The Units

SUNFLAG STEEL uses the (Sponge iron + Liquid Metal + Scrap)--Electric arc furnace--Ladle heating furnace--VD/AOD--Continuous casting machine--Rolling mills route, backed up by the state-of-the-art technology and computerized process control.

The production facilities include:

  Sinter Plant (SINTER):  A 33 M2 sinter plant, designed by Beijing Sino-Steel Industry & Trade Group Corp.(SSIT) and Jiangsu Province Metallurgical Designing Institute (JSMDI) Co. Ltd. The technology is based on principle of economical, applicable safe and operational. The annual production is 3,64,000 Tonnes.  
  Mini Blast Furnace (MBF):  A Blast furnace of working volume 350 M3 designed by MECON Ltd. to produce 3,00,000 MT / annum of basic grade hot metal has been installed and sucessfully commissioned. The hot metal is mainly used in the steel melting shop as a raw material and surplus hot metal poured in pig casting machine. The Pig casting machine is designed by KBS Paramount & capacity 800 Tonnes per day (TPD). The Blast furnace gas is used for stoves heating, heating of preheating furnace of bar and section mill, heating of boiler ,sinter plant. Slag which is a byproduct is mainly sold to cement plants.  
  Direct Reduction Plants (DRP):  Based on Krupp's Codir process. The DRPs can produce 2,62,000 tones per year of Sponge iron from iron ore and coal. Additionally, the flue gases help generate 30 MW of Electric power.  
  Power Plant (PP):  A 30 MW Captive Power Plant is having two turbine set and two boilers. One boiler operates on Waste Gas from the DRP and another on Coal fludised bed .  
  Electric Arc Furnace (EAF):  A Mannesmann Demag make 50/60 tones Ultra--high--power and Eccentric-- bottom-- tapping EAF with computer controlled continuous charging and dynamic energy management system. It ensures low tramp elements like bismuth, copper, tin etc. and at low cost.     
  Ladle Heating Furnace (LHF):  A Mannesmann Demag make 50/60 tones, rating 9 MVA, continuous Argon purging in the ladle bottom through porous plug, equipped with Continuous Alloy Feeding System, Weighment System and Calcium silicide wire feeder to refine and control morphology of inclusion.  
  Vacuum Degassing Unit (VD):  G.A. Danielli, India has supplied a 60 tonnes capacity Vacuum Degassing Unit having 8 ejectors which deliver a pump down time of 5 minutes to 1 m bar. Liquid metal is treated for removal of Hydrogen, Oxygen and Nitrogen. Lower pump down time ensures consistent and predictable drop in temperature during the VD process- Avoiding the re-heating of metal completely. Guarantee to reach desired vacuum level in all the heats. Effective degassing leads to very high cleanliness level & low gas levels ensures long trouble free component life. This will provide the capacity to manufacture high value added Steel needed for critical applications.  
  Continuous Casting Machine (CCM):  Double (10.25/18 meters) radius, 3 strand CCM is equipped with automatic mould level control, automatic powder feeder with liquid metal controlled at +/-3 mm, auto start up of cast & uniform rate of powder feeding, special tundish design, close casting, computerized secondary cooling, infra-red therometers for surface temperature monitoring, ceramic and bellow shrouds to prevent re-oxidation and Electro-magnetic stirrer for homogenization. Supplier is M/s CONCAST INDIA. Caster is feasible to Cast larger sections up to 280*320 mm with long Metallurgical length of 16 meters. It has a provision of online automatic heat number marking system.  
  Blooming Mill : (BM)   The 830 mm dia two high reversible blooming mill is supplied by M/s Daineli Morgardshammar, Sweden. Mill is facilitated with 60TPH dual fuel reheating furnace (Daineli Centro make) , 250 Bar Descaler unit, Manipulator with inbuilt bar tilter, Turn over cooling bed, hot saw cutter and automatic gauging system etc. Blooming mill rolls bloom sizes of 280x320 mm, 240x280 mm, 210x230mm, 160x160mm and ingot sizes of 620x520 mm. The product size is round 75 to 160 mm and Round Corner Square (RCS) 75 to 160 mm. Grades manufactured are Carbon steel, alloy steel, spring steel, free cutting steel & stainless steel.  
  Bar and section mill (BSM):  The 60 tones per hour, 20 stand, 2 high continuous Mannesmann designed rolling mill is equipped with duel fuel walking hearth type re-heating furnace, process control through ABB automation, Online gauging system, Closed circuit TV system for billet and bar movements. Variable Reduction mill (VRM) is being installed after stand # 20 to produce close tolerance product. Product sizes - Round (15-53 mm dia), Hex (13 to 38.5 mm), WRD (12 to 38 mm dia), WRB (4.6 to 16 mm)  
  Alloy steel mill (ASM):  This specialty 3 Hi reversible cross country mill produces the product sizes round dia 45 mm upto 105 mm and Round Corner Square (45-110 mm) in alloy, carbon, spring, free-cutting and stainless steel grades. The Alloy Steel Mill consists of 14 TPH duel fuel Pusher type re-heating furnace..
Five stands woth one stand of 3 Hi roughing, two stands of 3 Hi intermediate and one stand of 2 Hi finishing, Roller table, Hot saw cutter and Rake type cooling bed etc.
 
  Wire Rod Block Mill (WRB):  10 stand (Horizontal vertical configuration) wire rod block mill, supplied by Danieli Morgardshammar, Sweden produces the product sizes from wire rod 4.6 mm to 16 mm. This mill is facilitated with 4 nos. water box, high speed shear, pinch roll, laying head, 80 mtr stelmor cooling conveyor, coil re-forming station and coil handling system. Mill is running with ABB automation. Online gauge monitoring system installed for close monitoring of wire rod sizes along the length. Max rolling speed is 90 m/s. Max. Coil weight 1600 Kg. Coil ID/OD ~ 900/1200 mm. Grades manufactured are Carbon steel, alloy steel, spring steel, free cutting steel, stainless steel etc.  
  Garret Coiler (GC):  Supplied by Danieli Morgardshammar, Sweden. Garret Coiler with Rockwell control system, oil circulation for lubrication, 3 pinch rolls, coil unloader & Swiveling Elevator with hydraulic motor, 2 Slat conveyor. Product ranges from wire rod 12 mm to 38 mm coils, Grades manufactured are Carbon steel, alloy steel, spring steel, free cutting steel & stainless steel.  

Besides these there are other finishing facilities available at SUNFLAG.
In-house bright bar making facilities from 6 mm to 100 mm dia.
Both peeled and drawn bright bars can be manufactured.
100% Magnetic Particle, Eddy Current Testing & Ultrasonic inspection is being done for all bright bars.
Heat treatment facilities are available for
(a)  Normalizing
(b)  Spherodized Annealing
(c)  Annealing
(d)  Stress relieving
(e)  Solution Annealing
(f)   Hardening & Tempering
(g)  Bell Furnace for Coil annealing
Brand saw cutting facilities for supply of material is specific length.

All above facilities has assisted Sunflag to crescent its market share and the tonnage of steel that Sunflag can sell.
All this has brought the Sunflag on par with any of the alloy steel plant in India.


SUNFLAG IRON & STEEL CO. LTD

33 Mount Road, Sadar, Nagpur 440 001
India

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