Industrial tour report

On
Bangladesh Steel Re-Rolling Mills Ltd.
&
KYCR Coil Industries Ltd.

Name : Tanvir Ahmed Monon

Roll : 1910478126
Session : 2018-19
Course Title : Industrial Project
Course Code : MSE3222

Submitted to
Professor Dr. Md. Saidul Islam
Dept of Materials Science & Engineering
University of Rajshahi.
 PREFACE

Industrial tours are a powerful means of gaining practical insights into various
industries, processes, and technologies. They provide an opportunity for
students, professionals, and enthusiasts to step out of the classroom or office
and experience firsthand the real-world applications of theoretical knowledge.
Industrial tour allows participants to bridge the gap between theory and practice.
It enables them to witness the inner workings of industries, observe cutting-edge
technologies, and appreciate the complexity of production processes.
As we embarked on our voyage into the heart of steel production and coil
manufacturing. our curiosity was piqued by the vast and complex world that lay
ahead. The purpose of this visit was not merely to witness the mechanical
processes or to marvel at the scale of production but to delve deeper, to
comprehend the synergy between human ingenuity, technological prowess, and
environmental responsibility.
The pages that follow will chronicle our exploration, beginning with the raw
materials that form the backbone of this industry and the meticulous processes
that transform them into invaluable steel products. We will uncover the role of
cutting-edge technologies, such as induction furnaces and continuous casting
machines, in shaping the future of steel manufacturing.
In accordance with the course details of MSE3222: Industrial project, we have
finished our practical study with a great enthusiasm and gaiety by visiting
BANGLADESH STEEL RE-ROLLING MILL Ltd. situated in Zorargonj,
Mirsarai in 21st august and KYCR Coil Industries Ltd.at Kumira 25 KM from
Chattrogram in 22nd august. This report reflects understanding and studying of
the processes, machinery and equipment with their principal mechanism to
produce desired products. We have tried our level best to present information
regarding BANGLADESH STEEL RE-ROLLING MILL Ltd. and KYCR
Coil Industries Ltd.
 ACKNOWLEDGEMENT

I have the immense pleasure and satisfaction in presenting report, which is

termination of my project works at Bangladesh Steel Re-Rolling Mills Ltd.
and KYCR Coil Industries Ltd.
I am heartiest to all those who spare their time to share their mindful art of
judging merits and faults and have given valuable suggestions. However, at first,
we are very thankful to Materials Science & Engineering department for giving
us a wonderful chance of industrial training visit and to make familiar us with
practical aspects of engineering knowledge.
From the very outset, I would especially like to extend thanks to our chairman
of Materials Science & Engineering department Professor Dr. Anwarul Kabir
Bhuiya sir whose inspiration and consideration during the entire program made
it possible to prepare this report.
Our course coordinator Professor Dr. Md. Saidul Islam sir guided us all through
the process from selecting the venue to the end of the tour. Huge respect and
humble thanks to sir for supporting us.
It was great hospitality in Bangladesh Steel Re-Rolling Mills Ltd. and KYCR
Coil Industries Ltd. Thanks to the management of Bangladesh Steel Re-
Rolling Mills Ltd. and KYCR Coil Industries Ltd. for giving us the
opportunity to visit their plants and make our days truly worthy and memorable.
Finally, I want to thank all my classmates who were really excited for this tour
and their enthusiasm really makes training very enjoyable.
Bangladesh Steel Re-Rolling Mills Ltd.
 Overview

BSRM is the leading steel manufacturing company and one of the prominent
corporate houses in Bangladesh. Over the years, BSRM steel products have
been chosen solely for building major National landmarks and infrastructures.
To name a few, the Padma Bridge, Rooppur Nuclear Power Plant, Hatirjheel
Project, Zillur Rahman Flyover, Mayor Hanif Flyover and Shah Amanat Bridge
were built with BSRM.
BSRM Xtreme is a product that was introduced when there was no graded steel
in Bangladesh. It was a major change in the steel industry of Bangladesh. The
core driver was the belief in evolution in steel products, which resulted in
bringing the first EMF tested rod, the first steel brand that passed 5 million
cyclic loading Fatigue testing in the U.K. and conformed to 10 global standards.
With the largest steel producing factory in the country and employing the best
technology from Europe, the company maintains volume with uncompromising
quality. BSRM provides the best solution for the construction industry. The first
ever 50 mm rod was specially designed and rolled for the deep pilling
requirements of Padma Bridge. Various specialized products of BSRM are also
designed to meet special needs for the construction industry.
BSRM ventured into a new business area as part of continuous innovation
philosophy and diversification plan and set up BSRM Wires at Mirsarai,
Chattogram to manufacture various products such as galvanized wire, ACSR
core wire, LRPC Mig Wire, Welding Electrodes, etc.

Sister Concerns:
MEW Ltd.
KEW Ltd.
CPCL
BSRM Wires Ltd.
BSRM Steels
BSRM Recycling Ltd.
 COMPANY BACKGROUND

History:

The founder of the group and our Late chairman Mr. Akberali Alibhai
Africawala came to the then East Pakistan (present Bangladesh) from Africa. He
was originally from Gujrat, India.
1952: The Company started its business in Bangladesh.
1960: The hand-rolling mill (manual) was running with a small capacity.
1984: In 1984, Akberali Africawala (founder of the Group) and Alihussain
Akberali (current chairman of BSRM) went to the UK and bought a second-
hand automatic re-rolling mill to be set up in BSRM factory premises in
Chittagong and thus Introduced high strength cold twisted steel bars
(TORSTEEL) to the construction industry.

19987: Introduced High Strength Deformed reinforcing steel bars conforming

to ASTM 615 Grade 60 for the construction industry.

1996: Commissioned the then largest billet-making plant in the country -

Meghna Engineering Works Limited, now known as Steel Melting Works
(SMW) unit of Bangladesh Steel Re-Rolling Mills Ltd.

2006: Introduced micro reinforcement wires, below 8mm, for low-cost rural
construction.

2008: BSRM built a state-of-the-art rolling mill on 11 acres at Latifpur,

Fouzdarhat, Chittagong under the name of BSRM Steels Limited with the
capacity of producing 375,000 MT bars of 500 mpa strength at the brand name
of “Xtreme 500W”. Recently, BSRM has taken the step to increase the capacity
of the mill to 600,000 MT per annum.

2015: Capacity of BSRM Steels Limited enhanced from 600,000 MT to

700,000 MT per annum. 2. Introduced a new product - “BSRM Maxima” 3. The
capacity of Bangladesh Steel Re-Rolling Mills increased from 120,000 MT to
540,000 MT per annum which is the first and largest merchant mill in
Bangladesh.
 PRODUCT

Billet:
A billet is a semi-finished piece of metal that is typically rectangular or
square in shape. Billets are often used as raw material for various metalworking
processes, including forging, rolling, and extrusion, to produce finished
products like bars, rods, wire, and other metal components. In BSRM, billet is
produced that is typically 160×160 mm in width and 12 m in length. Its weight
is about 2.4 tons. Billets are a crucial part of the steel supply chain, serving as
the starting point for many downstream manufacturing processes that produce
various steel products essential for different industries.

Fig: Billets
 Machinery & Equipment

Scrap processing equipment:

Scrap processing equipment is essential in
BSRM for recycling and reusing scrap metal as a raw material in steel
production. Using scrap metal helps reduce the demand for virgin iron ore and
the energy required for iron and steel production, making it an environmentally
and economically sustainable practice.

Fig: Scrap processing equipment

Induction furnace:
An induction furnace is an electrical furnace that uses
induction heating to melt or heat metal. The furnace consists of a coil of wire
that is surrounded by a crucible or chamber that holds the metal. When an
alternating current passes through the coil, it creates a rapidly changing
magnetic field. This magnetic field induces eddy currents in the metal, which
causes the metal to heat up.

Induction furnaces are used to melt a variety of metals, including iron, steel,
copper, aluminum, and precious metals. They are also used to heat metal for
forging, welding, and other metalworking processes.

The principle of induction heating is mainly based on two well-

known physical phenomena:
 ▪ Electromagnetic Induction
The energy transfer to the object to be heated occurs by means of
electromagnetic induction. Any electrically conductive material placed in a
variable magnetic field is the site of induced electric currents, called
eddy currents, which will eventually lead to joule heating.

▪ Joule Heating
Joule heating is the physical effect by which the passing of current through an
electrical conductor produces thermal energy. This thermal energy is then
evidenced through a rise in the conductor material temperature, thus the term
“heating”. One can see Joule heating as a transformation between “electrical
energy” and “thermal energy”, following the energy conservation principle.

Fig: Induction furnace

Ladle Refining Furnaces (LRF):

In BSRM, Ladle Refining Furnaces are used to

desulfurize steel, remove other impurities and hold the molten steel for casting
operations. Large ladles are used in most metal-melting operations to transfer
molten metal from melting furnaces to refining or pouring stations.

The Ladle Refining Furnace process can be applied once the basic steel has
been produced in the induction furnace. In the LRF method, the steel is then
transferred to the ladle for further refining, such as chemistry adjustment or
inclusion modification. These treatments are carried out in the ladle, which is
provided with a heat source to heat the liquid metal and compensate for thermal
losses.

Benefits of LRF:

• Homogenizing the composition and temperature of the molten steel

• Making the steel cleaner, by the removal of oxygen inclusions
• Improving grain refinement in the microstructure
• Degassing of the steel, through inert gas purging
• Increasing productivity, as the melting furnace gets emptied earlier.

Fig: Ladle Refining Furnaces

Continuous Casting Machine:
A continuous casting machine (CCM) is a crucial
piece of equipment used in the BSRM to transform molten metal into solid
semi-finished products, such as billets in a continuous and efficient manner.
Continuous casting is a widely adopted method for producing high-quality steel
and other metals because it offers several advantages, including improved
product consistency and reduced energy consumption. Here are the key
components and features of a continuous casting machine:

Fig:
Continuous casting. 1: Ladle. 2: Stopper. 3: Tundish. 4: Shroud.
5: Mold. 6: Roll support. 7: Turning zone. 8: Shroud. 9: Bath level. 10:
Meniscus. 11: Withdrawal unit. 12: Slab.
Ladle:
The ladle in CCM is used to hold the molten metal before it is poured
into the tundish. The ladle is a refractory-lined container that can withstand the
high temperatures of molten metal.
Tundish:
Tundish, which is a refractory-lined container that holds the molten
metal. The tundish serves as a buffer between the melting furnace and the
casting machine.
Mold:
The mold is a water-cooled copper or steel structure that shapes the
molten metal into the desired cross-sectional shape of the final product, such as
a rectangular billet or a round bloom.
Secondary Cooling Zone:
After leaving the mold, the partially solidified metal continues to move
through a secondary cooling zone, where it is subjected to controlled water
sprays or other cooling methods.
Withdrawal Unit:
The continuous casting process relies on a withdrawal unit that slowly
pulls the solidifying metal strand downward through the mold and cooling zone.

Fig: Continuous Casting Machine

Water treatment plant:
Water treatment plants are integral components of billet
manufacturing facilities in BSRM to ensure the quality and availability of water
for various processes and cooling systerns. BSRM consumes significant
amounts of water for operational purposes. Proper water treatment is essential to
maintain the efficiency of equipment and prevent corrosion and scaling issues.

Fig: Water treatment plant

Vibrocharger:
A vibrocharger, also known as a vibratory feeder or a vibrofeeder,
is a piece of equipment used in BSRM material handling and feeding processes.

Fig: Vibrocharger
 MANUFACTURING PROCESS

Scrap or raw material collection:

Raw materials are unprocessed natural resources
or basic components used in the production of goods and services across various
industries. These materials are typically transformed through manufacturing or
processing into finished products. The availability and cost of raw materials can
significantly impact industries, economies, and global trade.

Scrap metal is a major raw material for the BSRM industry. The scrap metal
used by BSRM comes from a variety of sources, including:

• Shipbreaking: Bangladesh is a major shipbreaking yard, and BSRM is

one of the largest buyers of scrap metal from shipbreaking yards.
• Construction and demolition: Scrap metal is also generated from
construction and demolition activities.
• Industrial scrap: Scrap metal is also generated from industrial activities,
such as manufacturing and metalworking.
• Household appliances: Scrap metal is also generated from household
appliances, such as refrigerators and washing machines.

The company imports about 1.4 million tons of scrap metal annually, which is
used to produce about 1.2 million tons of steel. BSRM imports scrap metal from
a variety of countries, including India, the largest supplier of scrap metal to
BSRM, China, South Korea, Singapore, Canada etc.

The imported scraps are placed in RM yard (raw material yard or scrap yard)
and after that the scraps undergo processing and further processing.
 Fig: Scrap storage

Scrap processing:

Scrap processing is the collection, sorting, and preparation of

scrap materials for recycling or reuse. It is a crucial step in the recycling
industry and plays a significant role in conserving resources, reducing waste,
and minimizing environmental impact.

Upon arrival at the scrap yard, scrap materials are sorted and separated. This
step involves categorizing the materials by type, such as ferrous (e.g., iron and
steel) and non-ferrous metals (e.g., aluminum, copper), as well as by grade and
quality. This process is known as segregation. By segregation four types of
scrap can be separated.

Shredding Scrap:

Scrap metal shredding is the process of cutting scrap metal into

smaller pieces. This is done to make the scrap metal easier to handle and
process. The scrap metal is then shredded into smaller pieces to make it easier to
handle and process. The shredded scrap is typically reduced to pieces that are no
larger than 10 centimeters in size.
High melting scrap (HMS):

In scrap processing, HMS is typically separated from other types of

scrap metal, such as low melting scrap (LMS), because it requires different
melting conditions. LMS typically melts at a lower temperature and can
contaminate HMS with impurities.

Loose busheling scrap:

Loose busheling scrap is a type of ferrous scrap that is typically made

up of small, irregular pieces of steel. It is called "loose busheling" because it is
not tightly packed together. Loose busheling scrap is often used in the
production of steel because it is relatively inexpensive and easy to handle.

cast steel:

In scrap processing, cast steel is typically separated from other types of

scrap metal, such as wrought steel, because it has different melting and
processing characteristics.

Fig: Processed scrap

Feeding:

The stored scrap is then transported through transfer trolly to vibro-charger or

vibro-feeder and feed into it. Due to their high bulk density, shredded scraps are
first fed into the furnace, followed by scraps charged into the furnace via vibro-
chargers.

Typically, a vibratory feeder feeds a furnace on a trolley that rotates on rails. In

addition to receiving and storing the charge material to be fed into the furnace, it
contains a sturdy hopper.

Fig: Feeding scrap through vibro-charger

Melting:
The melting process in BSRM is a complex and energy-intensive
process. It involves melting scrap steel in an induction furnace. The induction
furnace uses an alternating current to create a magnetic field that heats the scrap
steel.

In BSRM, for each unit, two induction furnaces are used. There are two types
of furnaces: running furnace and alternating furnaces. As the running furnace
melts, an alternating furnace is prepared for further melting.

The temperature of molten steel is typically around 1,500 degrees Celsius. They
use 22 MW power while melting. About 57-ton scrap can be melted in a furnace
and the melting time is 90 minutes.
In this process, Fluxes such as calcium oxide (lime) and calcium fluoride
(fluorspar) are introduced into the furnace to reduce the presence of sulfur and
phosphorus impurities. Excess sulfur can result in a condition called hot
shortness, while phosphorous excess can cause cold shortness, both these
conditions can adversely impact the quality of steel. Additional refinement
process can reduce excess sulfur, but phosphorous can’t be effectively
eliminated.

Fig: scrap melting

Slag off:

During the melting process, impurities in the scrap steel react with the
molten metal to form slag. The slag is typically composed of oxides of iron,
silicon, and manganese.
The amount of slag produced in the steelmaking process depends on the
composition of the scrap steel and the operating conditions of the furnace. The
higher the iron content of the scrap steel, the more slag will be produced. The
higher the temperature of the furnace, the more slag will be produced.

The slag is removed from the molten steel through a process called slagging off.
In BSRM, slag is removed by tilting the furnace.

Tapping of melts:
Tapping of melts in a ladle is a critical step in the steelmaking process
that involves transferring the molten steel from induction furnace into a ladle for
further processing. The tapping process requires careful control to ensure the
quality and safety of the molten steel.

Before tapping, the ladle is prepared to receive the molten steel. This involves
ensuring that the ladle is in the correct position and properly preheated to
prevent the molten steel from solidifying prematurely. The ladle is positioned
under the tap hole or spout of the melting furnace. Proper alignment is crucial to
ensure a smooth and controlled flow of molten steel into the ladle. The tap hole
or spout of the furnace is opened, allowing the steel to flow into the ladle. The
control of the tap hole is essential to regulate the flow rate and prevent splashing
or overflowing. The ladle is lined with refractory materials that can withstand
the high temperatures of the molten steel. This lining helps protect the ladle
from damage and contamination. Molten steel flows from the furnace into the
ladle. The ladle may be filled to its capacity or partially filled, depending on the
intended use and the subsequent processing steps. Depending on the steel grade
and desired composition, alloying elements may be added to the ladle to achieve
the specified chemical properties. These alloying materials can include
ferroalloys like ferromanganese or ferrosilicon. Molten steel is transported to
the LRF (ladle refining furnace) section. To accomplish this, it is often mounted
on ladle car or crane.

BSRM used some tapping parameter such as:

Tap to Tap Time-95 minutes

Power on to Tapping Time-90 minutes

Power off to tap start (tapping time)-5 minutes.

Refining:
A Ladle Refining Furnace (LRF) is a crucial metallurgical equipment
used in BSRM to refine and improve the quality of molten steel produced in
primary steelmaking processes. The primary purpose of an LRF is to perform
secondary steelmaking operations to achieve specific composition and
cleanliness requirements, enhance steel properties, and reduce impurities.

After primary steelmaking in induction furnace, the molten steel is transferred

to the Ladle Refining Furnace. The LRF acts as an intermediate vessel for
holding and processing the steel.

The LRF is equipped with heating elements, typically electric resistance heaters
or gas burners, to maintain and control the temperature of the molten steel.
Temperature adjustments are made as needed to achieve the desired steel
temperature for refining.

The LRF is equipped with stirring mechanisms (typically inert gas injection or
mechanical stirring) to remove excess oxygen and other unwanted gases from
the molten steel. Deoxidation helps prevent defects and ensures steel quality.

Sulphur is a common impurity in steel that can negatively impact its properties.
The LRF often includes processes for desulfurization, such as adding lime-
based fluxes, to reduce sulfur content.

Inclusions, which are non-metallic impurities in steel, can be rem modified in

the LRF to improve steel cleanliness. Slag formed during refining captures
inclusions, which can then be removed from the molten steel.

Mechanical stirring or gas injection helps homogenize the molten steel's

composition and temperature, ensuring uniformity throughout the ladle.

The LRF can also contribute to reducing non-metallic inclusions, improving the
steel's mechanical properties and surface quality.

vacuum degassing systems are integrated into the LRF to remove dissolved
gases, such as hydrogen and nitrogen, from the molten steel.

Alloying elements can be added during the refining process to tailor the steel's
properties for specific applications.

Before refining process, molten metal is tested to find out the composition of
melt have. These chemical additives are added with their requirement.
Silico Manganese: Silico manganese increases the strength, toughness, and
wear resistance of steel, helps to control the shrinkage of molten steel during
casting.

Ferro Silicon: Ferro silicon can refine the grain structure of steel, resulting in
smaller and more uniform grains. Silicon can increase the heat resistance of
steel, making it suitable for high temperature applications.

Calcium Carbide: Calcium carbide reacts with sulfur in molten steel to form
calcium sulfide, which is a gas that bubbles to the surface and is removed from
the steel.

Pet coke or Pure Carbon: Pet coke and pure carbon can improve the
machinability of steel, making it easier to machine and shape, increase the
strength of the steel.

Phosphorous or carbon reduction is not possible in LRF section.

Fig: Refining in Ladle Refining Furnace

Cooling & Finishing:
BSRM uses continuous casting machine for cooling and solidifying refined
melts. continuous casting machine (CCM) is a crucial piece of equipment used
in the steel industry to produce continuous cast steel billets, slabs, blooms, and
other semi- finished steel products. Continuous casting is a modern and highly
efficient method of steelmaking that offers several advantages, including
reduced energy consumption, improved product quality, and increased
productivity.

The molten steel is poured into a refractory-lined intermediate vessel known as

the tundish. The tundish serves as a reservoir, providing a constant flow of
molten steel to the casting mold. It also helps in the removal of impurities and
inclusions.

The tundish directs the molten steel into a water-cooled mold. The mold's shape
and dimensions are designed to produce the desired cross-sectional shape of
billet. As the molten steel enters the mold, it begins to solidify and take on the
shape of the mold.

In order to produce billets, BSRM uses two different cooling process: primary
cooling and secondary cooling system.

First cooling system:

primary cooling system plays a crucial role in the cooling and

solidification of steel products during the continuous casting process. The
primary cooling system is responsible for rapidly reducing the temperature of
the newly cast molten steel as it passes through the continuous casting machine,
allowing it to solidify the outer shell (8mm) of billet.

Secondary cooling system:

The secondary cooling system in BSRM is a system of water sprays that
are used to cool the solidifying steel billet as it exits the continuous casting
machine. The water sprays help to control the cooling rate of the billet and to
prevent defects such as cracks and hot tears.
The secondary cooling system is a critical component of the continuous casting
process. It helps to ensure that the billet is cooled evenly and that it meets the
required quality standards.

The secondary cooling system in BSRM consists of a series of water pipes that
are located above the continuous casting machine. The water pipes are
connected to a pump that circulates water through the system. The water sprays
are located at various points along the length of the water pipes.

The water sprays are activated when the billet exits the continuous casting
machine. The water sprays cool the billet by evaporating. The evaporation of
water absorbs heat from the billet, which helps to cool it down.

The secondary cooling system in BSRM is a complex system that requires

careful control. The water pressure, water flow rate, and water temperature are
all important factors that need to be adjusted to ensure that the billet is cooled
evenly.

Upon solidification, the billet is then cut with an oxide cutter to the desired
length (6m, 8m, or 12m). After removing the mold, the billets are stacked in a
shed and stored.

Fig: Colling and Finishing of billet

 The flow chart of manufacturing process of billet

Imported scraps are placed in RM yard or

scrap yard.

SMS
SECTION Scrap processing through segregation

Charging /feeding

Melting

IF
SECTION
Slag off

Tapping of melt in ladle

LRF
SECTION Refining

Cooling and solidification

CCM
Billet forming
SECTION

Cutting & storage

KYCR Coil Industries Ltd. (unit 2)
 Overview

KYCR Coil Industries Ltd. owns and establishes mills, factories, and
workshops for manufacturing steel products. Its products include cold rolled
full hard coil, cold rolled close annealed coil and sheet, galvanized steel coil
and sheet, and galvanized plain and corrugated sheet. The company markets
its products under Murgi brand. KYCR Coil Industries Ltd. distributes its
products through dealers in Bangladesh and internationally.

The company was incorporated in 1995 and is headquartered in Chittagong,

Bangladesh. KYCR Coil Industries Ltd. operates as a subsidiary of KDS
Group. KYCR Coil Industries Ltd, a leading concern of KDS Steel is a state-
of-the-art Cold Rolling Mills Complex at Kumira, 28km from Chittagong
City.

The plant has been set up as a backward integration effort to provide

necessary raw material for the KDS owns Galvanizing plants and the surplus
to other business and consumer In the Industry. The plant notably is the only
European plan to fit skin din the country, supplied by SMS SEMAG,
Germany, a world leader in this sector. The Complex, which is built on a
10acre site, houses pickling line.6 Hi eve cold rolling Mill Slitting and
rewinding line with an annual capacity of 120.000 MT. Commission in 18
months under direct supervision and technical assistance of SMS SEMAG
Germany, there suites a continuous and efficient supply off wiles quality
product unrivalled by any other in the industry. Thus, enabling us to be the
most reliable supplier of cold rolled sheet in the region. All is catering the
predominantly production quantity of CR to our own Galvanizing unit. Color
Coating Unearned balance for Export in Africa & Southeast Asian market.

History:

KYCR Coil Industries Ltd. is a part of the KDS Group, which has a long
history in the industrial and business landscape of Bangladesh. The KDS
Group was founded and established by Mr. Khalilur Rahman in 1983. Over
the years, the group diversified its business interests into various sectors,
with a significant focus on steel manufacturing and processing.

KYCR Coil Industries Ltd. was established as a subsidiary of the KDS

Group, specializing in the production of steel products. The company has
played a vital role in contributing to the industrial and economic
development of Bangladesh, particularly in the steel sector.
 Product

Galvanized Preprinted Full Hard (GPFH):

Galvanized Preprinted Full Hard is a type of steel that is

coated with a layer of zinc and paint. The zinc provides corrosion resistance,
while the paint provides weather resistance and a smooth finish.

KYCR Coil Industries Ltd. produces GPFH in a variety of thicknesses, widths,

and lengths. The company also offers a variety of colors for the paint finish .

GP (Galvanized Plain):

This is a steel that is coated with a layer of zinc. It is used in

applications where corrosion resistance is required.

Galvalume coated steel:

KYCR Coil Industries Ltd. is a reputable manufacturer of galvalume

products. Galvalume is a type of steel that is coated with a layer of zinc and
aluminum. Zinc provides corrosion resistance, while aluminum provides
weather resistance. Galvalume products can be painted as per the demand.
 Machinery & Equipment

Cold rolling mill:

A cold rolling mill is a specialized machine used in the

manufacturing of rolled steel and metal products. Cold rolling is a process that
refines the thickness, surface finish, and mechanical properties of metal sheets,
coils, or strips, making it a crucial step in producing high-quality steel and metal
products.

Components of a Cold Rolling Mill:

Entry Section: This is where the raw material, typically a coil or sheet of hot-
rolled steel, enters the cold rolling mill. The material is guided through the
mill's various sections.

Rolling Mill Stands: The heart of the cold rolling mill consists of a series of
rolling mill stands. Each stand contains a pair of rolls, often made of hardened
steel or tungsten carbide, that apply pressure to the incoming steel. These rolls
reduce the thickness of the steel as it passes through the mill.

Coolant and Lubrication Systems: Cold rolling generates heat due to the friction
between the rolls and the steel. To prevent excessive heat buildup, coolant and
lubrication systems are employed. These systems help maintain the desired
temperature and provide lubrication to reduce wear on the rolls.

Tension Reels: After passing through the rolling mill stands, the cold-rolled
steel is wound onto tension reels. These reels maintain tension on the steel to
prevent it from loosening during the process.

Coiler and Exit Section: The coiler winds the finished cold-rolled steel into coils
or spools. The exit section may include additional processes such as edge
trimming and inspection.

Cold rolling is a preferred process over hot rolling because it produces a

stronger and more ductile metal product.
 Fig: Cold rolling mill

Galvanizing line:

A galvanizing line, often referred to as a galvanizing plant or

galvanizing facility, is an industrial setup used for the process of
galvanization. The galvanizing line typically consists of the following
components:

• Degreasing tank: This tank removes any dirt, oil, or grease from the steel
surface.
• Pickling tank: This tank uses an acid solution to remove any rust or scale
from the steel surface.
• Zinc bath: This tank contains molten zinc that coats the steel surface.
• Drying oven: This oven dries the coated steel surface.
• Coiling machine: This machine coils the finished galvanized steel.

Galvanizing lines are crucial for producing high-quality galvanized steel

products that protect against rust and corrosion, extending the lifespan of steel
components and structures.

The galvanizing line is a highly efficient process that can coat a large amount of
steel in a short period of time.
 Fig: Galvanizing line

Continuous coil coating line

Continuous coil coating line, also known as a coil coating plant

or coil coating system, is an industrial process used to apply a protective and
decorative coating to metal coils, primarily steel and aluminum. The coating
is applied evenly to the entire surface of the coil, and the process is continuous,
which means that the coil is constantly moving through the system. The
continuous coil coating line typically consists of the following components:

• Coil feeder: This feeds the coil into the system.

• Pretreatment section: This section removes any dirt, oil, or grease from
the surface of the coil.
• Coating section: This section applies the coating to the coil.
• Drying section: This section dries the coating.
• Coil winder: This winds the coated coil.
 Fig: Continuous coil coating line

Galvanizing bath:

The galvanizing bath in KYCR Coil Industries Ltd. is a bath of

molten zinc that is used to coat steel coils with a layer of zinc. The zinc bath is a
critical component of the galvanizing process, and it is important that the zinc
bath is properly maintained to ensure that the galvanized coils meet the required
quality standards.

The galvanizing bath in KYCR Coil Industries Ltd. is a large, rectangular tank
that is filled with molten zinc. The temperature of the zinc bath is maintained at
around 450 °C (842 °F). The steel coils are passed through the zinc bath, and
the zinc coating is applied evenly to the surface of the coils.

The zinc bath in KYCR Coil Industries Ltd. is constantly monitored to ensure
that the temperature and the composition of the zinc bath are within the required
limits. The zinc bath is also cleaned regularly to remove any impurities that
could affect the quality of the galvanized coils.

The galvanizing bath in KYCR Coil Industries Ltd. is a critical component of

the galvanizing process, and it is important that the zinc bath is properly
maintained to ensure that the galvanized coils meet the required quality
standards.
 Fig: Galvanizing bath

Annealing furnace:

Annealing furnace in KYCR Coil Industries Ltd. is a large, rectangular chamber

that is lined with refractory bricks. The furnace is heated by gas or oil burners,
and the temperature is controlled by a thermostat. The steel coils are placed in
the furnace and heated to a specific temperature, typically between 600 and 900
degrees Celsius (1112- and 1652-degrees Fahrenheit). The steel coils are then
cooled slowly in the furnace, typically over a period of several hours.
 MANUFACTURING PROCESS

➢ Raw materials:

KYCR Coil Industries Ltd. imports Raw materials (hot rolled coil)
with the thickness of 2 mm and width 925 mm from countries like Japan, China.
In unit 1, hot rolled steel is transformed into cold rolled steel, then transferred to
unit 2. KYCR Coil Industries Ltd. (unit 2) uses cold rolling as the raw material,
followed by coating.

➢ Entry section:
The imported hot rolled coil is cleaned by pickling process in a
certain section called alkali section. The pickling process is a chemical
treatment used in KYCR Coil Industries Ltd to remove impurities, scales,
rust, and oxides from the surface of metal products, typically steel or iron .
The pickling process is carried out in a bath of acid, typically hydrochloric acid.
The coil is then fed into a cold rolling mill. Cold rolling mill reduces the
thickness of a metal sheet by passing it through a series of rollers. The rollers
are progressively smaller, so the sheet is forced to decrease in thickness as it
passes through them. cold rolling mill reduces the coil thickness from 2 mm to
required thickness (0.17 mm, 0.2 mm, 0.3 mm) as per market demand whereas
the width remains same (925 mm). This type of coil is known as cold rolled
coil. This cold rolled coil is then introduced into annealing furnace. In KYCR
Coil Industries Ltd annealing furnace is about 46m long. Annealing furnace
heats cold rolled coils to a specific temperature and then cools them slowly to
relieve stresses and improve the ductility and machinability of the steel.

➢ Coating:

The coating process in KYCR Coil Industries Ltd. is a continuous

process that is used to apply a layer of coating to steel coils. The heated coils are
transferred to the zinc bath. Zinc bath varies depending on whether
“Galvanizing” or “Galvalume” coat is desired. The temperature of zinc bath for
both the galvanizing and galvalume is 600 degrees Celsius. In the laboratory, the
composition of the sample in the bath is carefully checked. The composition of
the sheet determines the grade of the sheet.
Galvanized steel:

The main ingredient of galvanized steel is zinc. This type of steel

contains 99% zinc and other elements like Fe, Ni etc.

Galvalume coat steel:

Galvalume steel is a type of galvanized steel that is made with an

alloy of aluminum and zinc. It contains 55% Aluminum, 43.6% zinc, 1.4%
silicon.

➢ Cooling:

The cooling process in KYCR Coil Industries Ltd. is a critical step. The
molten zinc coating is applied to the steel coils at a high temperature, and it is
important to cool the coils quickly to prevent the zinc from forming cracks or
blisters. The coated coil is air cooled by blower. A blower is a device that uses a
fan to move air. Then The coils are passed through a water bath to cool them
down quickly.

➢ Chemical coating:

Chemical coating in KYCR Coil Industries Ltd. is a process that uses

chemicals to apply a protective coating to steel coils. In KYCR Coil Industries
Ltd. two types of coating can be used: chromic acid coating and acrylic acid
coating. These processes are used to increase the lifespan of the product.

Chromic acid coatings are typically composed of hexavalent chromium

compounds, such as chromic acid (CrO3), and may also include other
chemicals, such as phosphates or fluorides, to achieve specific performance
characteristics. The exact composition may vary depending on the specific
application and regulatory requirements. If the coils are coated with chromic
acid, then color coating is required. The coil is then dried to remove any
remaining moisture and ensure the chromate coating adheres properly.

Acrylic acid coating is also a type of chemical coating that is used in KYCR
Coil Industries Ltd. It is a clear, colorless liquid that is applied to the steel coils
to provide corrosion resistance, improved appearance, and enhanced durability.
The coil is then dried after acrylic acid coating to remove any remaining
moisture and ensure the chromate coating adheres properly.
 ➢ Finishing:

After chemical coating, the company logo is printed on the product and the
product is recoiled in the coiler machine.

After this the coil is corrugated. This process involves passing the steel sheet
through a series of rollers. The rollers are shaped to create the desired pattern of
ridges and troughs. The number of ridges and the depth of the troughs will vary
depending on the desired properties of the finished product.

Flow chart of manufacturing process:

STORAGE OF RAW
MATERIALS

ENTRY SECTION

COATING

COOLING

CHEMICAL
COATING

FINISHING

CORRUGATING
 Conclusion

A visit to the BSRM (Bangladesh Steel Re-Rolling Mills Ltd.) and KYCR
(KYCR Coil Industries Ltd.) coil industries offers valuable insights into the
dynamic world of steel production and coil manufacturing. These companies
play pivotal roles in Bangladesh's steel industry, contributing significantly to
economic growth and infrastructure development.

During our visit, we had the opportunity to witness the entire steel production
process, from raw materials to finished products. We learned about the
importance of scrap processing. the efficiency of induction furnaces, the
precision of continuous casting machines, and the significance of water
treatment plants in maintaining environmental standards. The vibratory charging
system, employed to optimize furnace performance, and the slag off operation
to remove impurities showcased the commitment to innovation and quality.

Furthermore, our exploration of galvalume products, cold rolling mills, and the
application of various chemical coatings underscored the versatility and
adaptability of the steel industry to meet diverse customer needs. The emphasis
on environmental sustainability through efficient operations, waste reduction,
and recycling practices left a profound impact on our understanding of
responsible manufacturing.

In addition to technological advancements, both BSRM and KYCR prioritize

safety and employee well-being, ensuring a conducive work environment for
their skilled workforce. The tours highlighted the importance of industry-
academia collaborations, research, and development to foster innovation and
stay competitive in the global steel market.

Overall, the visits to BSRM and KYCR Coil Industries Ltd. served as a
compelling educational experience, shedding light on the complex processes,
innovations, and dedication that go into producing high-quality steel and coil
products. It was a testament to the resilience and Vision of these companies in
the ever-evolving steel industry, contributing to the nation's progress and
prosperity.