Steel Mill Service
FSNL is involved in the Steel mill services since its inception .In the process of steel making slag is generated in Blast Furnace and SMS containg residual scrap in it.
FSNL is processing the slag for recovery of such scrap and returning back to Steel Plant for recycling.Scrap is also generated in various shops due to rejection /solidification/waste in steel making process.These scrap is collected and processed by FSNL and returned back to steel plant for recycling.The slag after recovery of metallics is further processed for recycling in Sinter Plant ,Blast Furnance as a substitute of lime stone and in road making and as rail ballast.
Ferrous scrap recovery is a process that reclaims ferrous metallics from muck and debris arising out of iron & steel making which was hitherto considered as a waste, was started in an effort to gain for the country crores worth of metallics recycled annually thereby saving precious raw - materials.
Over a period of time, it has been established that usage of ferrous scrap to produce steel leads to considerable savings in energy and natural resources.
Production of one tonne of raw steel from steel scrap when compared to BF / BOF route results in.
- 74% savings in energy;
- 90% saving in virgin materails - one tonne of scrap would lead to savings of 1.5 mt. iron ore, 0.9 mt. of coking coal and 0.5 mt. of lime stone.
- 40% saving in water requirements and 76% reduction in water pollution.
- 85% reduction in air pollution, and
- 97% reduction in mining wastes.
• In iron and steel making an estimated metal I.OSS ranging between 4 to 7% of metal produced occurs in each process which is termed as "scrap".
• There are mainly two categories of scrap.
Primary scrap :
Primary scrap is relatively clean and almost free from slag & its recovery does not require separation from slag. Its processing involves downsizing for remelting in steel making.
Secondary scrap :
Secondary scrap is found mixed with impurities like slag, debris, muck, refractories etc. and requires a special and capital intensive mechanised process for recovery.
Scrap Recovery Process
Manual process :
- Hand - picking of scrap.
- Chiselling and hammering of large pieces manually.
- Hand loading.
Semi - mechanised process :
- Combination of manual operations picking and breaking to size.
- Usage of small capacity handling equipments for loading
Mechanised process (mobile) :
- Heavy duty capital intensive processing and handling equipments like.
- Crawler electric / diesel crane with magnet.
- Hydraulic Excavator
- Magnetic separator (mobile)
Mechanised process (stationary) :
- Fixed plant with facilities of 
- Conveyors.
- Hoppers
- Feeders
- Magnet drums
- Screens
- Crawler electric / diesel crane with magnet
- Hydraulic excavator
Operations at Steel Plants
Elements of activities :
Cooling, digging, loading and transporting BF & SMS slag dumped in slag pits and making slag pits available for current dumping.
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Separation of iron & steel scrap from slag through magnetic separator and recovery and processing of scrap.
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Unloading of wagons received with loads of thimble skulls, ladle skulls and jams.
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Processing of thimble skulls, ladle skulls and jams by lancing and subsequent balling.
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Recovery and processing of iron and steel scrap from dump.
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Collection, processing, loading and transportation of maintenance scrap.
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Collection, processing and segregation of mill rejects.
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Scarfing of slabs.
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Collection, recovery and processing of PCM, LRS & cast house scrap.
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Processing of ingots, shorts & butts.
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Processing of moulds and bottom plates by balling
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Transportation of processed scrap to SMS, blast furnace and sintering plant.
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Crushing & Screening of LD Slag to be used in Sinter Plant, Blast Furnance and as Rail Ballast.
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Transportation of worked through Slag from operation site after Metallic recovery to an Ear- Markrd place
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Handling of Solid waste like Sludge & Ash.
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Handling of Lime Dust.
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Handling of Coke.
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Packaging work at Crm- Hook welding of wagon.
