FORM2
THE PATENTS ACT 1970
39 OF 1970
&
THE PATENT RULES 2003
COMPLETESPECIFICATION
(SEE SECTIONS 10 & RULE 13)
1. TITLEOF THE INVENTION
“A PROCESS FOR PRODUCING CATHODE COLLECTOR BAR FOR ALUMINIUM INDUSTRIES BY UNIVERSAL ROLLING MILL
ROUTE”
2. APPLICANTS (S)
NAME NATIONALITY ADDRESS
JINDAL STEEL & POWER LIMITED AN INDIAN COMPANY KHARSIA ROAD,
RAIGARH - 496001 (CG),
INDIA
3. PREAMBLETOTHEDESCRIPTION
COMPLETESPECIFICATION
The following specification particularly describes the invention and the manner in which it is to be performed

FIELD OF INVENTION
[001] The present subject matter described herein, relates to the field of aluminium smelting and manufacturing. More particularly, to a process for producing cathode collector bar by universal rolling mill in aluminium smelting industry.
BACKGROUND AND PRIOR ART AND PROBLEM IN PRIOR ART
[002] Over the past decades, demand of cathode bar for aluminum smelting industries has been increasing to produce more aluminium with less energy consumption. Keep in mind the increasing market demand of cathode collector bar, there is always a need to develop the effective and superior Cathode collector bar with in-house facility to full fill the demand of different aluminum industries. However, the quality of the final product often depends on the choice and quantity of raw materials. Conventionally, resistive materials have chosen for 25 production of cathode collector bar, which not only results compromise in quality in the cathode bar, also results in high energy consumption.
[003] Further, conventionally, rolling is generally used for production of cathode collector. Cathode collector for aluminum industries are supplied by cross country rolling mill and machining of bar with conventional machines. But, in the conventional techniques, the mill production is very less and product quality is not up to mark and required lot of offline process for rectification. Also the final product is not finished in one shed, required different process at different location to make it finished product ready to use for customer. Hence, with this technology, customer always need to maintain high inventory as the required delivery time is too long.
[004] None of the above prior arts can fulfill the requirements of the invention for which it has been developed. Hence, the present invention has been introduced.

OBJECTS OF THE INVENTION
[005] It is therefore the object of the invention to overcome the aforementioned and other drawbacks in prior art.
[006] The principal objective of the present invention is to provide an improved process for producing cathode collector bar by universal rolling mill in aluminium smelting industry.
[007] Another object of the present invention is to provide an improved process for producing cathode collector bar that leads to increased production and lesser energy consumption.
[008] Another object of the present invention is to provide an improved process for producing cathode collector bar that results into lesser resistivity of cathode tube bars.
[009] Another object of the present invention is to provide an improved process for producing cathode collector bar that leads to low inventory for customers and reduced delivery time.
[0010] These and other objects and advantages of the present subject matter would be apparent to a person skilled in the art after consideration of the following detailed description taken into consideration with accompanying drawings in which preferred embodiments of the present subject matter are illustrated.
SUMMARY OF THE INVENTION
[0011] One or more drawbacks of the conventional technology based on existing apparatus and processes are overcome, and additional advantages are provided through the present subject matter.
[0012] Additional features and advantages are realized through the technicalities of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered to be a part of the claimed disclosure.
[0013] In an embodiment of the present subject matter, a process is developed for producing cathode collector bars using ultralow carbon steel having carbon 0.01%

in a universal rolling mill in aluminium smelting industry. The present process for producing cathode collector bars by universal rolling mill in aluminium smelting industry comprises the steps of two main process i.e. rolling and machining for obtaining the final cathode collector bars. Herein, the raw material is first rolled into cathode bars and further machined through machining process to obtain the finished cathode collector bars. The rolling process is carried out by means of universal rolling mills that comprise of horizontal mill and universal mills.
[0014] It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined to form a further embodiment of the disclosure.
[0015] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter, and are therefore not to be considered for limiting of its scope, for the invention may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system or methods or structure in accordance with embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which:
[0017] Figure 1 illustrates a schematic view of the process for producing cathode collector bar by universal rolling mill in aluminium smelting industry in accordance with an embodiment of the present disclosure;

[0018] Figure 2 illustrates a schematic view of the cathode collector bar in accordance with an embodiment of the present disclosure;
[0019] Figure 3 illustrates a schematic view of the process of making of steel in accordance with an embodiment of the present disclosure;
[0020] Figure 4 illustrates a schematic view of the rolling route process in accordance with an embodiment of the present disclosure;
[0021] Figure 5 illustrates the final finished product obtained by the present process in accordance with an embodiment of the present disclosure;
[0022] The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION
[0023] The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein are not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
[0024] It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
[0025] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a",” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further

understood that the terms “comprises,” “comprising,” “includes” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
[0026] It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
[0027] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0028] The process of shaping metals into semi-finished or finished forms by passing between rollers is called rolling. Rolling is the most widely used metal forming process. It is used to convert metal ingots to simple stock members like blooms, billets, slabs, sheets, plates, strips etc. In rolling, the metal is plastically deformed by passing it between rollers rotating in opposite direction. The main objective of rolling is to decrease the thickness of the metal. Ordinarily, there is negligible increase in width, so that the decrease in thickness results in an increase in length.
[0029] The range of products that can be produced by rolling is very large. Rolling is a more economical method of deformation than forging when metal is required in long lengths of uniform cross-section. It is one of the most widely used among all the metal working processes, because of its higher productivity and lower cost. The materials commonly rolled are steel, copper, magnesium, aluminum and their alloys.

[0030] As illustrated in Figure 1 to 5, the present subject matter discloses a process for producing cathode collector bar using low carbon steel having carbon <0.06% in a universal rolling mill used in aluminium smelting industry. The present process for producing cathode collector bar by a universal rolling mill comprises the steps of two main process i.e. rolling and machining for obtaining the final cathode collector bars.
[0031] The rolling process comprises the steps of (a) charging bloom material into
a furnace and heated to a temperature between 1150oC-1250oC, wherein the raw
boom material consists of low carbon steel having carbon ≤ 0.06%, (b) De-scaling
the heated blooms in a high pressure water De-scaler, (c) Roughing and shaping of
the De-scaled blooms in a roughing mill, wherein size of the blooms within a
range of 5% to 20 % of original size in each of five roughing stands numbered as
stand 1 to stand 5 to obtain stock material, (d) Transferring the roughed stock
material to a set of intermediate universal mills on a set of five stands numbered as
stand 6 to stand 10, for further shaping of the stock material into a pre-finished
cathode bar profile, (e) Transferring the pre-finished cathode bar to a set of
finishing universal mills on a set of five stands numbered as stand 11 to 15, for obtaining finished cathode bar profile, (f) Transferring the finished cathode bar to an online and automated, digital profile gauge for online measurement of the dimensional profile along the length of the finished cathode bar, (g) Transferring the finished cathode bar to a rack type cooling bed, at a temperature in the range 850 – 950 °C, for cooling, (h) Transferring and further cutting of the finished cathode bar at a temperature below 150 ° C by a pair of cold saws, wherein the cutting length is between 6 to 12 m, (i) Transferring the cut cathode bars to a stacker, (j) Transferring the stacked cathode bars to a set of automated tying machines for tying the cathode bars into bundles and (k) Transferring the cathode bar bundles to a collection bed prior to machining process. The present rolling process is carried out through a combination of horizontal mill and universal mills.
[0032] The next process subsequent to rolling process is machining route carried out in a customised single station CNC (Computer Numerical Control) machine, comprising the steps of (a) Transferring the cathode bars to a stacking table, wherein the cathode bars are stacked in rows and automatically transferred to a band saw, (b) Cutting of cathode bar using a band saw into a length ranging

between 1.8 to 2.5 m, (c) Machining of cathode bars in a CNC machine to obtain finished and machined cathode bar at a single CNC machining station, (d) Transferring the finished cathode bars for quality inspection and ( e) Packaging of the finished cathode bars.
TECHNICAL ADVANTAGES:
[0033] The present process results into a less resistive material thus reducing the energy consumption in aluminium smelting industries.
[0034] The present process results into cathode collector bars that are ready to use simply in the industry.
[0035] The present process reduces the delivery time to customers as multiple bars are produced during through a single round of the present process and thus increasing the process efficiency and productivity.
[0036] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art

will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
[0037] It will be further appreciated that functions or structures of a plurality of components or steps may be combined into a single component or step, or the functions or structures of one-step or component may be split among plural steps or components. The present invention contemplates all of these combinations. Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention. The present invention also encompasses intermediate and end products resulting from the practice of the methods herein. The use of “comprising” or “including” also contemplates embodiments that “consist essentially of” or “consist of” the recited feature.
[0038] Although embodiments for the present subject matter have been described in language specific to structural features, it is to be understood that the present subject matter is not necessarily limited to the specific features described. Rather, the specific features and methods are disclosed as embodiments for the present subject matter. Numerous modifications and adaptations of the system/component of the present invention will be apparent to those skilled in the art, and thus it is intended by the appended claims to cover all such modifications and adaptations, which fall within the scope of the present subject matter.

We Claim:
1. A process for producing cathode collector bar by universal rolling mill in aluminium smelting industry, the process comprising the steps of:
A. rolling comprising the steps of:
(a) charging raw bloom material in a furnace heated to a temperature between 1150oC-1250oC for heating the raw bloom material;
(b) De-scaling the heated blooms in a high pressure water De-scaler;
(c) Roughing and shaping of the De-scaled blooms in a roughing mill, wherein size of the blooms within a range of 5% to 20 % of original size in each of five roughing stands to obtain stock material;
(d) Transferring the roughed stock material to a set of intermediate universal mills on a set of five stands for further shaping of the stock material into a pre-finished cathode bar profile;
(e) Transferring the pre-finished cathode bar to a set of finishing universal mills on a set of five stands for obtaining finished cathode bar profile;
(f) Transferring the finished cathode bar to an online and automated, digital profile gauge for online measurement of the dimensional profile along the length of the finished cathode bar.
(g) Transferring the finished cathode bar to a rack type cooling bed, at a temperature in the range 850 – 950 °C, for cooling.
(h) Transferring and further cutting of the finished cathode bar at a temperature below 150 ° C by a pair of cold saws, wherein the cutting length is between 6 to 12 m;
(i) Transferring the cut cathode bars to a stacker;

(j) Transferring the stacked cathode bars to a set of automated tying machines for tying the cathode bars into bundles;
(k) Transferring the cathode bar bundles to a collection bed prior to machining process;
B. machining comprising the steps of:
(a) Transferring the cathode bars to a stacking table wherein the cathode bars are stacked in rows and automatically transferred to a band saw;
(b) Cutting of cathode bar using a band saw into a length ranging between 1.8 to 2.5 m;
(c) Machining of cathode bars in a CNC machine to obtain finished and machined cathode bar at a single CNC machining station;
(d) Transferring the finished cathode bars for quality inspection; and
(e) Packaging of the finished cathode bars.

2. The process as claimed in claim 1, wherein the rolling is done through a combination of horizontal and universal mill.
3. The process as claimed in claim 1, wherein machining is carried out in a customised single station CNC machine.