MINING, METALS & STEEL INDUSTRIES
Mining, Metals & Steel Industries
Industry Overview
The Mining, Metals & Steel Industries sector encompasses the industrial chain involved in the extraction, beneficiation, processing, conversion and manufacture of mineral, metallic and steel products.
The sector covers mining operations, mineral handling and beneficiation, ore processing, pelletisation, sintering, coke production, iron making, steel making, casting, rolling, finishing and associated utility, material-handling and environmental facilities.
The industrial chain can broadly be understood as:
The exact route varies according to the mineral, ore characteristics and final product.
Mining & Mineral Processing Route
A typical mineral-processing chain is:
Depending on the mineral and process, beneficiation may include:
Beneficiation may include
- Magnetic separation
- Gravity separation
- Flotation
- Dense-media separation
- Washing
- Classification
- Leaching / hydrometallurgical processes, where applicable
Integrated Iron & Steel Process Route
For an integrated iron and steel plant, the principal process route can be represented as:
Alternative iron-making routes may use:
Major Industrial Applications
The major industrial applications of the sector cover mining and mineral extraction, beneficiation and processing, pelletisation and sintering, coke and coal processing, iron making, steel making, continuous casting, rolling and finished steel products, non-ferrous metals, and the utilities, infrastructure and environmental systems that support them.
1. Mining & Mineral Extraction
- Open-cast mining
- Underground mining
- Mineral extraction
- Ore handling
- Mine material transportation
- Mine dewatering
- Crushing and screening
- Stockyard facilities
2. Mineral Beneficiation & Processing
- Ore beneficiation
- Concentration plants
- Magnetic separation
- Flotation plants
- Gravity separation
- Washing plants
- Grinding and classification
- Dewatering
- Concentrate handling
3. Iron Ore Pelletisation & Sintering
- Pelletisation plants
- Green pellet preparation
- Pellet induration
- Pellet screening
- Sinter plants
- Sinter cooling
- Sinter screening and handling
4. Coke & Coal Processing
- Coal handling
- Coal preparation
- Coke ovens
- Coke screening
- Coke handling
- Coke oven gas systems
- By-product recovery
5. . Iron Making
- Blast furnaces
- Direct reduced iron plants
- Hot-metal production
- Furnace gas systems
- Raw-material charging
- Hot-metal handling
6. Steel Making
- Basic oxygen / converter steelmaking
- Electric arc furnace steelmaking
- Induction furnace steelmaking
- Ladle metallurgy
- Secondary refining
- Vacuum treatment, where applicable
7. Continuous Casting
- Slab casting
- Bloom casting
- Billet casting
- Tundish systems
- Mould systems
- Secondary cooling
- Strand withdrawal
- Cutting systems
8. Rolling & Finished Steel Products
- Hot rolling
- Cold rolling
- Plate mills
- Strip mills
- Bar mills
- Wire rod mills
- Section mills
- Pipe / tube production
- Galvanizing / coating
- Heat treatment
- Finishing and inspection
9. Non-Ferrous Metals
- Aluminium processing
- Copper processing
- Zinc / lead processing
- Smelting
- Refining
- Casting
- Rolling / extrusion
- Metal finishing
10. Utilities, Infrastructure & Environmental Systems
- Power generation and distribution
- Water systems
- Cooling systems
- Compressed air
- Oxygen / nitrogen systems
- Industrial gases
- Dust collection
- Gas cleaning
- Effluent treatment
- Slag handling
- Waste management
Major Units, Facilities, Systems & Packages
The following sections set out the major units, facilities, systems and packages of the Mining, Metals & Steel Industries sector, covering mining, ore handling and beneficiation, pelletisation and sintering, coke production, iron and steel making, casting, rolling, pipe manufacturing and coating, utilities, material handling and brownfield, expansion and shutdown projects.
| Ref. | Section | Groups |
|---|---|---|
| 1 | Mining & Ore Extraction | Mining FacilitiesMaterial HandlingMine Dewatering |
| 2 | Crushing, Screening & Ore Handling | CrushingScreening & ClassificationOre Handling |
| 3 | Mineral Beneficiation | Grinding & MillingSeparationConcentrate Treatment |
| 4 | Pelletisation & Sintering | PelletisationSinter Plant |
| 5 | Coal Handling & Coke Production | Coal HandlingCoke OvensBy-Product Systems |
| 6 | Iron Making | Blast FurnaceFurnace GasDirect Reduced Iron |
| 7 | Steel Making | Converter / BOF RouteElectric SteelmakingSecondary MetallurgyLadle & Material Handling |
| 8 | Continuous Casting | Casting EquipmentCasting Product Handling |
| 9 | Rolling Mills | Hot RollingPlate / Strip MillsLong ProductsFinishing |
| 10 | Steel Pipe & Tube Manufacturing | Systems listed directly under this section |
| 11 | Surface Treatment & Coating | Systems listed directly under this section |
| 12 | Utilities & Industrial Infrastructure | PowerWater & CoolingIndustrial GasesEnvironmental Systems |
| 13 | Material Handling & Lifting Systems | Systems listed directly under this section |
| 14 | Brownfield, Expansion & Shutdown Projects | Plant ExpansionEquipment ReplacementShutdown / Maintenance |
1. Mining & Ore Extraction
Mining and ore extraction covers the facilities that win the ore, the equipment that handles and moves it, and the systems that keep the mine dry. The groups below cover mining facilities, material handling and mine dewatering.
Mining Facilities
- Open-cast mining facilities
- Underground mining facilities
- Mine shafts
- Mine galleries
- Ore extraction systems
- Mine dewatering systems
- Mine ventilation systems
Material Handling
- Haul roads and material transfer systems
- Conveyor systems
- Crushers
- Feeders
- Hoppers
- Transfer stations
- Stackers
- Reclaimers
- Stockyards
Mine Dewatering
- Dewatering pumps
- Sump systems
- Drainage systems
- Pump stations
- Water transfer pipelines
2. Crushing, Screening & Ore Handling
Crushing, screening and ore handling reduce the ore to size, separate it by size and move it onward. The groups below cover crushing, screening & classification, and ore handling.
Crushing
- Primary crushers
- Secondary crushers
- Tertiary crushers
- Jaw crushers
- Gyratory crushers
- Cone crushers
- Impact crushers
Screening & Classification
- Vibrating screens
- Trommel screens
- Grizzlies
- Classification systems
- Feeders
Ore Handling
- Belt conveyors
- Transfer chutes
- Hoppers
- Bins
- Stockpiles
- Stackers
- Reclaimers
- Magnetic separators
3. Mineral Beneficiation
Mineral beneficiation grinds the ore, separates the valuable mineral from the waste and treats the resulting concentrate. The groups below cover grinding & milling, separation and concentrate treatment.
Grinding & Milling
- Ball mills
- Rod mills
- SAG mills
- Grinding circuits
- Cyclones
- Classification systems
Separation
- Magnetic separators
- Flotation cells
- Gravity separators
- Dense-media systems
- Hydrocyclones
- Spiral separators
Concentrate Treatment
- Thickening
- Filtration
- Dewatering
- Drying
- Concentrate storage
- Concentrate loading
4. Pelletisation & Sintering
Pelletisation and sintering agglomerate fine ore into a form suitable for iron making. The groups below cover the pelletisation plant and the sinter plant.
Pelletisation
- Raw-material preparation
- Grinding
- Mixing
- Binder dosing
- Pelletizing discs / drums
- Green pellet screening
- Induration furnaces
- Pellet coolers
- Finished pellet screening
- Pellet storage and handling
Sinter Plant
- Sinter raw-material preparation
- Proportioning systems
- Mixing systems
- Sinter machines
- Ignition systems
- Sinter coolers
- Crushers
- Screening
- Sinter return-fines systems
- Sinter storage and handling
5. Coal Handling & Coke Production
Coal handling and coke production receive and prepare coal, convert it to coke in the coke ovens and recover the by-products. The groups below cover coal handling, coke ovens and by-product systems.
Coal Handling
- Coal receiving
- Coal crushers
- Coal screens
- Coal conveyors
- Coal storage
- Stackers / reclaimers
- Coal blending
Coke Ovens
- Coke oven batteries
- Coal charging systems
- Coke pushing systems
- Coke quenching
- Coke screening
- Coke handling
By-Product Systems
- Coke oven gas collection
- Gas cooling
- Tar recovery
- Ammonia recovery
- Benzol recovery, where applicable
- Gas cleaning and treatment
6. Iron Making
Iron making produces hot metal or direct reduced iron from the prepared raw materials. The groups below cover the blast furnace, furnace gas systems and direct reduced iron.
Blast Furnace
- Blast furnace
- Raw-material charging systems
- Hot-blast stoves
- Hot-blast piping
- Blast furnace blowers
- Pulverized coal injection, where applicable
- Tuyere systems
- Hot-metal handling
- Slag handling
Furnace Gas
- Blast furnace gas collection
- Dust removal
- Gas cleaning
- Gas cooling
- Gas distribution
Direct Reduced Iron
- DRI shaft furnaces
- Gas reforming systems
- Reducing-gas systems
- DRI cooling
- DRI screening
- DRI handling and storage
7. Specialty Chemical & Formulation Plants
Steel making converts hot metal or scrap into steel and refines it to the required composition and temperature. The groups below cover the converter / BOF route, electric steelmaking, secondary metallurgy, and ladle & material handling.
Converter / BOF Route
- Basic oxygen furnaces
- Hot-metal charging
- Oxygen lance systems
- Flux addition
- Converter tilting
- Slag handling
- Fume extraction
Electric Steelmaking
- Electric arc furnaces
- Induction furnaces
- Electrode systems
- Furnace transformers
- Cooling systems
- Fume extraction
Secondary Metallurgy
- Ladle furnaces
- Vacuum degassing
- Argon stirring
- Alloy addition
- Temperature control
- Chemical composition control
Ladle & Material Handling
- Steel ladles
- Ladle preheating
- Ladle transfer systems
- Overhead cranes
- Slag handling
- Refractory systems
8. Continuous Casting
Continuous casting turns liquid steel into slabs, blooms and billets and handles the cast product. The groups below cover casting equipment and casting product handling.
Casting Equipment
- Tundish systems
- Mould assemblies
- Oscillation systems
- Strand withdrawal
- Secondary cooling
- Straightening systems
- Torch / mechanical cutting
- Slab / billet / bloom handling
Casting Product Handling
- Slab yards
- Billet yards
- Bloom handling
- Transfer systems
- Marking systems
- Inspection systems
9. Rolling Mills
Rolling mills reduce and shape cast steel into plate, strip, long products and other finished forms. The groups below cover hot rolling, plate / strip mills, long products and finishing.
Hot Rolling
- Reheating furnaces
- Roughing mills
- Finishing mills
- Descaling systems
- Cooling systems
- Coilers
- Shears
Plate / Strip Mills
- Plate mills
- Hot strip mills
- Cold rolling mills
- Pickling lines
- Continuous annealing
- Skin-pass mills
- Tension levellers
Long Products
- Bar mills
- Wire rod mills
- Section mills
- Structural mills
- Rebar mills
Finishing
- Straightening
- Cutting
- Surface inspection
- Grinding
- Heat treatment
- Bundling
- Packaging
10. Steel Pipe & Tube Manufacturing
Steel pipe and tube manufacturing forms, welds, treats, tests and finishes pipe and tube. The items below are listed directly under this section.
Steel Pipe & Tube Manufacturing
- Pipe forming
- ERW pipe mills
- Seamless pipe manufacturing
- Pipe welding
- Pipe sizing
- Heat treatment
- Hydrostatic testing
- NDT
- Coating
- Pipe finishing
- Pipe handling and storage
11. Surface Treatment & Coating
Surface treatment and coating cleans, treats and protects steel surfaces. The items below are listed directly under this section.
Surface Treatment & Coating
- Pickling
- Acid treatment
- Galvanizing
- Electroplating
- Coating lines
- Painting
- Surface preparation
- Drying / curing
- Coating inspection
12. Utilities & Industrial Infrastructure
Utilities and industrial infrastructure support the process areas with power, water and cooling, industrial gases and environmental systems. The groups below cover each of these.
Power
- Captive power plants
- Substations
- Transformers
- Switchyards
- Electrical distribution
- Emergency power
Water & Cooling
- Raw-water systems
- Cooling-water systems
- Cooling towers
- Process-water systems
- DM / RO systems
- Water storage
Industrial Gases
- Oxygen plants
- Nitrogen plants
- Argon systems
- Compressed air
- Instrument air
- Gas storage and distribution
Environmental Systems
- Dust collection
- Bag filters
- ESPs
- Gas cleaning
- Fume extraction
- Effluent treatment
- Wastewater systems
- Slag handling
- Solid-waste handling
13. Material Handling & Lifting Systems
Material handling and lifting systems move materials, ladles and products around the plant. The items below are listed directly under this section.
Material Handling & Lifting Systems
- EOT cranes
- Gantry cranes
- Ladle cranes
- Slag handling cranes
- Hoists
- Conveyors
- Stackers
- Reclaimers
- Bucket elevators
- Feeders
- Transfer systems
14. Brownfield, Expansion & Shutdown Projects
This section covers work on existing plants: expansion, equipment replacement, and shutdown / maintenance. The groups below set out the items under each.
Plant Expansion
- New production lines
- New furnaces
- New rolling mills
- Capacity expansion
- New material-handling systems
- Utility expansion
- Electrical expansion
Equipment Replacement
- Crushers
- Mills
- Pumps
- Fans
- Compressors
- Furnaces
- Transformers
- Switchgear
- Rolling equipment
- Cranes
Shutdown / Maintenance
- Furnace inspection
- Mill overhaul
- Conveyor inspection
- Pressure-system inspection
- Equipment replacement
- Piping modification
- Electrical maintenance
- Structural inspection
- Recommissioning
Sector wise Commodities
The Mining, Metals & Steel sector has a particularly broad industrial asset base combining mineral-handling equipment, heavy mechanical machinery, process equipment, fabricated steel structures, pressure systems, rotating machinery and high-capacity electrical equipment.
The applicable CQRA inspection universe can be considered under SS17, SS18 and SS19.
SS17
Basic Metals & Fabricated Metal Products
- Raw Materials
- Process Piping & Components
- Fabricated Products
- Static & Process Equipment
- Food / Hygienic Fabrication
- Fabrication & Welding
SS18
- Crushing & Grinding Equipment
- Material Handling Equipment
- Pumps
- Fans & Blowers
- Furnaces & Thermal Equipment
- Steelmaking Equipment
- Rolling & Finishing Equipment
- Valves
- Lifting Equipment
- Process / Skid Equipment
SS19
Electrical & Optical Equipment
- Power Generation
- Transformers
- Switchgear & Distribution
- Electrical Machines
- Furnace / High-Power Electrical Systems
- Cables & Bus Systems
- Protection & Substation Equipment
- Backup & Protection
SS17 – Basic Metals & Fabricated Metal Products
SS17 — Basic Metals & Fabricated Metal Products covers the following categories for this sector: Raw Materials, Process Piping & Components, Fabricated Products, Static & Process Equipment, Food / Hygienic Fabrication and Fabrication & Welding. The items under each category are listed below.
Raw Materials
- Plates & Sheets
- Pipes & Tubes
- Bars
- Forgings
- Castings
Structural & Fabricated Steel
- Structural Steel
- Columns & Beams
- Bracings
- Platforms
- Walkways
- Gratings
- Equipment Supports
- Pipe Racks
- Frames
- Conveyor Structures
- Fabricated Chutes
- Hoppers
- Bins
Piping & Components
- Process Piping
- Utility Piping
- Pipe Fittings
- Flanges
- Fasteners
- Gaskets
- Metallic piping components
Static & Process Equipment
- Process Tanks
- Storage Tanks
- Pressure Vessels
- Heat Exchangers
- Condensers
- Air Receivers
- Process Columns
- Separators
- Furnace-related fabricated equipment
- Material-handling structures
Fabrication & Welding
- Heavy fabrication
- Structural fabrication
- Conveyor fabrication
- Chute / hopper fabrication
- Welding inspection
- WPS / PQR / WPQ
- NDT
- Heat treatment
- Dimensional inspection
- Material traceability
SS18 – Machinery & Equipment
SS18 — Machinery & Equipment covers the following categories for this sector: Crushing & Grinding Equipment, Material Handling Equipment, Pumps, Fans & Blowers, Furnaces & Thermal Equipment, Steelmaking Equipment, Rolling & Finishing Equipment, Valves, Lifting Equipment and Process / Skid Equipment. The items under each category are listed below.
Crushing & Grinding Equipment
- Jaw Crushers
- Gyratory Crushers
- Cone Crushers
- Impact Crushers
- Ball Mills
- Rod Mills
- SAG Mills
- Grinding Mills
Material Handling Equipment
- Conveyors
- Feeders
- Stackers
- Reclaimers
- Bucket Elevators
- Transfer Systems
Pumps
- Slurry Pumps
- Centrifugal Pumps
- Process Pumps
- Dewatering Pumps
- Cooling-Water Pumps
- Chemical Dosing Pumps
Fans & Blowers
- ID Fans
- FD Fans
- Cooling Fans
- Process Blowers
- Furnace Blowers
- Gas-cleaning Fans
Furnaces & Thermal Equipment
- Reheating Furnaces
- Heat Treatment Furnaces
- Induction Furnaces
- Sintering / Induration Equipment
- Coke Oven Equipment
- Thermal Processing Equipment
Steelmaking Equipment
- Blast Furnace Equipment
- BOF / Converter Equipment
- Electric Arc Furnaces
- Ladle Furnaces
- Vacuum Degassing Equipment
- Continuous Casting Equipment
Rolling & Finishing Equipment
- Rolling Mills
- Roughing Mills
- Finishing Mills
- Coilers
- Straighteners
- Shears
- Pickling Equipment
- Galvanizing Equipment
- Coating Equipment
Valves
- Gate Valves
- Globe Valves
- Ball Valves
- Butterfly Valves
- Check Valves
- Control Valves
- Special-service valves
Lifting Equipment
- EOT Cranes
- Ladle Cranes
- Gantry Cranes
- Jib Cranes
- Hoists
- Lifting Accessories
Process / Skid Equipment
- Chemical Dosing Packages
- Hydraulic Power Units
- Lubrication Packages
- Filtration Systems
- Water Treatment Packages
- Gas Treatment Packages
- Other applicable skid-mounted equipment
SS19 – Electrical & Optical Equipment
SS19 — Electrical & Optical Equipment covers the following categories for this sector: Power Generation, Transformers, Switchgear & Distribution, Electrical Machines, Furnace / High-Power Electrical Systems, Cables & Bus Systems, Protection & Substation Equipment and Backup & Protection. The items under each category are listed below.
Power Generation
- Generators
- Turbo Generators
- DG Sets
- Emergency Generators
Transformers
- Generator Transformers
- Power Transformers
- Furnace Transformers
- Distribution Transformers
- Auxiliary Transformers
Switchgear & Distribution
- HV Switchgear
- MV Switchgear
- LV Switchgear
- MCCs
- Electrical Panels
- Distribution Boards
- Substation Equipment
Electrical Machines
- HV Motors
- LV Motors
- Crusher Motors
- Mill Motors
- Conveyor Motors
- Pump Motors
- Fan Motors
- Electrical Drives
Furnace / High-Power Electrical Systems
- Furnace Transformers
- EAF Electrical Systems
- Electrode-related electrical equipment
- High-current bus systems
- Rectifier systems, where applicable
Cables & Bus Systems
- HV / MV / LV Cables
- Power Cables
- Control Cables
- Busducts
- High-current bus systems
Protection & Substation Equipment
- Circuit Breakers
- Protection Relays
- CTs
- PTs / VTs
- Surge Arresters
- Isolators
- Protection & Control Panels
Backup & Protection
- UPS
- Battery Chargers
- Battery Banks
- DC Systems
- Earthing Systems
- Lightning Protection
Industrial Inspection & assurance services supporting quality, compliance and effective project execution.
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