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Displaying the prowess of our solutions capability in a true blue steel plant

Read about how we helped one of India’s leading steel makers integrate handling in their entire plant. Our solution included two unique designs for cranes with rotating trolleys, to suit different applications.

Read about how we helped one of India’s leading steel makers integrate handling in their entire plant. Our solution included two unique designs for cranes with rotating trolleys, to suit different applications.

background-logoBACKGROUND

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About BMM Ispat Ltd.

BMM Ispat Ltd. is an INR 2000 crore (USD 330 million) company. Their plant at Danapur, Hospet, Karnataka is a true blue steel plant manufacturing high quality steel products. As a part of a new brownfield project, the company is expanding its capacity from 0.8MTPA to 1.25MTPA. This facility is being constructed to expand the product range and will include a semi-automatic process for enhanced productivity.

challenge-logoCHALLENGES

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The handling challenges at BMM Ispat Ltd.

Steel Melting Shop (SMS)

In the SMS, raw material is melted to form billets of desired shape and size. Ladles are used to handle the metal in molten form. The formed billets are to be rotated by 900 and transferred on to idle rollers to take them to one of two different storage locations.

Furnace and rolling mills

The process involves handling of metal billets that are 12m in length on average, over a 200m long bay. The process is initiated by passing the billets from the furnace on to idle rollers installed beside it. Preheated billets are then passed through various horizontal and vertical rolling mills to give them the desired shape. Cranes in this area are also required to frequently change the dies of the presses to suit the product being rolled, which include rolled angles, TMT bars, metal rods and I-beams.

Quenching and cooling

Here, the products are rapidly cooled, which produces a harder material and prevents low temperature processes such as phase transformation in the material. The products are further cooled and then sent for the final finishing process.

Despatch area

The despatch yard is spread over a 380m long and 50m wide area. This consists of parking bays for trucks and a railway track for loading on railway carriages. Long rods and beams are required to be handled and stored in the despatch area. Cranes with rotating crabs are used to control the angle of long metal bars and other similar components in the despatch bay.

solution-logoSolutions

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Solutions from ElectroMech.

ElectroMech responded to BMM Ispat's challenge with some unique ideas. Detailed analysis, design and iterations resulted in an integrated solution that achieves the intended tasks swiftly and in the most optimum manner.

A total of 13 cranes were designed to handle the material through various processes, right from the steel melting shop to the placement of bars and rods on railway carriages.

Steel Melting Shop (SMS)

In the SMS where billets are formed, a total of 4 cranes with rotating trolleys assist in the manufacturing and storage of the billets. Two 20MT, 32.8m span and two 20MT, 27.2m span cranes with rotating crabs cover the manufacturing and storage of the billets before they are sent for further processing. Since these cranes are part of a process and in constant use, they are designed for M8 duty.

The ambient temperature in the steel melting shop is approximately 60 0C, requiring all the components of the crane to be able to withstand such high temperatures. Hence, a slewing wheel on curved rail type of arrangement was selected to be able to work in this area. An air conditioned cabin is also provided for the operator.

Furnace

The furnace is served by a 10MT crane with 22m span, which also has a rigorous initial application of installing the furnace and rollers. Once the installation of the furnace is completed, the crane will be used for replacing the rollers and for regular maintenance applications.

Rolling mills

Two Double Girder cranes serve this area; one 25/5MT, 28m span and one 20/5MT, 34m span. Since the dies have to be changed depending on the product to be manufactured, the 25/5MT crane is in constant use. All these cranes are designed for M7 duty.

Quenching and cooling

The material to be handled in this stage is in the form of bundles. Here, two 15MT, 28m span, M7 duty, Double Girder cranes are installed to handle the material being processed in this bay. These cranes will also assist in the installation of the machinery during plant set up stage.

Despatch

The despatch bay is served by by three 12.5MT, 34m span, M7 duty cranes. Like the steel melting shop cranes, these cranes also have 3600 rotating crabs; however, the mechanism used here is a slewing bearing. This mechanism was narrowed down upon after many discussions between ElectroMech's design team and the BMM team.

Rotating solutions

Two types of rotating mechanisms were finalised - one operating with the help of gears and a slewing bearing, the other, using curved rails and wheels. The slewing bearing arrangement was selected for the despatch area since the cranes will be used for continuous operations and hence the maintenance had to be kept to the lowest possible.

The cranes in the Steel Melting Shop need to operate continuously as part of a process at an ambient temperature 0 of 60 C, requiring easy accessibility and simple mechanisms. Hence the wheel on curved rail type of arrangement was selected for this area.

background-logoSYNOPSIS

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Challenges

  • Challenging environment with dust and high ambient temperatures of 60° C
  • High duty classification
  • Complex processes to be integrated
  • Achieve easy handling in a constrained space
  • Allow continuous and rigorous operation

Solutions

  • Customised cranes with 360° rotation mechanisms
    - Rotating trolley with slewing bearings
    - Rotating trolley with slewing wheels
  • Cranes built with highly reliable components which allow continuous operation, easy accessibility, reduce downtime and lower maintenance costs.

Total number of cranes: 13

SWL (DG EOT)SpanHeight of liftClass of dutyApplication
12.5MT (360 rotating crab)34m12mM7Despatch Bay
12.5MT (360 rotating crab)34m12mM7Despatch Bay
12.5MT (360 rotating crab)34m12mM7Despatch Bay
25/5MT28m16.5mM7Mill Bay(Rolling Mill)
20/5MT34m1.5mM7Mill Bay(Rolling Mill)
15MT28m16.5mM7Mill Bay (Quenching and Cooling)
15MT28m16.5mM7Mill Bay (Quenching and Cooling)
10MT22.4m16.5mM8Furnace
20MT (360 rotating crab)32.8m11.5mM8SMS area(Billet storage bay)
20MT (360 rotating crab)32.8m11.5mM8SMS area(Billet storage bay)
20MT (360 rotating crab)27.2m11.5mM8SMS area(Billet storage bay)
20MT (360 rotating crab)27.2m11.5mM7SMS area(Billet storage bay)
25/5MT (3600 rotating crab)18m11.5mOxygen Plant

Benefits

How BMM Ispat benefitted from ElectroMech solution

  • Total integration of handling in the plant helped in increasing throughput and enhancing plant efficiency
  • Rotating mechanism of the crane in the despatch bay allows easy loading in a constrained space
  • Light weight cranes allow lighter structure for factory shed which helps in reducing the overall project cost
  • Highly efficient and reliable cranes mean minimal maintenance and no down time
  • Completely indigenous design rigorously tested at the factory ensured reliability and yet could achieve economy
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