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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