Production Processes and Technology Used in Steel Industries in Nepal

Production Processes and
Technology used in Steel Industries

in Nepal
Prepared by:
Aastha Dhungel
Anjana Tamang
Abhises Wasti
Bishal Adhikari
Garima Joshi
What is steel? How steel is made ?
● Ferrous alloy material
composed of iron (0.2%) and
carbon(2.14%)
● Many other elements like
manganese, silicon,
chromium ,nickel, oxygen etc
can be present or added
purposely to get the required
properties.
● Steel is environmentally
friendly, recyclable,
sustainable, and produced in
various shapes and forms.
Research Objectives
General Objectives Specific Objectives
To study about: To study about:

● Status of Steel Industries in ● Production Process of TMT Rebars
Nepal ● Production Process of Galvalume
● Steel Production in Nepal Sheets
● General input to output ● Quality Control and Production
process in steel capacity
manufacturing ● Available use of technology in
context of Nepal and Abroad
Top Steel Manufacturing Companies of Nepal
Steel Production in Nepal
Two Ways of Manufacturing Steel Products in Nepal:

● Using induction furnace to extract steel from cast and pig iron
● Directly importing iron billets and processing and refining it in
domestic industries
Among a total of 30 steel industries:

● 24 industries directly import billets
● 6 industries use induction furnace
Metal Waste Management through Recycling
Steel Industries using induction

furnace technology do great job in
recycling scrap metals. This process
happens in steps:
● Collection
● Inspection and Sorting
● Processing
● Melting
● Purification
● Solidification
Fig: Inspection of scrap waste being
done in Jagadamba Steels Industry
TMT Rebars Production in Nepal
● TMT rebars mean Thermo Mechanically Treated Rebars
Source: Ambe Steels

● Mechanical Properties of Fe 500 and Fe 500D
grade TMT rebar:
TMT Rebar Manufacturing Process
Step 1: Reheating Furnace

● Steel Billets reheated up to temperatures
1050 to 1150 degree celsius
● It softens the billets
● Billets can be transformed into desired
shape and dimension after reheating
Step 2 : Hot Rolling
● Hot billets passed through
rollers
● Done to reduce size of billet
bars
● This process transforms
billets into rebars of desired
diameter
Fig: Billet going through Rollers

Step 3 : Quenching and Tempering
● Rolled billets are quenched and tempered to give desired micro properties
● Surface Temperature changes from 900 degrees celsius to 280 degree celsius
● Temperature of inner layer remains constant
Advantages of this process:

● Consistent Quality
● High Ductility
● Simple and Easy Fabrication
● Highly Strong
Change in properties of steel during quenching

process
Step 4 : Flying Shear
● A computer controlled flying shear is used to cut the TMT bar
Fig: Ready to cut Fig: Cutting Operation

Galvalume Sheets Production in Nepal
Galvanized Sheets:
● Cold rolled iron sheets coated with a thin zinc layer
Galvalume Sheets:
● Cold rolled iron sheets coated with 55% of Aluminum,
43.5% of Zinc, and 1.5% of Silicon
Use of roofing sheets in Nepal:
● Galvanized iron sheets with corrugated profile are in high

demand. Fig: Corrugated Profile Roofing
● Such sheets are used in construction of factory sheds, Sheet
temporary homes for rehabilitation, roofing, etc.
Galvalume Sheets Manufacturing Process
Input Material for the Process:

● Hot Rolled Coils imported from
India
● Plain sheets made of iron, rolled
into coils
● 3mm thick at the beginning
● Presence of rust and scales over the
surface
Step 1 : Pickling Process
● HR coils are decoiled and processed
through a solution of HCL or Nitric
acid or sulphuric acid by spray
nozzle continuously
● Removes surface rust, scales
● Makes surface of iron sheet clean
and workable
Step 2 : Cold Rolling Process
● Coiled sheet passed through a roller
setup
● Reduces thickness of sheet to upto
0.13 mm
● Rolling Mill Types: 4 HI and 6 HI
● Rolling mill consisting of four rolls is
termed as 4 HI
● Rolling mill consisting of six rolls is
termed as 6 HI
Fig: Cold Rolling Mill
Step 3 : Galvalume Process
● Cold rolled sheets are passed through
molten pool of metal alloy
● Molten alloy consists 55% of
Aluminum, 43.5% of Zinc, and 1.5% of
Silicon
● Gives layer of galvalume coating to
sheet of desired thickness
● Thickness controlled by rolling speed
and pool temperature
Step 4 : Colour Coating Process
Acrylic Coating:
● Acrylic is a synthetic resin
● It has its own colour close to
transparent but distinct from non-
coloured sheets
● Provides durability
Chemical Coating:
● It gives colours like red, green, blue,
yellow, etc. to sheets.
Fig: Sheet being colour coated

Step 5 : Roll Forming
● After coating, sheets are now passed
through series of roller arrangement
● Each roller acts as a die and applies
mechanical pressure to gradually deform
plain sheet into desired profile
● Plain sheet goes in, corrugated sheet comes
out
● Depth and no. of ribs increases as the sheet
passes through the roll forming machine
● Shearing is done after the sheet is formed
into corrugated profile at the end of the
process.
Fig: Roll Forming Machine
Step 6 : Shearing
● Long plain sheet in the coil at the end of
roll forming machine is passed through
shearing machine via bed fitted with
rollers
● Suitable length is automatically cut by
machine
● Most commonly available lengths in
Nepalese market are 6ft, 9ft, and 12 ft.
● Shearing may be done before forming if
plain sheet is desired.
● Blade of shearing machine is matched to
the profile taken by sheet.
Fig: Corrugated sheet shearing machine
After cutting, sheets are packaged and bundled. Each bundle contains 12 or 24 sheets depending on
manufacturer or supplier. Price per bundle varies according to length and thickness of each sheet.
Quality Control
Tests performed to test the quality of products are:
1. Tensile Test 7. Pressure Test
2. Bending Test 8. Drop and
Deflection Test
3. Flaring Test 9. Exposure Test
4. Flattening Test 10. Impact Test
5. Zinc Coating Test 11. Boiling Test
6. Thread Accuracy Test 12. Non-Destructive
Thank You

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Production Processes and Technology Used in Steel Industries in Nepal

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Production Processes and

Technology used in Steel Industries

To study about: To study about:

Two Ways of Manufacturing Steel Products in Nepal:

Among a total of 30 steel industries:

Steel Industries using induction

● TMT rebars mean Thermo Mechanically Treated Rebars

Source: Ambe Steels

Step 1: Reheating Furnace

Fig: Billet going through Rollers

Advantages of this process:

Change in properties of steel during quenching

Fig: Ready to cut Fig: Cutting Operation

● Cold rolled iron sheets coated with a thin zinc layer

Use of roofing sheets in Nepal:

● Galvanized iron sheets with corrugated profile are in high

Input Material for the Process:

Fig: Sheet being colour coated

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