Final Report On Hot Rolled Coils.

GALVALUME ISPAT INDUSTRIES LIMITED
INTRODUCTION
HOT ROLL COILS
Hot rolling is a metalworking process that occurs above the recrystallization temperature
of the material. After the grains deform during processing, they recrystallize, which
maintains an equated microstructure and preventing the metal from work hardening.
The starting material is usually large pieces of metal, like semi-finished casting
products, such as slabs, blooms, and billets. If these products came from a continuous
casting operation the products are usually fed directly into the rolling mills at the proper
temperature. In smaller operations the material starts are room temperature and must
be heated. This is done in a gas- or oil-fired soaking pit for larger work pieces and for
smaller work pieces induction heating is used. As the material is worked the
temperature must be monitored to make sure it remains above the recrystallization
temperature. To maintain a safety factor a finishing temperature is defined above the
recrystallization temperature; this is usually 50 to 100 °C (122 to 212 °F) above the
recrystallization temperature. If the temperature does drop below this temperature the
material must be re-heated before more hot rolling.
Hot rolled metals generally have little directionality in their mechanical properties and
deformation induced residual stresses. However, in certain instances non-metallic
inclusions will impart some directionality and work pieces less than 20 mm (0.79 in)
thick often have some directional properties. Also, non-uniformed cooling will induce a
lot of residual stresses, which usually occurs in shapes that have a non-uniform cross-
section, such as I-beams and H-beams. While the finished product is of good quality,
the surface is covered in mill scale, which is an oxide that forms at high-temperatures. It
is usually removed via pickling or the smooth clean surface process, which reveals a
smooth surface
51
MAJOR COMPANIES WHO SUPPLY HR
 ISPAT INDUSTRIES LIMITED

 JSW
 ESSAR
ISPAT INDUSTRIES LIMITED
Ispat Industries Limited manufactures international standard hot rolled (HR) coils at its
Hot Strip Mill (HSM), situated at Dolvi in the state of Maharashtra, India. The production
of these coils involves the use of state-of-the-art equipment and manufacturing
processes that ensure products of the highest quality.
Ispat's HSM uses a combination of the advanced Conarc Process and Thin Slab
Casting technology, which facilitates the rolling of coils that are as thin as 1.2 mm with a
width of 1250 mm. These are superior to commercial grade cold rolled (CR) coils, and
are quite often a substitute for CR products in certain applications, due to their thinner
gauges and finer surface quality.
APPLICATIONS
Ispat's HR coils are used in the most critical engineering applications and also in certain
applications in the automotive sector. In addition, some of the value-added HR coil
products include steel for LPG cylinders, API grade, corrosion resistant steel, critical
structural application steel, boiler quality, auto grades, precision tubes and medium/high
carbon grades, among others.
52
UNIQUE FEATURES OF ISPAT'S HR COILS
 Superb surface quality

 Superior width to thickness ratio
 Ease in cold rolling
 Accurate coil geometry
 Thickness tolerance
53
JSW
Vijaynagar Works
Vijaynagar works was the first Greenfield project in

world to use Corex technology to produce steel. On
February 18,2009 India largest Blast Furnace of
2.8MT capacity was commissioned here. With this
commissioning, JSW Steel become the largest
private sector steel producer in India with 7.8MT capacity. It is also in the advance stage
of setting up of 5MTPA state of the act Hot Strip Mill which will be commissioned in the
second half of fiscal 2009-10. The next phase of expansion taking the total production to
10mtpa plant at Vijaynagar Works is also under implementation. It will be commissioned
in fiscal 2010-11. This makes it among the fastest growing steel plant in the world.
It's eco-friendly approach has also led to the development of Vijaynagar into a modern
township. Enveloped by acres of greenery and maintained by JSW, Vijaynagar is
prospering by leaps and bounds. Be it education, career opportunity or women
empowerment, the Company's initiative has gone a long way in making Vijaynagar the
success that it is today.
54
ESSAR STEEL
Hazira Facility
Their steel complex at Hazira, Gujarat, houses a 5.0 MTPA sponge iron plant, the
world's largest gas-based HBI producer. The plant provides raw materials for our state-
of-the-art 4.6 MTPA hot rolled coil (HRC) plant, the first and largest of India's new
generation steel mills. This plant is fed with inputs from three electric arc furnaces and
three casters. The complex's sophisticated infrastructure includes independent water
supply and power, oxygen and lime plants, a township and a captive port capable of
handling up to 8 MTPA of cargo with modern handling equipment like barges and
floating cranes.
55
PRODUCTION PROCESS
Process Flow Diagram for HR Black to HR Pickled:

diagram 1
Hot Rolled
Slitting Shearing Pickling Strapping
Black Strips Oiling Dispatch
Process Process Process / Packing
/ Coils
Process Flow Chart for CR Coil to CR CTL:

diagram 2
Cold Rolled Strips / Slitting Shearing Strapping /
Dispatch
Coils Process Process Packing
HR Processing
In accordance with the Material Flow, the hot roll coils in HR Slitting Line to the required
Length and further certain Coils are pickled in hydrochloric acid medium by Push –
Pickling process to remove the scales from the hot rolled coils. The pickled coils are
then further slit to the requirement. The Slit Coils are further processed in HR Cut to
Length Line as per requirement. The cut Lengths are packed and dispatched.
56
FORMS OF STEEL SUPPLIED IN THE MARKET
 Coil
 Plates
 Sheets
 Pickling
1. Coil Form
The steel produced in the company is always in the form of coil. Which can be always
processed further according to the requirement of the Dealer, Retailer and End User.
42,200 Tons per month is supplied in the region of Maharashtra. That is 48% from all
the form.
2. Plates
Steel produced in the factory are in the form of Coils but the requirements are not
always the same so the Coil are cut down into pieces according to the desired width
and Thickness to make it Plates. And they are cut down into plates so that they can use
it in the desired industry. 6,100 tons per month is supplied in the region of Maharashtra.
That is 7% from all the form
57
3. Sheets
Steel produced in the factory are in the form of Coils but the requirements are not
always the same so the Coil are cut down into pieces according to the desired width
and Thickness to make it sheets. . And they are cut down into Sheets so that they can
use it in the desired industry. 38,950 tons per month is supplied in the region of
Maharashtra. That is 44% from all the form.
4. Pickling
Many hot working processes and other processes that occur at high temperatures leave
a discoloring oxide layer or scale on the surface. In order to remove the scale the work
piece is dipped into a vat of pickle liquor. The primary acid used is hydrochloric acid,
although sulfuric acid was previously more common. Hydrochloric acid is more
expensive than sulfuric acid, but it pickles much faster while minimizing base metal loss.
1,400 tons per month is supplied in the region of Maharashtra. That is 1% from all the
form.
58
COILS USED FOR
 Transport Industry
 Welded Steel Tubes and Pipes
 Cold - Rolling and Drawing
 Line Pipe
 Corrosion Resistance
 Boiler Quality Plates
 Tin Mill Black Plate
 Pressure Vessels
Benefits
 Pickling and oiling improves hot-rolled durability and workability at a low cost
 A cleaner surface hot rolled product suitable for painting
 Barrier to rust formation
PLATES USED FOR
 Boiler & Pressure Vessels

 Ship Building
 Railways
 Heat Exchangers
 Oil & Petrochemicals
 Marine Containers
 Oil & Petrochemicals
 Coal & Mining
 General & Heavy Engineering
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SHEETS USED FOR
 LPG Cylinder Fabricators

 Railways
 Automobiles
 Marine Freight Containers

 General and Heavy Engineering
OBJECTIVE OF THE PROJECT:
To study the Distribution Channel used by the Competitors for their Hot Rolled Coils in
the Region of Maharashtra.
60
DATA RELATED TO THE SAMPLE SURVEY
SAMPLE SIZE
Dealers End User
Krishna Sheet Processors Pvt.Ltd Gange Pressings Ltd

Anmol Steel Processors Pvt Ltd Auto Line Press Component
Delta Iron & Steel Co. Pvt. Ltd Panse Auto Pvt Ltd
Akshanta Mercantile Pvt Ltd Carline Pressings Pvt Ltd
Rohit & Company Press Tools
Param Shakti Steel Pvt Ltd Pressisions Pressons
Ratnesh Enterprice
Prestech Steels
RETAILERS
Trimurti Steel Pvt ltd
Azincya Electrical Pvt Ltd
1. Essar Steel
Shreeji Steels
2. Ispat Industries Limited
Bharat Iron Syndicate
3. JSW
D. Pratap
Ashvi Trading Company
Chagan Mohan & Company
61
DISTRIBUTION CHANNEL
As we can see the Distribution Channel we can find out that the Hot Rolled Coils are
manufactured and then send to the Stock Yard and from the Stock Yard and from
Stock Yard to the Traders. The Hot Rolled Coils are also send to the Traders. As we
can also see that the Traders receive the goods through Steel Service Center where
the goods are future processed according to the trader requirements. Another process
is where goods from Plant are send to the Steel Service Center and from there to the
Retail outlet and from the Retail Outlet to the Retail Customer (End User). Goods are
also send to the Retail outlets directly. These all transactions are done through the use
of trucks.
62
DISTRIBUTION MODELS:
Model 1
PLANT TRADERS
 In model 1 we can see that the goods manufactured in the plants are directly
transported to the traders.
Model 2
PLANT RETAIL
transported to the Steel Retail Shops.
Model 3
PLANT END USER
transported to the End User for direct uses.
63
Model 4
PLANT STOCK YARD TRADERS
 In model 4 we can see that the goods manufactured in the plants are send to
the Stock Yards where the goods are stocked and according to the
requirements of the traders goods are released at their warehouse.
Model 5
TRADERS
PLANT STEEL SERVICE CENTER
END USER
the Steel Service Center. The role of SSC is that the goods are manufactured
in coil form and if the Traders or End User wants in some other form like
Sheets, Plates, and Pickling etc. All these processes are done here and then
send to the Traders and End User according to the requirements.
Model 6
PLANT STEEL SERVICE CENTER RETAIL END USER
SSE and from there it is processed in the required form and supplied to the
Retail Outlets according to their requirements and then the Retail Outlets sells it
to the End User .
64
Model 7
PLANT RETAIL END USER
 In the model 7 we can see that the goods manufactured in the plants are
directly send to the Retail Outlets as this is the new concept in the Steel
Industry to supply directly to the Retail Outlets. Retail outlets are a concept
where the companies are trying to use the Just in Time concept where the End
User gets the goods in great speed. Retail outlets provide End User better
Associability.
65
Supply Chain Management
As we can see that the goods move in a systematic manner. Supply Chain means
supply from the Raw Material to the End User. Supply Chain reduces the unnecessary
handling cost, inventory cost and carrying cost of the goods. We can see that the goods
flow on the following manner:
66
QUANTITY SUPLLIED IN TONS BY THE SAMPLE & IN WHICH FORM & QUANTITY
67
68
69
TOTAL QUANTITY SUPPLIED IN TONS PER MONTH IN WHICH FORM &

QUANTITY
Sheets Plates Pickled Coil

Quantity Supplied in tons/ per month 38950 6100 1400 42200
70
THIKNESS IN WHICH IT IS SUPPLIED TO DIFFERENT SECTORS
Auto(min) Auto(max) Machinery(min) Machinery (Max) Project & Construction (Min) Project & Construction (Max)
Thikness(mm)
Customer
Krishna Sheet Processors Pvt.Ltd 1.6 5 1.6 5
Anmol Steel Processors Pvt Ltd 1.6 20
Essar steel (Retail) 1.6 5 1.6 5
Ispat ( joint Service center) 1.6 10 10 12 10 16
JSW (Retail) 1.6 3 2 3
Delta Iron & Steel Co. Pvt. Ltd 1.6 3 5 12
Akshanta Mercantile Pvt Ltd 1.6 4 1.6 2
Rohit & Company 1.6 4
Param Shakti Steel Pvt Ltd 1.6 5 1.6 2
Ratnesh Enterprice 1.6 4
Prestech Steels 1.6 12 1.6 2
Trimurti Steel Pvt ltd 1.6 4
Azincya Electrical Pvt Ltd 1 20
Shreeji Steels 1 20
Bharat Iron Syndicate 1.6 3
D. Pratap 1.6 3 5 12
Ashvi Trading Company 1.6 5
Chagan Mohan & Company 1.6 3
71
WIDTH IN WHICH IT IS SUPPLIED TO DIFFERENT SECTORS
Auto(min) Auto(max) Machinery(min) Machinery (Max) Project & Construction (Min) Project & Construction (Max)
Width(mm)
Customer
Krishna Sheet Processors Pvt.Ltd 1000 1550 1000 1550
Anmol Steel Processors Pvt Ltd 1000 1550
Essar steel (Retail) 900 1550 1500 1850
Ispat ( joint Service center) 1250 1550 1250 1550 1250 1550
JSW (Retail) 800 1250 800 1250
Delta Iron & Steel Co. Pvt. Ltd 1250 1800 1200 1800
Akshanta Mercantile Pvt Ltd 1250 1500 1250 1550
Rohit & Company 1250 1500
Param Shakti Steel Pvt Ltd 1250 1500
Ratnesh Enterprice 1250 1500 1250 1500
Prestech Steels 1250 1500
Trimurti Steel Pvt ltd 1250 1500 1250 1500
Azincya Electrical Pvt Ltd 1000 1500
Shreeji Steels 1250 1500
Bharat Iron Syndicate 1250 1800
D. Pratap 1250 1800
Ashvi Trading Company 900 1550
Chagan Mohan & Company 1250 1500
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WELCOME TO A WHOLE NEW WAY OF BUYING STEEL.
RETAIL OUTLETS
 ISPAT INDUSTRIES LIMITED
 ESSAR
 JSW
MODELS USED FOR RETAIL OUTLETS BY THE COMPANIES ARE:
Model 2
PLANT RETAIL
Model 6
PLANT STEEL SERVICE CENTER RETAIL END USER
Model 7
PLANT RETAIL END USER
73
ESSAR HYPER MART & EXPRESS MART
Essar Steel Hyper Mart
Retail business is changing the paradigm of purchase across the world. Essar Steel, the
flagship company of Essar Group, has always been a pioneer in providing innovative
solutions to serve customers better. Essar Steel hyper mart is one such step in this
direction.
India. Essar Steel hyper mart is a strong network of over 65 hyper marts and 15 express
marts.
We have a strong workforce of over 230 employees—across the country—who are

committed to meeting the requirements of small manufacturers, local fabricators and
engineering and construction companies who today buy steel from local intermediaries
or traders.
74
At Essar Steelhypermart you can choose from a comprehensive range of flat steel
products for variety of applications.
The five Value propositions of Essar Steelhypermart are:
1. Trust of Essar Quality

2. Immediate Delivery
3. Transparent Pricing
4. Easy Contact ability
5. Pan-India presence
Welcome to a whole new way of buying steel.
75
JSW SHOPEE
JSW ON RETAIL
In an endeavor to expand retail base and ensure the easy available of quality and
branded steel in all its market, JSW Steel plans to setup 200 exclusive JSW Shoppes
across the length and breadth of the country by 2010. It has launched JSW Shoppe at
Hubli and Jaipur.
Mr. Sajjan Jindal, vice chairman and managing director, JSW steel has inaugurated two
exclusive JSW Shoppe in Hubli, Karnataka on December 4, 2007 and target is to open
several more Shoppe in India.
The concept originated from the fact that the company wants the end consumer to get
the right quality of product at competitive prices at the right place. It will help in building
trust with the end user and provide them steel at their door-step.
76
All technical specification and details on manufacturing ranges are available in JSW
Shoppe. Information of all types of JSW steel product, ranging from HR coils to Color
Coated Steel and Long Products would help in enhancing the awareness on wide usage
of steel among cross section of society & industries.
At JSW Shoppe, end consumer will also know about different application of different
steel products being manufactured by M/s JSW Steel through actual components and
pictures from Automobile, White Goods Sectors, and Construction.
NUMBER OF SHOPPES
State No. Of Shoppes

AP 2
Assam 1
Goa 1
Gujarat 2
Haryana 4
Karnataka 8
Kerela 1
Maharashtra 8
MP 1
Orissa 1
Punjab 2
Rajasthan 2
TN 6
UP 7
WB 4
77
ISPAT INDUSTRIES LIMITED
ISPAT ON RETAIL
Ispat is also into the Retail Selling Concept to face the competition company has
decided to have 100 Retail outlets by the end of 2010. They have their retail outlets in
the Brand name of ―ISPAT CHOWK‖
78
QUANTITY SUPPLIED BY EACH COMPANY TO THEIR RESPECTIVE RETAIL

OUTLET
Retail Sector (tons per month) JSW ESSAR ISPAT

Sheets 400 1000 2500
Plate 400 1000
Coil 2000 1250
Pickled 200 1250
79
QUANTITY SUPPLIED BY EACH COMPANY TO THEIR RESPECTIVE RETAIL

OUTLETS IN MAHARASHTRA
 ISPAT INDUSTRIES LIMITEED 4 OUTLETS
 ESSAR STEEL 6 OUTLETS
 JSW 8 OUTLETS
Retail within Maharashtra (tons per month) JSW ESSAR ISPAT

Sheets 3200 6000 10000
Plate 3200 6000
Coil 12000 5000
Pickled 1600 5000
80
FUTURE IN RETAIL BY THE END OF 2010
 ISPAT INDUSTRIES LIMITEED 100 OUTLETS
 ESSAR STEEL 300 OUTLETS
 JSW 200 OUTLETS
QUANTITY REQUIRED BY THE END OF 2010 BY EACH COMPANY TO MEET THE

DEMAND
Retail Sector by end of 2010 (tons per month) JSW ESSAR ISPAT
Sheets 80000 300000 250000
Plate 80000 300000
Coil 600000 125000
Pickled 40000 125000
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Recommendation
Hot rolled coils are the oldest product in the steel market. So the steel was
supplied the traditional way.
Now companies have realized that to survive in the Competition they have to
follow the new concepts of Just in Time, Kanban Kaizan & Total Quality
Management.
Companies can only make good profits that have a shorter and faster Distribution
Channels.
Customers need the product in the shorter period and at a greater quality.
Companies are now entered the Retail business of selling steel which was one of
the greatest moves in the steel sector.
The future of steel really lies in the proper management and planning of the each
Retail outlet which will enhance the distribution channel.
Ispat Industries Limited should concentrate on Thickness of 1.6 mm to
5mm for the Automobile Sector.
Ispat Industries Limited should concentrate on Width of 1000mm to
1550mm for the Automobile Sector.
Ispat Industries Limited should concentrate on Thickness of 1.6mm to
12mm and Width of 1000mm to 1850mm for Machinery Sector.
Conclusion
Steel sector was seen as the Production and Selling era where companies produced
and transported their goods as required by Customers. But now the time has changed
and companies have realized that to beat the competition companies have to supply the
goods Just in Time. So the steel sector is experiencing the whole new concept of setting
up Retail Outlets and selling the products and reaching the Customer rather then
Customers reaching them.
82
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GALVALUME ISPAT INDUSTRIES LIMITED

HOT ROLL COILS

MAJOR COMPANIES WHO SUPPLY HR

 ISPAT INDUSTRIES LIMITED

ISPAT INDUSTRIES LIMITED

UNIQUE FEATURES OF ISPAT'S HR COILS

 Superb surface quality

Vijaynagar works was the first Greenfield project in

Process Flow Diagram for HR Black to HR Pickled:

Process Flow Chart for CR Coil to CR CTL:

FORMS OF STEEL SUPPLIED IN THE MARKET

COILS USED FOR

 A cleaner surface hot rolled product suitable for painting

 Barrier to rust formation

PLATES USED FOR

 Boiler & Pressure Vessels

 General & Heavy Engineering

SHEETS USED FOR

 LPG Cylinder Fabricators

 Marine Freight Containers

OBJECTIVE OF THE PROJECT:

DATA RELATED TO THE SAMPLE SURVEY

Dealers End User

Krishna Sheet Processors Pvt.Ltd Gange Pressings Ltd

PLANT END USER

PLANT STOCK YARD TRADERS

PLANT STEEL SERVICE CENTER RETAIL END USER

PLANT RETAIL END USER

Supply Chain Management

TOTAL QUANTITY SUPPLIED IN TONS PER MONTH IN WHICH FORM &

Sheets Plates Pickled Coil

THIKNESS IN WHICH IT IS SUPPLIED TO DIFFERENT SECTORS

WIDTH IN WHICH IT IS SUPPLIED TO DIFFERENT SECTORS

WELCOME TO A WHOLE NEW WAY OF BUYING STEEL.

 ISPAT INDUSTRIES LIMITED

MODELS USED FOR RETAIL OUTLETS BY THE COMPANIES ARE:

PLANT STEEL SERVICE CENTER RETAIL END USER

PLANT RETAIL END USER

ESSAR HYPER MART & EXPRESS MART

Essar Steel Hyper Mart

We have a strong workforce of over 230 employees—across the country—who are

The five Value propositions of Essar Steelhypermart are:

1. Trust of Essar Quality

Welcome to a whole new way of buying steel.

State No. Of Shoppes

ISPAT INDUSTRIES LIMITED

QUANTITY SUPPLIED BY EACH COMPANY TO THEIR RESPECTIVE RETAIL

Retail Sector (tons per month) JSW ESSAR ISPAT

QUANTITY SUPPLIED BY EACH COMPANY TO THEIR RESPECTIVE RETAIL

 ISPAT INDUSTRIES LIMITEED 4 OUTLETS

 ESSAR STEEL 6 OUTLETS

Retail within Maharashtra (tons per month) JSW ESSAR ISPAT

FUTURE IN RETAIL BY THE END OF 2010

 ISPAT INDUSTRIES LIMITEED 100 OUTLETS

 ESSAR STEEL 300 OUTLETS

 JSW 200 OUTLETS

QUANTITY REQUIRED BY THE END OF 2010 BY EACH COMPANY TO MEET THE

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