Processes

Research into industrial processes

Research into processes is organised according to:

  • Ceramics Research Centre
  • Environment
  • Ironmaking
  • Long Product Rolling
  • Measurement Integration and Engineering
  • Rolling Metal Strip
  • Steelmaking & Casting

Ceramics Research Centre

In a Ceram survey carried out in 2000, the expertise of the Ceramics Research Centre (CRC) was rated amongst the top 3 worldwide. The main function of this department is the continuous improvement of the design of inorganic installation linings needed to produce iron, steel and aluminium and the materials to be used for the linings.

The Refractories Application & Development group offers advice about refractories, operating costs and installations. It also tests refractory materials and constructions under practical or simulated conditions.
The Microstructure Crystallography & Thermal Analysis group focuses on the analysis and characterisation of materials as well as experimental and analytical studies to explain and predict material behaviour under actual process conditions.
The Materials Engineering & Mathematical Modelling group combines expertise in materials engineering and process engineering. This includes mathematical modelling to predict the thermal behaviour of materials, processing of ceramic or metallic powders, thermo mechanical characterisation of materials at high temperatures (up to 2400ºC) and the application of engineered ceramic products under process conditions.

Environment

The main task of the Environment department is to evaluate the environmental impacts associated with Tata Steel processes and products and develop options for improvement.

The Environmental Chemistry group develops and applies analytical techniques to characterise and understand the formation of process emissions. They apply knowledge of process chemistry to identify techniques for reducing pollutants at the source.
The Environmental Engineering and Monitoring group assists business units in developing pollution control strategies. This starts by developing and applying measurement techniques to evaluate process emissions, then they provide design and operational guidance on pollution control plant and evaluating novel monitoring and control techniques for cost-effective abatement.
The Environmental Impact group looks at the environmental impacts of Tata Steel operations and products on employees, neighbours and the local environment. The group traces the sources of these impacts and tries to set cost-effective priorities for abatement action. They look at air quality, noise reduction, radiation, and toxicity of effluents.
The Sustainability group provides support to demonstrate the environmental credentials of metals by assessing Tata Steel operations and product applications in the context of sustainable development. The group also works on risk assessment, the remediation of contaminated land and materials recycling.

Ironmaking

The Ironmaking department works on the development of new or improved processes for the production of high quality iron at low cost, including the environmental and recycling aspects of the iron making processes. The department comprises three knowledge groups that focus on ironmaking technology and the preparatory stages:

The Coal & Coke group works on improving the processes of coke making and the properties of the resulting raw material.
The Ferrous Materials group focuses on improving the processes for ore agglomeration and the improvement of product properties. Plus the processing of process waste from the steel plant in iron making processes.
The Ironmaking group focuses on the development and optimisation of the blast furnace process for the production of hot metal, as well as alternative processes to produce high quality hot metal quality at minimum cost.

Long Products Rolling

The Long Product Rolling department aims to improve the process of reheating, rolling and finishing of ‘long products’ like rails. Its work is based on expertise on these three process steps and on mathematical modelling.

  • The Reheating Technology group focuses on the reheating process to bring the bloom up to hot rolling temperature and also to optimise the effect of reheating on the final product.
  • The Product Rolling Optimisation group has expertise in all aspects of rolling including descaling, mill engineering, roll wear, etc, and interacts between the reheating process group and the finishing end of a long products mill.
  • The Finishing Technology group specialises in long product finishing technology, focusing on enhancing the process to make the end product fit the customer’s needs.
  • The Product Modelling and Control group provides modelling support by developing models in-house, in addition to applying commercial software packages.
  • The Long Product Development Facility and Experimental Support group provides technical support and runs the existing pilot equipment as well as preparing a replacement for this ageing equipment. The group also does melting work for third parties, e.g. the nuclear industry.
  • The Through Process Engineering group provides expertise in controlling complex manufacturing processes through the application of closed loop control and intelligent decision support system, using advanced technologies from the fields of knowledge and control engineering, data analysis and modelling as well as Information Technology.

Measurement Integration and Engineering

The Measurement Integration and Engineering focuses on measurement systems and measurement integration:

  • The Strip & Coated Product Measurement group focuses on extracting and processing process and product information. The emphasis is on performance and quality indicators like geometry, plant performance, cleanliness, material properties, surface quality and appearance.
  • The Long Product Measurement & Inspection group develops and applies measuring and inspection techniques for long products and related processes.
  • The Prototyping group aims to support the development of industrial production methods, instrumentation and equipment for Tata Steel RD&T, Tata Steel business units and their customers. The group has a workshop at its disposal to actually produce prototypes or models used to visualise design concepts.

Rolling Metal Strip

The Rolling Metal Strip department provides Tata Steel business units with solutions and control models that allow them to apply cost effective process technology to produce uncoated steel and aluminium strip without compromising the environment.

  • The Reheating and Annealing group focuses on reheating and annealing processes in steel strip mills
  • The Hot Rolling Process Development group focuses on the hot rolling process for both steel and aluminium. A special emphasis is placed on the development of technologies to increase productivity, production consistency and product quality.
  • The Cold Rolling Process Development group concentrates on the cold rolling, temper rolling and (tension) levelling processes for both steel and aluminium.
  • The Surface Technology Group focuses on the continuous improvement of the surface properties of uncoated steel and aluminium strip products, which implies the (further) development of technologies to improve production consistency and surface quality. The emphasis in the work is on the effect of the rolling process on the strip surface.

Steelmaking and Casting

The Steelmaking & Casting department focuses on the development of new processes and the improvement of existing processes, process routes and equipment to produce high quality steel slabs, strips, billets, blooms and ingots at low cost. Particular attention is paid to the economic and environmental aspects of the production processes. The department also develops and utilises advanced mathematical, thermochemical, heat and mass transfer modelling and experimental techniques for process analysis.

The Process Metallurgy group focuses on the development of methods to produce quality liquid steel from solid or liquid iron feedstock.

  • The General Steelmaking group aims at improving process control and steel quality as well as reducing costs by applying advanced models, decision support tools and diagnostic analysis techniques. The group deals with both oxygen steelmaking and steelmaking in electric arc furnaces, as well as with secondary metallurgy.
  • The Steelmaking Engineering & Technology group delivers engineering solutions to all steel making operations to improve plant performance in terms of reliability and environmental issues.
  • The Casting Process Design & Engineering group aims to improve casting performance and product quality through the application of process modelling, engineering and technical support to the design, operation and enhancement of casters.
  • The Casting Process Metallurgy group works on metallurgical research related to the casting of slabs, blooms and billets for long products, focusing on process optimisation, quality improvement and on new and improved products.
  • The Caster Technology group focuses on measurement technologies to enhance continuous casting operational security and to improve product quality and yield.
  • The Casting Metallurgy of Flat Products group concentrates on process metallurgical research for casting slabs for flat products, mainly in support of the Tata Steel IJmuiden plant.
  • The Advanced Casting Technologies group focuses on new casting technologies and other medium/long term strategic developments
  • The Computational Fluid Dynamics group aims at improving all Tata Steel processes that rely on fluid flow. The group has vast experience in fluid flow phenomena and in using commercial CFD packages to investigate these further.
  • The Process Dynamics group contributes to process improvement and innovation through in depth process analysis. The group uses experimental facilities to analyse fluid dynamics, heat and mass transfer and reaction kinetics, as well as sophisticated software for process modelling
  • The Process Modelling and Thermochemistry group evaluates and optimises process design and operation at all stages of the processing of raw materials, liquid metals and products through the use of experimental and computational simulation tools.

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