PROCESS OF INDUCTION FURNACE 
                Raw materials for the process are scrap, fluxes and Ferro alloys. Sponge iron can substitute scrap 
                up to 50%. The Steel Scrap received from various suppliers will be placed in the steel scrap 
                storage yard based upon the Grade and Size at different locations. 
                The scrap from the storage yard is handled either manually or by a small dosing device to the 
                Bundling Machine and will be stored in the steel Scrap Yard as per the Grade if any. The 16”x16” 
                size  Scrap  bundles  will  be  Lifted  and  Transported  by  Over  head  cranes  and  fed  to  Induction 
                Furnace. 
                Scrap/  sponge  iron,  fluxes,  Ferro  alloys  are  melted  in  an  Induction  furnace,  wherein  electric 
                current is passed through it. In the Induction Melting Furnace the scrap melts at temperature of 
                about 16500C. When the total charge is melted into hot liquid metal then the metallurgy of steel in 
                terms of carbon, phosphorus content, alloy elements etc, is controlled at this stage. Based upon the 
                Composition of the molten steel, additives will be added to get the requisite composition and grade 
                of Steel .The molten material is poured into mould to produce ingots. 
                 
                The ladle is placed over the Continuous Casting machine to cast the molten steel into required size 
                of billets. The Cut Billets are transported by a Billet handling crane and stored in the Storage yard 
                as per the Grade and Quality for dispatch.  
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
                 
             
             STEEL MAKING PROCESS IN THE INDUCTION FURNACE 
                        
                                   LIST OF MACHINERY/ EQUIPMENTS 
                                     FOR INDUCTION FURNACE UNIT 
                   
                  S.                                  Description                                 Quantit
                  No                                                                              y 
                       Induction furnace with Transformer, 33 KV VCB, H.T L.T. Cables, Complete with  2 
                  1    crucibles, one year spares& instrumentation. One crucible in operation and another in  1Nos 
                       Stand by. 
                  2    Casting Crane 70/10 T approx. 22 M span                                    1 No 
                  3    Charging crane for feeding scrap through magnet                            2 Nos 
                  4    Electro magnet 1800 mm dia Copper wound with 20 minutes battery backup with all  2 Nos 
                       electric accessories & batteries 
                  5    Vibro feeder for sponge iron                                               1 No 
                  6    Wet lab equipment for chemical Analysis                                    1 Set 
                  7    Water pumps for Furnace and Concast water Cooling.                         3 Sets 
                  8    Emergency water circulation system for Induction furnace Coil D.G. Pump.   1 Set 
                  9    Cooling Tower for Furnace and CCM Circulating water.                       3 Sets 
                                                       2
                  10   Air Compressor 120 CFM at 8 Kg/Cm  1 No                                    1 Set 
                  11   Pipe and pipe fittings                                                     1 Lot 
                  12   Shed 22 X 100 m with rail height at  17 m                                  1 No 
                  13   Induction furnace Building pump house with CT& Lab                         1 No 
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
              
        DESIGN PHILOSOPHY OF POLLUTION CONTROL SYSTEMS 
         The design philosophy of pollution control system is given as following: 
         Quantum of Emissions:  
         Considering the temperature of charge the volume of pot and continuous charging of 
         input materials from the beginning up to few minutes before tapping it has been found 
         that total volume of gaseous of emissions including inspiration of air from surrounding 
         atmosphere may reach a maximum 50,000 M³/Hr. From test results it has been found 
         that hydrocarbon are near above 50 mg/lit/hour and CO+ CO2 are less than 1 ppm. The 
         suspended particulate matter ranges from 125 to 450 mg/cum. If the charge consists of 
         oily and highly rusted scrap the SPM may go to 1000 mg/cu. m.  
          
         Size of SPM: Considering the mixed steel scrap charge used in melting it is found out 
         that the particulate size varies from 0.7 to 8.0 microns. The SPM range in terms of 
         weight will be 0.7 to 1.0 Kg/ton of steel or approx 0.15% of steel scrap melted. SPM 
         may go up to 600-1000 mg/M3.