WE CLAIM:
1.High carbon steel wire rod suitable for tire cord and textile carding applications comprising of steelcomposition having from0.6 to 1.2 %C with Mn content ranging between 0.5 to 1.2 %, silicon content less than 0.7%, phosphorus less than 0.015%, sulphur less than 0.005%, titanium less than 15 ppm, aluminium less than 30 ppm, nitrogen less than 35 ppm and rest iron
2. High carbon steel wire rod as claimed in claim 1 having diameter in the range of 5 to 10 preferably about 5.5. mm dia comprising less than 15 ppm Ti and with fine inclusions in the range of 2 to 5 micron deformable inclusions of manganese silicate, and detrimental presence of TiN < 5 micron
3. High carbon steel wire rod as claimed in anyone of claims 1 or 2 having nil grain boundary cementite.
4. High carbon steel wire rod as claimed in anyone of claims 1 to 3 comprising of plastic inclusions with composition MnO between 45 and 55%, SiO2 between 30 and 40%, Al2O3 less than 6%, MgO less than 4%, CaO less than 5% and inclusion size less than 5microns, the MnO/SiO2 ratio being between 0.5 to 2 enabling low melting point inclusions and which are deformable in nature during cold wire drawing.
5. A process for the manufacture of high carbon steel wire rod as claimed in anyone of claims 1 to 4 comprising:
i) Providing select steel composition and carrying out primary
steel making through Energy Optimisation Furnace involving oxidizing all the solutes in hot metal by blowing the hot metal with oxygen, fluxing oxides with lime to form a suitable slag and generating primary steel with carbon to less than 0.060, manganese to less than 0.05, silicon less than 0.0015, phosphorus to less than 0.015, titanium less

than 15 ppm and nitrogen gas level less than 35 ppm and rest iron;
ii) subjecting the thus generated primary steel to ladle refining process involving adding Si metal, Mn metal, CPC and carbon wire to get a steel composition of 0.6 to 1.2 %C with Mn content ranging between 0.5 to 1.2 %, silicon content less than 0.7%, phosphorus less than 0.015%, sulphur less than 0.005%, titanium less than 15 ppm, aluminium less than 30 ppm, nitrogen less than 35 ppm and rest iron; adding slag generator including selectively Lime and Quartzite to get top slag composition with CaO/SiO2 ratio in the range of 1.3 to 1.8 preferably around 1.5; followed by,
iii) subjecting the thus ladle refined steel obtained to treatment under vacuum in a vacuum degassing process to achieve Nitrogen level below 35 ppm and Sulphur below 0.005%. and inclusion floatation including MnO.SiO2 inclusions;
iv) casting the steel into billets; and finally
v) hot rolling to obtain the high carbon steel wire rod of
steelcomposition having from0.6 to 1.2 %C with Mn
content ranging between 0.5 to 1.2 %, silicon content less
than 0.7%, phosphorus less than 0.015%, sulphur less than
0.005%, titanium less than 15 ppm, aluminium less than 30
ppm, nitrogen less than 35 ppm and rest iron, deformable
inclusion sizeup to 20 micron max favouring cold wire
drawing deformation and with average grain size up to 25
microns.
6. A process for the manufacture of high carbon steel wire rod as claimed in
claim 5 wherein said step of primary steel making process through an
Energy Optimization Furnace is carried out such as to favour removal of
carbon to less than 0.060, manganese to less than 0.05, silicon less than

0.0015, phosphorus to less than 0.015, titanium less than 15 ppm and nitrogen gas level less than 35 ppm and rest iron and include dephosphorisation involving a tailored slag with basicity 2 to 3 preferably about 2.5 and FeO content between 25-30%.
7. A process for the manufacture of high carbon steel wire rod as claimed in anyone of claims 5 or 6 wherein said step of secondary steel making in ladle refining furnace, include coke addition during tapping at the rate of about 0.3 kg/ton of steel and also Si and Mn addition for initial deoxidation to remove the oxygen in the primary steel preferably accompanied with reduced refractory wear additives preferably Dolime at a rate of 1.4 kg/ton to 1.6 kg/ton preferably about 1.5 kg/ton to reduce refractory wear and wherein said lime is added at rate of 7 kg/ton to 9 kg/ton preferably about 8 kg/ton, such that oxide products from deoxidation are fluxed by the said slag such that any residual fine oxide inclusions are a fine dispersion of manganese silicate inclusions in molten steel that are plastic during the cold wire drawing operations in final application.
8. A process for the manufacture of high carbon steel wire rod as claimed in anyone of claims 5 to 7 comprising addition of spar at rate of 1kg/ton to 1.5 kg/ton preferably about 1.2 kg/ton for improving slag fluidity,
9. A process for the manufacture of high carbon steel wire rod as claimed in anyone of claims 5 to 8 wherein said lime addition and quartzite sand addition is carried out such that the slag has low alumina content and the basicity is maintained between 1.5 to 2.0 for efficient desulphurization and inclusion removal and wherein the top slag chemistry is maintained at 51 to 55 %CaO- 4 to 7 %MgO - 28 to 33 % SiO2 – 5 to 8%Al2O3-3 to 5%CaF2, said slag enabling avoiding hard inclusion phases with Al2O3 constitution in the final product.
10. A process for the manufacture of high carbon steel wire rod as claimed in anyone of claims 5 to 9 comprising controlled solidification of the molten

steel involving continuous casting process where the cooling conditions are maintained hard to maintain lower macro segregation.
11. A process for the manufacture of high carbon steel wire rod as claimed in anyone of claims 5 to 10 comprising heating the billets produced through reheating furnace to a temperature preferably about 1200oC, descaled and hot rolled with reversing mill- H-V mill and finally followed by non-twist mill(NTM) to generate said wire rod and wherein a reduction ratio preferably about 1078:1 is followed in the rolling process, the laying head temperatures in NTM is maintained between 880 to 920oC, for ensuring proper coil formation with good surface finish.
12. A process for the manufacture of high carbon steel wire rod as claimed in anyone of claims 5 to 11 comprising cooling the wire rods in a Stelmor cooling bed involving blowers such that the cooling is not too slow to generate grain boundary cementite and not too hard cooling to promote martensite , preferably a cooling rate of 14ᵒC/sec to 17ᵒC/sec preferably about 16ᵒC/sec in the Stelmor conveyor to prevent grain boundary cementite formation with reduced stelmor conveyor length of 60meters and favour the plastic inclusions with composition MnO between 45 and 55%, SiO2 between 30 and 40%, Al2O3 less than 6%, MgO less than 4%, CaO less than 5% and inclusion size less than 5 microns with the MnO/SiO2 ratio maintained between 0.5 to 2 for desired low melting point inclusions and which are deformable in nature during cold wire drawing.
13. A process for the manufacture of high carbon steel wire rod as claimed in anyone of claims 5 to 11 comprising:
said primary steel making through Energy Optimisation Furnace is carried
out following:
charging hot metal having composition comprising of C-4.2% to 4.4%
%;Si-0.6%to

0.8%;Mn – 0.08% to 0.14%; P-0.08% to 0.12%; S-0.035% to 0.055%; rest
iron;
blowing oxygen 3500 to 3800 Nm3;
air blowing 130 to 160 Nm3;
maintaining tap temperature in the range of 1530 °C. to 1560 °C and heat
duration 35 to 40 min;
said secondary steel making in ladle comprising:
and involving
tap additions- CPC-0.3kg/ton; Si Metal-1.6kg/ton; HCFeMn-3kg/ton
slag additions - Lime- 7-9 kg/ton; Quartzite-1.5 kg/ton; Spar-1 to 1.5 kg/ton
alloying additions -HCFeMn-2.5 to 3 kg/Ton; Si Metal-2.8 to 3.3 kg/Ton;
Mn Metal-2.4 to 2.6 kg/Ton Calcined; Petroleum Coke-8 to 9 kg/ton;
Carbon wire-0.3 to 0.5 kg/ton;
Vacuum degassing under 0.5 mbar, holding time 10 to 12 min and argon
flow rate 5 to 8 Nm3/hr;
Using slag composition comprising CaO-40 to 55% % SiO2-25 to 30 %
Al2O3-4 to 10%
MgO-5 to 8%; CaF2-2 to 4 % such as to achieve metal composition
comprising
C- 0.70 to 0.85 % Si-0.15 to 0.25% Mn-0.50 to 0.55 % P- 0.008 to 0.015 % S-<0.005% Al-<0.003%% Ti-< 0.0015% N- 30to 35 ppm; Rest iron followed by
Soft rinsing involving Argon flow rate- 0.3to 0.5 Nm3/hr; Rinsing time of
10 mins; and
Lifting temperature in the range of 1520 °C. to 1550 °C
Said casting including casting speed of 1.8m/min, super heat in the range of 20 to 25 °C.

14. A process for the manufacture of high carbon steel wire rod as claimed in anyone of claims 5 to 13 comprising carrying out wire rolling for wire rod including:
RHF parameters Preheating Zone: 860 to 880°C, Heating zone-1050 to 1150°C, Soaking Zone- 1180 to 1220 °C,
Laying head temperature in the range of 880 to 920°C; and Stelmor cooling rate in the range of 14°C/sec to 17°C/sec.