm. This trend shows heat treatment effectiveness slows down for inside
positions.But it is within our requirement.

SUGGESTIONS TO AVOID DEFECTS WHILE INCRESING THE CRUSHING LIFE:

Inspection should be done properly.
The spillages should be avoided.
Flow of material should be uniform.
Heat treatment as per proposed cycle is difficult to achieve due to poor func-
tioning valves, actuators.



We will also increase Crushing life of Hammers by We will also increase Crushing life of Hammers by We will also increase Crushing life of Hammers by We will also increase Crushing life of Hammers by

Proper alloying additions:

As per our study on BHH all the properties required for BHH
is coinciding with properties of Tungston.So we may replace CR50 MO4 with tung-
ston but its not economical and having high melting point.

Spheroidizing annealing should be done:

As we think of altering the heat treatment cycle we end up
with conclusion that no other annealing processes will not increase machinability
like spheroidizing.

Proper care during heat treatment can be done:

Pyrometer may be used for checking temp of different
bullhead hammer at different position. According to this measured temp different
burners of heat treatment furnace may be kept on or off so that uniform temp of
each bull head hammer may be achieved as per proposed heat treatment cycle.

Quenching with saline water:

As we know that salt water is a good heat conductor so it
will quickly absorb the heat from the component than water and its not economi-
cally expensive.