Page | 1 Batala Steels TABLE OF CONTENTS Serial # Description Page# 01 Executive Summary 03 02 Industry profile 04 03 Analysis of steel industry 05 04 Vision 09 05 Mission 10 06 Quality policy 11 07 Testing facility 12 08 Process 14 09 Hierarchy and Departments 17 10 Administratio n and personnel 18 University of Central Punjab, PCBA-PICS
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Page | 1
Batala Steels
TABLE OF CONTENTS
Serial # Description Page#
01 Executive
Summary
03
02 Industry profile 04
03 Analysis of steel
industry
05
04 Vision 09
05 Mission 10
06 Quality policy 11
07 Testing facility 12
08 Process 14
09 Hierarchy and
Departments
17
10 Administration and
personnel
Department
18
11 Marketing
Department
20
12 Accounts
Department
24
13 Strengths 26
14 Weaknesses 27
15 Opportunities 28
16 Threats 29
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17 Plausible Problems 30
18 Reccomendations 32
19 Conclusion 33
20 Bibliography 34
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EXECUTIVE SUMMARY
Prior to detailed description, I am stating the summary of internship report. Basic
purpose behind this is to give a clear view of the efforts that have been taken to
complete the program.I was assigned to work in Batala steels as internee for the
practical exposure. My job was started on 08 NOV, 2010 till Dec 28,2010 with aim
to study each and every aspect of organizational setup, departmental working,
working process and the documentation proceed by the organization.I being the
BBA student was deputed in Administration and personnel department.The report
in hand consists of my six weeks experience during internship. The report starts
with introduction of the organization,which covers detailed history and
background,and products downstream industry, organizational structure and some
other important aspects. After there are functions performed by different
departments working in the organization.As we all are aware that development and
growth of any country is largely dependent upon the iron and steel industry. So the
improvements and development of that industry is of much importance for any
country and especially the developing countries like Pakistan. Although,Batala
steel is working well in this current political and economic unstable environment
but still there is room for improvement.
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Batala Steels
INDUSTRY PROFILE:
Most Pakistanis do not realize that a Steel Mill is actually more essential than a nuclear
plant, or a missile. A steel mill is the backbone of the infrastructure of any country. Whether
it is roads, bridges, or sugar mills, everything comes from a steel mill.
After independence in 1947, it did not take long for Pakistan to come to the realization that
progressive industrial and economical development would be impossible without the
possession of a self reliant iron and steel making plant. The dependence on imports would
cause serious setbacks to the country along with an extortionately high import bill which
would be impossible to support.
Unfortunately Pakistan could not get a steel mill from 1947-1973. Most powers would not
sell the technology that could undermine the industrial prowess as well as the export
capability of Western enterprise.
The initial idea for a domestic iron and steel mill was put forward in the first five year plan of
Pakistan (1955 - 1960). Debates over the manufacturing process, supply sources of the
requisite machinery and raw materials, plant site, domestic ore versus imported ore,
ownership pattern, product mix and above all foreign financing credit kept the project onhold
for a considerable time.
The steel industry is often considered to be an indicator of economic progress, because of
the critical role played by steel in infrastructural and overall economic development. The
volume of steel consumed has been the barometer for measuring development and
economic progress. Whether it is construction or industrial goods, steel is the basic raw
material. However with the advancement in technology, lighter metals and stronger alloys
have been developed. Plastics and synthetics have replaced steel in many areas.
Still, “Steel” today is one of the most common materials in the world, with more than 1300
million tons produced annually. It is a major component in buildings, infrastructure,
tools,ships, automobiles, machines, appliances, and weapons.
The ores used in making iron and steel are iron oxides, which are compounds of iron and
oxygen. The major iron oxide ores are
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A Brief Analysis of the Steel Industry in Pakistan:
Hematite, which is the most plentiful
Limonite, also called brown ore
Taconite
Magnetite, a black ore
The three raw materials used in making pig iron (which is the raw material needed to make
steel) are the processed iron ore, coke (residue left after heating coal in the absence of air,
generally containing up to 90% carbon) and limestone (CaCO3) or burnt lime (CaO), which
are added to the blast furnace at intervals, making the process continuous. The limestone or
burnt lime is used as a fluxing material that forms a slag on top of the liquid metal. This has
an oxidizing effect on the liquid metal underneath which helps to remove impurities.
Approximately two tons of ore, one ton of coke, and a half ton of limestone are required to
produce one ton of iron.
There are several basic elements which can be found in all
commercial steels:
Carbon is a very important element in steel since it allows the steel to be hardened
by heat treatment. Only a small amount of carbon is needed to produce steel: up to
0.25% for low carbon steel, 0.25-0.50% for medium carbon steel, and 0.50-1.25% for
high carbon steel. Steel can contain up to 2% carbon, but over that amount it is
considered to be cast iron, in which the excess carbon forms graphite.
The metal manganese is used in small amounts (0.03-1.0%) to remove unwanted
oxygen and to control sulfur. Sulfur is difficult to remove from steel and the form it
takes in steel (iron sulfide, FeS) allows the steel to become brittle, or hot-short, when
forged or rolled at elevated temperatures. Sulfur content in commercial steels is
usually kept below 0.05%.
A small quantity of phosphorus (usually below 0.04%) is present, which tends to
dissolve in the iron, slightly increasing the strength and hardness. Phosphorus in
larger quantities reduces the ductility or formability of steel and can cause the
material to crack when cold worked in a rolling mill, making it cold-short.
Silicon is another element present in steel, usually between 0.5-0.3percent. The
silicon dissolves in the iron and increases the strength and toughness of the steel
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Batala Steels
without greatly reducing ductility. The silicon also deoxidizes the molten steel
through the formation of silicon dioxide (SiO2), which makes for stronger, less porous
castings.
Types of Steel Mills:
INTEGRATED MILL:
Integrated mills are large facilities that are typically only economical to build in
2,000,000 ton per year annual capacity and up. Final products made by an integrated
plant are usually large structural sections, heavy plate, strip, wire rod, railway rails,
and occasionally long products such as bars and pipe.
A Brief Analysis of the Steel Industry in Pakistan
An integrated steel mill has all the functions for primary steel production:
Iron Making (conversion of ore to liquid iron),
Steelmaking (conversion of pig iron to liquid steel),
Casting (solidification of the liquid steel),
Roughing Rolling/Billet Rolling (reducing size of blocks)
Product Rolling (finished shapes).
Because of the energy cost and structural stress associated with heating and cooling a blast
furnace, typically these primary steelmaking vessels will operate on a continuous production
campaign of several years duration. Even during periods of low steel demand, it may not be
feasible to let the blast furnace grow cold. Due to the large employment of integrated
plants, often governments will financially assist an obsolescent facility rather than take the
risk of having thousands of workers thrown out of jobs.
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Batala Steels
MINI MILL:
A mini-mill is traditionally a secondary steel producer. Usually it obtains most of its
iron from scrap steel, recycled from used automobiles and equipment or byproducts
of manufacturing.
A typical mini-mill will have an electric arc furnace for scrap melting, a ladle furnace or
vacuum furnace for precision control of chemistry, a strip or billet continuous caster for
converting molten steel to solid form, a reheat furnace and a rolling mill.
Often a mini-mill will be constructed in an area with no other steel production, to take
advantage of local resources and lower-cost labor. Mini-mill plants may specialize, for
example, making coils of rod for wire-drawing use, or pipe, or in special sections for
transportation and agriculture.
Capacities of mini-mills vary; some plants may make as much as 3,000,000 tons per year, a
typical size is in the range 200,000 to 400,000 tons per year, and some old or specialty
plants may make as little as 50,000 tons per year of finished product. Since the
electric arc furnace can be easily started and stopped on a regular basis, mini-mills
can follow the market demand for their products easily, operating on 24 hour
schedules when demand is high and cutting back production when sales are lower.
Another element that plays an important part in the processing of steel is oxygen.
Some large steel mills have installed their own oxygen plants, which are located near
basic oxygen furnaces. Oxygen injected into the mix or furnace "charge" improves
and speeds up steel production.
Steel can be given many different and useful properties by alloying the iron with
other metals such as chromium, molybdenum, nickel, aluminum, cobalt, tungsten,
vanadium, and titanium, and with nonmetals such as boron and silicon.
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Batala Steels
The steel industry in Pakistan comprises the following:
Steel Melters: this segment, re-melts both imported as well as locally
generated scrap to largely produce cast billets and thin ingots; total installed
capacity of this segment is estimated at 2.0mtpa.
Steel Re-rollers: this segment largely comprising manually operated cross-
country mills that use billets, thin ingots, slabs and rollable materials to
make rebars and steel sections; total installed capacity of this segment is
estimated at 3.2mtpa.
Ship Demolition Industry: this segment supplies re-rollable / remeltable
scrap, using relatively obsolete demolition technology; current output is
estimated at 0.2mtpa.
It can't be denied in the modern times that an overall development of a country
depends to a greater extent on Iron and Steel Industry because we are passing
through the 'Steel Age', where right from a sewing needle to aircraft all the goods
require iron and steel to come into being. Iron and steel is indispensable to use for
making machines, tools, war items and other various goods of daily life.Rail tracks,
rail bogies, aero-planes, ships, motor cars, bridge dams, tunnels and pipe lines
required iron and steel.
Significance of iron and steel could be accessed through the following facts:
a) Fast, modern and cheap means of transport play decisive role in the economic
development of a country. For this purpose, rails, ships, aero planes, motor vehicles
etc.
b) If the supply of consumer’s goods are abundant in a country, it is the symptom
that the country is self sufficient and does not depend on others. The consumer’s
goods are made on machines which are made of iron and steel.
In the light of this discussion, it could confidently be concluded that if a country is
deficient in iron and steel,it should not dream for the economic development.
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Vision
As our forefathers laid down a foundation of solid business practices upon which to build a
future for generations to come, our vision at batala steel is principled in the same way.
When this nation was born, Batala Steel was an inherent factor in development of
infrastructure and transportation, helping bridge the new nation and keep it together as a
single cohesive unit.
In the 21st century, Batala Steel sees itself as the foundation of all rural development in
Pakistan. As our nations' furthest recesses continue to industrialize and mature, Batala Steel
finds itself at the core of all the upcoming groundbreaking development.
Batala Steel is committed to the prosperity and growth of this nation and as such will lend
itself to further that commitment. Generations of the Batala Steel Corporate Family will stand
buy and build this nation to greatness.
Batala products:
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Batala Steels
Mission Statement
At Batala Steel our top priority has always been the manufacturing of a top quality product
that meets international standards, giving the label "Made in Pakistan" the honor and dignity
that is commands. We pride ourselves on the production of an excellent steel product that is
unmatched in Pakistan, a product that is favoured by our loyal customers in Pakistan and
across the world.
With trainings and seminars to keep our employees at par with international industry
standards, and competitive pricing to stay competitive with the market, our aim for the future
is to make sure that Batala Steel remains a front-runner in the steel industry.
Greater response to customer's present & future needs.
Focus on productivity and Quality.
Facing Challenges of free Market Economy.
Ensuring higher rate of return on invested capital.
Developing Human resource and motivating employees through
empowerment and hard consequences.
Safe Working and Environment friendly conditions.
Minimizing process wastages, rejections and recycling .wastes.
Good Governance.
Fulfilling Social Obligations.
Improving Corporate Image.
We at BATALA STEEL believe that Quality is not just a manufacturing specification
but it is something which is to be internalized. We measure customer satisfaction above
all and endeavor to achieve it by maintaining the quality standards in products we
deliver.
For this we have a well equipped quality lab with latest testing facilities. We conduct
various chemical and mechanical tests to ensure the required specification. The testing
is done under our proficient and diligence staff. The quality department promptly
reports the feedback to the production department and thus ensures that every single
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Batala Steels
product produced is of top quality.
Quality Policy
The Company is committed to:
Ensure maximum customer satisfaction by maintaining the consistency in
quality.
Respond innovatively and competitively to the changing needs of our customers
through persistently adapting new technologies with the same excellence.
Fulfill its legal and statutory obligations and international standards.
Involve manufacturing processes that are environment friendly
We at Batala Steel, strictly adhere to the ASTM and BSI international standards. For
this purpose we have established most modern laboratories to maintain the highest
quality precision standard. The perfection of our work has captured the sharp eyes of
discerning clients, in the public and private sector including some of the top
multinational construction firms. To produce high quality steel according to the requires
specification, Batala Steel is equipped with both chemical and physical laboratories at
our site in lahore. Prime Quality M.S billets are processed through semi-automatic re-
rolling plants, which are designed to manufacture standardized products of exact and
international specifications; special attention is paid to the custom requirements
instruction of each particular client. Beside these we have potential to meet special
requirements of our customers.
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Batala Steels
Testing Facilities:
The physical testing laboratory at batala steel is equipped with modern testing
equipment,well maintained and regularly calibrated by reputed agencies including
Engineering University Lahore. The laboratory is capable of performing several requisite
tests on mild steel manufactured. Frequent tests are performed for each heat / lot on in-
coming, in-process and final dispatch stage.Apart from the usual physical testing
laboratory, batala steel is the only steel industry in Pakistan to have the chemical testing
facilities through most advanced but expensive - Spectrolab. This enables the company
to apply comprehensive quality control measures at input, in process and final stage.
Installed with latest and modern testing equipment, chemical and physical testing
laboratories of batala steel are taken at par with any internationally recognized testing