Sourcing of high-quality sponge iron
The company uses high-quality magnetite iron ores and reduces it through the proprietary sponge iron process where a finely divided iron ore is being reduced.
Steel and TMT (Thermo-Mechanically Treated) bars are essential materials in modern construction, renowned for their strength, flexibility, and durability. Understanding the production process of these materials sheds light on why they are so reliable and widely used. Here’s a step-by-step explanation of how steel and TMT bars are produced:
The company uses high-quality magnetite iron ores and reduces it through the proprietary sponge iron process where a finely divided iron ore is being reduced.
Coke, ore, and sinter, as well as limestone, are fed into the top of the Electric Arc furnace. A jet of hot air is pumped through nozzles in the furnace's base. The iron in the ore and sinter is melted off, forming a pool of molten metal in the furnace's bottom, or hearth. Limestone reacts with impurities and molten rock from the iron smelter.
To create billets, the metal is first heated to a liquid condition by burning out impurities, then transported straight into a continuous casting process. In continuous casting, the steel passes from the tundish through ceramic tubes to three water-cooled copper moulds where it starts to solidify.
The company uses Billet cutting machine is a kind of cold shearing machine, which is used to cut the steel billet. With PLC control, automatic feeding, automatic cutting , automatic counting, automatic lubrication and overloading protection . Billets are then sheared into the required sizes.
Once the solidifying billets exit the continuous casting machine, they enter a secondary cooling chamber. Here, the semi-finished billets are sprayed with water to achieve complete solidification. This process is important for maintaining the shape of the solidified billets, improving their quality in the long run.
Next, the solidified metal strands are reheated again in our reheating furnace. This is done to recrystallize the metal, improving quality and reducing material losses. The recrystallization process is very important because the metal strands can then be processed in the rolling mill without destroying the bonding.
The most significant metal forming process is rolling. Metals are moulded into final shapes by passing between rollers that run in opposing directions. Steel rolling is the process of reducing the cross-section of large billets. The main focus is to produce finished TMT Bars that have various applications in the construction industry. It is the metalworking method, which is most famous across the industries for heating the metal above the recrystallization temperature. During this process, the volume and features of the metal remain the same.
At RD TMT our vision is to produce products as per the standards and the certification of the International Standards Organisation. Therefore we only produce C-rib design patterns on our TMT bars which is widely accepted across the world in all construction practises.
The TMT produced then undergoes a process of rapid cooling which results in obtaining high-strength steel using water as a quenching medium. Once the hot rolled bars release from the finished mill it enters the water spray system. The best quality tmt bars manufacturing process uses Tempcore Technology that cools down the outer core rapidly and ensures the ductility of TMT Rebars. Rapid cooling hardens the outer core of the TMT Rebars to a depth optimized for each section, forming a martensitic rim while the core remains hot & Austenitic.
The cooling bed is located in the rolling mill after the rolling of the steel material is completed. It supports and permits the hot rolled bars from the last stand of the mill to cool. Cooling bed cools the bars as well as cross transfers them towards the discharge end. In a cooling bed the temperature of the entire length of the bar is to be cooled at the same time. If not, it develops stresses in the bar.
Bending is a process where all the bars are bent to a certain radius. The fine produce is then tagged and is safely packaged to ensure that the bars are secure so that they can be transported without being damaged. Each TMT bar is quality checked once again in this last step and then tagged for dispatch.