The heart of our production at Village Raowali comprises medium-frequency induction melting furnaces configured for rapid, energy-efficient meltdown of prime segregated scrap and high-purity ferroalloys.
Unlike conventional cupolas, our electric induction melting eliminates carbon pick-up and fuel sulphur contamination. Electro-magnetic bath stirring guarantees homogeneous alloy dissolution, optimal thermal distribution, and precise slag separation before tapping.
Every batch of steel undergoes rigorous stage-gate tracking to preserve structural homogeneity and metallurgical purity.
Click above to inspect the complete engineering flowsheet in high resolution
Rigorous chemical sorting of scrap charges, ensuring free from galvanized, tin, or unwanted tramp materials.
Clean electric induction heating with programmed power curve to prevent oxidation and nitrogen absorption.
Calibrated additions of metallic deoxidizers (Al, FeSi) and synthetic flux to trap impurities into disposable slag.
Bottom-bubbling high purity argon through porous plug to homogenize bath chemistry, temperature, and float non-metallics.
Coin sample spark analysis on SPECTROMAXx spectrometer; melt is only cleared for tapping once all element limits pass.
Smooth stream teemed into dressed molds with insulating hot tops, preventing piping defects and shrinkage cavities.
Gradual cooling kinetics to ensure fine, equiaxed central crystal growth and avoid internal thermal stress cracks.
Ingots stripped, visual inspection for seams, laps, cold shuts, or surface pinholes, followed by head cropping.
Ingots transferred to walking-beam / pusher reheating furnaces for rolling into bars, flats, and sections at KJSRM.
Heat number hard-stamping, color-code marking, Mill Test Certificate generation, and crane loading onto trucks.
Established in 2004, our integrated rolling mill division allows us to convert cast ingots and billets into precision hot-rolled rounds, squares, flats, and profile sections under controlled finishing temperatures.
Equipped with multi-stand roughing and continuous finishing trains, flying shears, and cooling beds, the rolling unit ensures uniform grain refinement and minimal decarburization.
Click to examine high-resolution rolling plant diagram
EC Identification No: EC23A1010PB5892517N
BHAWANI SHANKAR CASTINGS PRIVATE LIMITED operates with full statutory compliance under the Ministry of Environment, Forest and Climate Change (MoEFCC), Government of India.
Under official Clearance Order EC23A1010PB5892517N, our plant is formally authorized to expand manufacturing capacity from 29,700 TPA to 98,000 TPA of steel ingots/billets through modernized induction melting furnaces, bag filters, and fume extraction systems.
This approval underscores our commitment to sustainable industrial growth, low specific carbon emissions, and strict ambient air quality norms.
