Steel Manufacturing Infrastructure
We build relationships that will support the next stage of your company’s expansion.
We build relationships that will support the next stage of your company’s expansion.
All Incoming and Outgoing material is weighed at our weigh bridge.
Scrap yard with scrap preheating facility and PLC controlled super jumbo baling machine where the scrap is segregated and sorted as per their grades.
We have APS which is used for purging Argon in Electric melting furnaces and ladles. It helps to reduce metallic inclusions to improve the overall purity of the steel.
Dry Mechanical vacuum pumping system (Edwards U.K.) for Vacuum Degassing process, which achieves below 1 Mbar vacuum within 5 minutes. Lowest vacuum achieved is 0.25 Mbar. The vacuum-degassing process will not remove impurities found in steel; however, it will remove most of the gaseous impurities and make the level go down to below 25 PPM of oxygen and less than 2 PPM of hydrogen. During the steel melting process, many unwanted gases are dissolved in the liquid. This can result in numerous defects and imperfections. Vacuum degassing helps to eliminate any of the dissolved gases which will improve ductility of steel.
Ingots cooling pit filled with Vermiculite with storing capacity of 200 MT Forging ingots at once.
In house several varieties of Grinders and other tools for dressing and processing the material.
Every product manufactured is checked for different parameter at our inspection area like size, random grade checking, physical defects and their rectification etc before shifting to dispatch area. Our various quality check instruments ensure 100 % product quality.
Every Incoming and Outgoing material is thoroughly tested and ensured that it should be 100 % radiation free.
Two Electric Melting Furnaces with latest temperature measuring instruments.
We have the latest LRF facility with an electrode regulation system. We use it for making all grades of steel and alloy steel resulting better quality of Forging ingots and Billets/Blooms. LRF facilitates better refining, homogenizing (both chemistry and temperature), desulfurizing (deep sulphur removal) and Inclusion floatation (removal of non metallic inclusions) giving better purity in liquid steel.
After Refining, Forging ingots are bottom poured through ladle in variety of cast iron ingotsMoulds which are available in more than 20 different sizes and shapes.
PLC operated twin Strand Billets / Blooms Continuous Caster with all latest technology.
PID controlled six channel calibrated Car Bottom Electric 6.5 meter long Heat Treatment Furnace gives us precise control even at a temperature of 1150 °C, thereby resulting in greater uniformity and helps in achieving the required mechanical properties. Heat treatment processes like Annealing, Quenching, Tempering, Stress relieving are used to change their physical, Mechanical properties of steel and improves manufacturing objectives like machining, formability & ductility. So this technology not only helps other manufacturing processes but also improves product performance by increasing strength and other desirable characteristics.
Ample area is available for the storage of Forging ingots, Rolled Bars and Continuous Cast Billets / Blooms where we retest and ensure 100% radiation free material is dispatched.
The ladle refining furnace (LRF) is where steel is finished after melting. The ladle furnace process works in four steps: the melted steel is tapped into a ladle and moved to the LRF; graphite electrodes heat the steel under a slag cover to hold temperature; argon is purged through the steel to stir it, make temperature and chemistry uniform and float non-metallic inclusions into the slag; and alloys are added to hit the target analysis. Ladle refining furnace working principle in one line: electric arc heating plus argon stirring under a refining slag.
At Kesari Alloys the LRF has an electrode regulation system and is used for all grades of steel and alloy steel. The ladle refining furnace process gives better refining, homogenizing of chemistry and temperature, desulfurizing (deep sulphur removal) and inclusion flotation, so the forging ingots and billets and blooms that follow have better purity. From the LRF the ladle goes to vacuum degassing (VD) and then to the ingot casting pit or the continuous casting machine.
Electric melting furnace steel making starts the process: sorted and preheated scrap and alloys are charged into one of our two electric melting furnaces, which have modern temperature measuring instruments. Steel from the electric melting furnace is tapped into the ladle for refining. Electric melting gives close control of temperature and chemistry, which is why it is used for alloy, stainless and carbon steel grades alike. See the forging ingots and billets and blooms made from this heat.
Steel heat treatment changes strength, hardness and toughness by heating and cooling steel in a controlled way. Our electric heat treatment furnace is a car bottom type, 6.5 meters long and temperature controlled up to 1150 °C, used for forging ingots and bars. The steel heat treatment process has four common methods: annealing, normalizing, hardening (quenching) and tempering, plus stress relieving and case hardening. The steel heat treatment chart and steel heat treatment temperature chart below give typical temperatures for carbon and low alloy steel; the exact figures depend on the grade, so use the heat treatment section on each grade page.
| Heat treatment method | Typical steel heat treat temperature | Purpose | Cooling |
| Stress relieving | 550 to 650 °C | Remove residual stress after forging, welding or machining | Slow cool |
| Annealing | About 30 to 50 °C above the upper critical temperature (roughly 780 to 880 °C) | Soften steel, improve machinability and ductility | Furnace cool |
| Normalizing | About 30 to 50 °C above the upper critical temperature (roughly 840 to 920 °C) | Refine grain and make the structure uniform | Still air |
| Hardening | About 820 to 880 °C for medium carbon and low alloy steel | Form a hard martensitic structure | Quench in oil, water or polymer |
| Tempering | 150 to 650 °C | Reduce brittleness and set the final hardness | Air |
| Carburizing (case hardening) | About 900 to 950 °C | Hard wear resistant case with a tough core | Quench then temper |
Carbon steel heat treatment chart and metal heat treatment chart values are indicative. Always follow the heat treatment section of the grade you order, for example EN8, EN24 or 16MnCr5. These heat treatment methods of steel are applied to our ingots, billets and bars on request.
Annealing steel purpose: annealing softens steel, relieves internal stress, refines the structure and improves machinability before forging, rolling or cutting. In the steel annealing process the steel is heated in an annealing furnace to the steel annealing temperature, held to equalise the temperature through the section, and cooled slowly in the furnace. Typical steel annealing temperature for carbon and low alloy steel is about 780 to 880 °C, depending on carbon content (see the steel annealing temperature chart above).
Steel annealing time depends on the section size: a common rule is to hold for about one hour per 25 mm of thickness after the steel has reached temperature, followed by slow furnace cooling. Heavy ingots take much longer. Our steel annealing furnace (electric) and the car bottom heat treatment furnace handle steel annealing for ingots and bars; steel annealing oven is the name some buyers use for the same equipment. Annealed condition is available for forging ingots, billets and bars.
Normalizing steel heat treatment heats the steel to about 30 to 50 °C above its upper critical temperature, holds it briefly and lets it cool in still air. The normalizing steel process refines coarse grain from forging or casting and makes the structure uniform.
Normalizing steel temperatures run from roughly 840 to 920 °C for carbon and low alloy grades, higher for higher carbon steel. The grade page lists the recommended treatment.
After normalizing the microstructure is fine ferrite and pearlite (or bainite in some alloy steels), which is stronger and more uniform than an as-cast or as-forged structure. Normalizing is cooled faster than annealing, so the structure is slightly harder.
Normalizing steel after welding restores grain size and toughness in the weld and heat affected zone, particularly in thick sections and pressure parts. Stress relieving is used where only residual stress needs to go.
Stainless steel heat treatment depends on the family. The stainless steel heat treatment chart below covers our stainless grades; temperatures are typical and the grade page and the order requirement decide the exact cycle.
| Grade | Annealing | Hardening | Note |
| SS410 | About 815 to 900 °C, slow cool | About 925 to 1010 °C, oil or air quench, then temper | Martensitic: hardenable |
| SS430 | About 790 to 845 °C | Not hardenable by heat treatment | Ferritic |
| SS409 | About 790 to 845 °C | Not hardenable by heat treatment | Ferritic |
It is heating steel to a set temperature, holding it and cooling at a controlled rate to change hardness, strength or toughness. The main methods are annealing, normalizing, hardening, tempering and stress relieving.
Annealing cools slowly in the furnace to make steel soft. Normalizing cools in still air, which gives a finer and slightly harder structure.