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TRAINING REPORT ON
BOKARO STEEL BOKARO STEEL PLANTPLANTSAILSAIL
Presented By:- Beyas Presented By:- Beyas MazumdarMazumdarRoll Number:- Roll Number:- AUE/13/25AUE/13/25Semester:- 5th Semester:- 5th
contentscontentsCompany BackgroundBasic InformationTownshipMedicalSources of Raw MaterialsProcess flow of Raw Material into
STEELLeading ConsumersCertificate
BackgroundBackground Fourth Integrated Steel PlantIntegrated Steel Plant in Public Sector, well
known as Swadeshi Plant, maximum indigenization in equipment, materials & know-how
Originally incorporated as a Limited Company Limited Company on 29.01.64
Collaboration agreement with Soviet Union (USSR) on 25th Jan, 1965 ( SAIL Foundation DaySAIL Foundation Day)
After formation of SAIL on 24th January 1973, merged with SAIL on 01.05.78
Collaboration with the then USSR Total area 33,045.35 acres Flat Product : HR Coil, HR Sheet, CR Coil, CR Sheet,
Tin Mill Black Plate, Galvanised Plain&GC
Basic InformationBasic Information Location : ;approx. 50 kms from Dhanbad and 140 kms
each from Ranchi and Jamshedpur Latitude : 230 39' Longitude : 860 09' Altitude : 210 metres (average) varying from 195 to 224
metres Climate : Extreme Annual Rainfall : Average 157 cms; Maximum 195 cms Temperature : Maximum 48½0 Celsius
: Min. 2½0 Celsius Wind direction : South-West to North-East Type of Soil : Loamy up to 1 to 2 metres, sandy soil below
that Total land area : 33,045.35 acres Plant, Slag-dump,
Cooling Ponds, Ancillaries, Marshalling Yard
: 17,208.01 acres
Township(including Airstrip)
: 10,114.53 acres Garga Reservoir : 3,886.87 acres Railways : 1,835.94 acres
TownshipTownshipLocated on the southern bank of damodar on
North Parasnath HillsArea 10,114.53 acres10 Sectors Various amenities in neighbourhoods 37,472
permanent housesBSL run 42 schools (21 CBSE & 21 affiliated to
JSSEB) having around 1200 teachers and 31,000 students
State run 4 colleges and private run 31 colleges with 31,750 students
Exemplary performance of students in various exams CBSE, ICSE, Engineering, Medical, Management, Civil Services etc.
BSL-BOKARO GENERAL HOSPITALBSL-BOKARO GENERAL HOSPITAL 910 bed Bokaro General Hospital with various specialized Units like
Emergency Ward, Intensive Coronary Care, Dialysis, Intensive Burn, Physiotherapy, Rehabitation, Special Baby Care, Nuclear Medicine, Cancer Therapy, CT Scan, ultra modern operation theater, Neuro Surgery etc.
10 Health Centre and 4 Primary Health Centres in peripheral areas Occupational Health Services Centre inside Plant premises A team of around 200 skilled doctors and over 1000 paramedical
staff
Recognition by Indian Medical Council for imparting training to Housemen &
Interns Nursing Council of India for training of Student Nurses National Board of Examinations, New Delhi as a Centre for
imparting Post-graduate training
Sintering Plant
BF1 BF2 BF3 BF4 BF5
Blast Furnace
300 TCon-1
300 TCon-2
Steel Melting Shop - 2Steel Melting Shop - 1
130TCon-1
130 TCon-2
130 TCon-3
130 TCon-4
130 TCon-5
Tandem Mill-1
Tandem Mill-2
Soaking Pit
ll
SPM 1 & 2 Hot Dip Galvanizing Line
Galvanized Sheet Shearing Line
Galvanized Sheet Corrugation Line
HR Coil
HR PLATE / SHEET
CR Coil
CR Sheet GP Coil
Galvanized Corrugated & Plain Sheet
Iron Ore
Fluxes
O H P
Continuous Casting
Department
ReheatingFurnace
SAILBokaro
Pig Casting Machine
H R C F
PROCESS FLOW
BF Coke
Coking Coal
Coke Breeze
PL-II
PL-I
ANNEALING CRCF
COKE OVEN BATTERIES
DCR Mill
Slabbing Mill Hot Strip Mill
Iron Ore, Lime Stone & Dolomite Fines
Raw Materials coming from Raw Materials coming from MinesMines
Sources of Raw MaterialSources of Raw MaterialMaterial No. of Beds
(240 M)Stock
No of DaysSource
Iron Ore Lump 4 24 Kiriburu, Meghataburu, Bolani, Barsua
Iron Ore Fines 6 16 Kiriburu, Meghataburu, Bolani, Gua
Lime Stone BF Grade
4 13 Bhawanathpur, Khanabanjari, Purnapani
Lime Stone SMS Grade
2 ½ 21 Kuteshwar, Jaisalmer, Nanwara
Dolomite Lump 16 Bhawanathpur Birmitrapur, Tulsidamar, Sonakhand
Wagon Tippler – Tippling a wagonWagon Tippler – Tippling a wagon
Coke Ovens• 8 Batteries of 5 meter height, 69 Ovens each• The process of coke making consists of destructive distillation of coal in
absence of air. The phenomenon is called high temperature (above 12000c -13000c carbonisation of coal
• Volatile matters are driven out leaving behind the residue called COKE• By-Product Plant: - Gas Condensate Section - Ammonium Sulphate Plant - Benzol Recovery Plant - Tar Distillation Plant - Sulphuric Acid Plant• Desired Analysis vs Indian Coals:
Desired Analysis
Indian Coals Imported Coals
Ash% < 16 19-24 3-12 (Av 9)
Volatile Matters% > 25 24-26 19-28 (Av 23)
Moisture% 7-9 7-8 8-11 (Av 9)Sulphur% < 0.05 0.56 < 0.05
Phosphorus% < 0.05 0.09 < 0.05
Coke Oven BatteryCoke Oven Battery
Quenching of CokeQuenching of Coke
Material Flow Diagram : Coal & CokeCoking Coal
FromVarious Source
Wagons Coal Handling Plant
Coke Sorting Plant Coke Battery ( 8 Nos.)
Blast FurnaceCoke
+ 25 -80 mm
NutCoke
CokeBreeze-15 mm
Blast Furnace
Coke Oven Gas
By Product Plant
Sinter PlantSold
Sintering Plant• 3 Sinter Machines: Capacity 6.25 million tonnes per
annum• Sintering is the process where incipient fusion takes
place by combustion of Coke within moving bed of loosely packed fines of mainly Iron ore, Coke & Flux so as to agglomerate into a compact porous mass called Sinter
• 75-80% Sinter is being used in the burden of BF• Area of each Siter belt is 252 sq.m.• Productivity of Sintering Band : 1.2 T/M2/hr• Three Sectionsa) Raw Material Sectionb) Stock Bin & Proportioning Sectionc) Sinter Machine Section
A view of Sinter beltA view of Sinter belt
Blast Furnace• The iron oxide of ore and sinter is reduced to iron with
the help of carbon monoxide & Coke• Functions of coke in BF are manifold. It provides strong
porous bed to burden and supplies the heat load. Part of the heat load is supplied by the hot air blast
• 5 Furnaces each of 2000 cubic meter useful volume and 2640T/day HM capacity
• All furnaces have Bell-less Top charging System for continuous charging & better distribution of charge
• Coal Dust Injection in Fce.# 4 & 5• CHSGP in Fce. # 4 & 5• Capacity of B F 4.585 MT of Hot Metal per annum• Hot Metal Temperature 1460-14800C• BF Productivity: 1.4 T/m3/Day• Coke Rate 520 Kg/THM
A view of Blast FurnaceA view of Blast Furnace
MATERIAL FLOW DIAGRAM FOR BLAST FURNACESintering
Plant
Dust catcherIn BF
Gas Cleaning Plant
RM & MHP
SP
ProcessSteam
Net work
Stove of BF
ChargingSection
ofBlast
FurnaceCoke Ovens
ForSale
Pig Casting M/C
ForDistribution
Mixer of SMS
IMF
Slag DumpYard
TBS
BFCHSG/SGP
Blast Furnace
Hot Metal
Iron Ore Lime Stone
Mn Ore
Sinter
Coke
Slag Granules for Sale
Raw BF gas Flue Dust
Cleaned BF Gas
Partially Cleaned BF Gas
Iron Ore(Lump)
Lime Stone, Mn Ore, Quartzite
Sinter
Coke
Cold Pig
Process Steam
Hot air Cold air
Slag
Quartzite
Hot Metal being charged into the Hot Metal being charged into the converterconverter
Steel Melting Shop• SMS-I: 5 Converters each of 100/130T capacity, 2 Mixers each
of 1300 T capacity (Rated Capacity 2.5 MT/Yr)• SMS-II: 2 Converters each of 300 T capacity, 2 Mixers each of
2500 T capacity (Rated Capacity 2.25 MT/Yr)• Total capacity 4.5 MT of liquid steel• Oxygen of high purity(99.9 %) is blown into the converter
from the top through water cooled lance so as to remove the impurity of hot metal through oxidation
• Impurities of Si, C & P are oxidised and Forms slag with lime• Killed, Semi-killed and Rimming steels are made• SMS-II has got suppressed combustion system• Lining life :
SMS-I = 800 – 1000 heatsSMS-II = 2000 – 2500 heats
Concast Slab coming out of CasterConcast Slab coming out of Caster
Continuous Casting Shop• Two Twin strand curvilinear casters with capacity to produce
2.16 MT of Slabs• Steel Refining Unit (SRU) with LF/LRS for treatment of steel
before casting • On-line slab cutting • Steel Killed with Al/Si to O2<5ppm + Argon purging sulphur
reduced <0.015%• Slab size : Thickness 200, 225 & 250 mm
Width 950-1850 mm Length 9-10.5 mtr.
• MgO lined Tundish of 50 T capacity• Tundish Capacity = 50 T• Slide Gate System• Slab Produced
- Mild Steel : DD, EDD, Bioler Plate etc.- Low Alloy Steel : LPG, WTCR, SAILCOR & API grades
Slabbing Mill• 12 groups of Soaking pits with each group
having 4 pits ; total 48 pits wherein ingot are heated to a temperature above 13000C
• On line hot & cold scarfing M/c for surface scale/defect removal
• One 1250 mm Roll dia 2-high Reversible Universal Mill to produce slabs of thickness 150-300 mm, width 950-1850 mm and length 2.5 – 10.5 mtr.
• 2800 Ton Hydraulic Shear (6 cuts/min)• 4MT Capacity (Rolling Rate 600-800T/Hr)• Main Sectionsa) Ingot Storage Yard b) Soaking PitC) Mill Proper d) Slab Storage Yard
Strip Coming out of Finishing Strip Coming out of Finishing standsstands
Hot Strip MillHot Strip Mill• Hot Rolling involves plastic deformation of
a metal under squeezing force (a pair of Rolls) above its re-crystallization temperature.
• This mill is designed to roll thin & wide strips for use in various industries such as wagon building, tube & pipe industry, drum & furniture manufacturing and further rolling in Cold Rolling Mill
• 3 Walking Beam Reheating Furnaces & 1 Pusher type furnace
• Vertical Scale Breaker• 5 Roughing Stands, 7 Finishing Stands• Hydraulic AGC in last four Strands4
Hydraulic Coilers with automatic strapping & Robot marking
Material Flow Diagram of HSMSlab Slab yardyard
FurnFurnacesaces
FurnFurnacesaces
VSB R1 R2 R3 R4 R5F. Shear
F6F7F8F9F10
F11
F12CC CC
CoilersCoilersFinishingFinishing StandsStands
Roughing StandsRoughing Stands
Zinc coating on Cold Rolled Coil - HDGL
Cold Rolling Mills• Cold rolling is done to produce thinner gauge strip of
smooth finish with better mechanical properties than those obtained by Hot Rolling
• Uses : Automobile Bodies, Steel Furniture, Drum & Barrels, bending and shaping applications.
• Capacity: 1.66 MT of CR saleable• CRM I: H2So4 Pickling Line, 4-Stand Tandem Mill (2-4.5mm
thick into 0.63-2mm thick) Annealing Furnaces, SPM-I & SPM-II, Shearing Line I & II, Slitting Line and Shipping-I
• CRM II: HCl Pickling Line, 5-stand Tandem Mill (1.4-2mm thick into 0.63-1.6mm thick) , ECL, CAL, DCR Mill, HDGL and Shipping-II
• Besides Continuous Annealing furnace103 Annealing Furnaces and 230 Bases are available in three areas. Annealing is done at 680-7200C in inert atmosphere (95% N2+5%H2) with the help of mixed Gas of 1550-1600 CV
Leading CustomersLeading Customers1) Indian Railway2) Surya Lights3) Jindal Group4) Bhushan Group5) Indian Oil6) Tata Motors7) Ashok Leyland8) T.P.I Group 9) Surya Global
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