Overview of Bokaro Steel Plant

by V. K. GAHLOT AGM (HRD)

Background
Fourth Integrated Steel Plant in Public Sector,well known as Swadeshi Plant, maximum indigenisation in equipment,materials & know-how Originally incorporated as a Limited Company on 29.01.64 Collaboration agreement with Soviet Union (USSR) on 25th Jan, 1965 ( SAIL 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, TMBP, GP&GC

Background
Capacity
First Phase : 1.7 MT of ingot steel Second Phase : 4.0 MT of ingot steel After modernization : 4.5 MT of liquid steel Enough scope for further expansion (Plan for 7 MT)

Milestones
Start of construction : 06.04.68 Start of hot metal production : 02.10.72 Completion of 1.7 MT stage : 26.02.78 Completion of 4 MT stage in phases Start of last modernization : 23.07.93 (completed in 1997) Next modernization for 7 MT : Evaluation Process started

Basic Information

Location Latitude Longitude Altitude Climate Annual Rainfall Temperature Wind direction Type of Soil Total land area

: Southern bank of ; approx. 50 kms from Dhanbad and 140 kms each from and : 230 39' : 860 09' : 210 metres (average) varying from 195 to 224 metres : Extreme : Average 157 cms; Maximum 195 cms : Maximum 480 Celsius : Min. 20 Celsius : South-West to North-East : Loamy up to 1 to 2 metres, sandy soil below that : 33,045.35 acres

Plant, Slag-dump, Cooling : 17,208.01 acres Ponds, Ancillaries, Marshalling Yard Township(including Airstrip) : 10,114.53 acres Garga Reservoir Railways : 3,886.87 acres : 1,835.94 acres

Township
Located on the southern bank of damodar on North Parasnath Hills Area 10,114.53 acres 10 Sectors Various amenities in neighbourhoods City Centre, Shopping Centres, Schools, Park, Play ground 37,472 permanent houses / hostels (incl. 4773 leased out) Various types of residential units A, B , C/C-D , D & E/EF/F Maintenance post in each sector Community Centre / Kalyan Mandap in most of the sectors

 BSL run 42 schools (21 CBSE & 21 affiliated to JSSEB) having around 1200 teachers and 31,000 students No fee in JSSEB schools & nominal fee in CBSE schools State run 4 schools / colleges and private run 31 schools / colleges with 31,750 students Exemplary performance of students in various exams CBSE, ICSE, Engineering, Medical, Management, Civil Services etc.

Education

Medical
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

 Bokaro Ispat Pushtakalaya with a collection of over 40,000 books. 6 sector libraries besides central and technical libraries. City park with boating facility and lake view restaurant. J.N. Biological Park Welfare Schemes: Family Benefit Scheme, Group Insurance Scheme, Co-operative Credit Societies

Enrichment of Life

UTILITIES & SERVICES

WATER SUPPLY POWER SUPPLY DVC CHANDRAPURA Bokaro Power Supply Co. Ltd. 200MVA (Contract) 1 x 12 MW (back pressure) 2 x 55 MW 3 x 60 MW Total Road length 392 Kms. GARGA DAM & TENUGHAT DAM

PROCESS FLOW
Fluxes
COKE OVEN BATTERIES Coking Coal Iron Ore, Lime Stone & Dolomite Fines

SAIL Bokaro
BF Coke Coke Breeze

Iron Ore

BF1 Sintering Plant

BF2

BF3

BF4

BF5 OHP

Blast Furnace

130T Con-1

130 T Con-2

130 T Con-3

130 T Con-4

130 T Con-5

300 T Con-1

300 T Con-2

Pig Casting Machine

Steel Melting Shop - 1

Continuous Casting Department

Steel Melting Shop - 2

HR Coil

Soaking Pit
Slabbing Mill
ll

Reheating Furnace Hot Strip Mill

HRCF

HR PLATE / SHEET

PL-II

Tandem Mill-2

PL-I
Tandem Mill-1

A N N E A L I N G

DCR Mill

Galvanized Sheet Corrugation Line

Hot Dip Galvanizing Line SPM 1 & 2 CRCF

CR Coil CR Sheet GP Coil

Galvanized Sheet Shearing Line

Galvanized Corrugated & Plain Sheet

Commissioning dates and Capacity of Major Units

Unit Agreement with UUSR Coke Ovens Sinter Plant Blast Furnaces Steel Melting Shop I Steel Melting Shop II Continuous Casting Date of Commissioning 25 Jan, 1965 Sep'72 Dec'85 Sep'72 Dec'82 Oct'72 - Jun'85 Jan'74 Dec'78 Jun'83 - Jan'85 Sep'97 - Mar'98 8 Batteries of 69 Ovens 3 Machines of 252 m2 area 5 furnaces of 2000 m3 volume 5 LD converters of 130 T 2 LD Converters of 300 T 2 Double Strand casting m/c 3.48 6.20 4.585 2.20 2.25 2.16 BF Coke Skip sinter Hot Metal Ingot Steel Liquid Steel Cast Slab Number Capacity (MT) Product

Commissioning dates and Capacity of Major Units

Unit
Slabbing Mill

Date of Commissioning
Dec'74

Number
8X4 Soaking pits of 160 T & one 1250 mm universal Slabbing Mill 4 reheating Furnaces, 5 roughing & 7 finishing stands

Capacity (MT)
1.90

Product
Rolled slab

Hot Strip Mill

Dec'75

3.36

HR Coil

Hot Rolled Coil Finishing

Cold Rolling Mill 1

Jan'76
Jun'77

2 Shearing line
Pickling Lines, Tandem Mills

1.1

HR Plate/Sheet
Saleable CR

Cold Rolling Mill 2

Sep'91

Annealing Lines, Skin Pass Mills-2, Temper/DCR Mill-1, Shearing lines-5, Slitting lines-3 & Hot Dip Galvanising Complex -1

1.66

Product CR coils/Slit coil/ sheet, slit coil, Black Plate, GP&GC

Raw Materials coming from Mines

Wagon Tippler Tippling a wagon

ORE HANDLING PLANT

Basic functions:
Receive different raw materials from various mines through wagons and their unloading & stacking with the help of tipplers & stackers Blend raw material by making layers in beds & cross sectionwise cutting beds by re-claimer Keep buffer stock to take care of irregularities and supply raw materials to different Units as per their requirements

Basic facilities:
4 Rotary Wagon Tipplers - 20 Wagons/Hr each 7 Twin boom Stackers - 1200 T/Hr each 5 Barrel Type Reclaimers - 1000 T/Hr each 1 Bucket Wheel Type Reclaimer - 500 T/Hr 2 Transfer Cars, 10 Shuttle Conveyors, 11 Cranes, 8 Telphers

Sources of Raw Material

Material No. of Beds (240 M) 4 6 4 Stock No of Days 24 16 13 Source

Iron Ore Lump Iron Ore Fines Lime Stone BF Grade Lime Stone SMS Grade Dolomite Lump

Kiriburu, Meghataburu, Bolani, Barsua Kiriburu, Meghataburu, Bolani, Gua Bhawanathpur, Khanabanjari, Purnapani

21

Kuteshwar, Jaisalmer, Nanwara

16

Bhawanathpur Birmitrapur, Tulsidamar, Sonakhand Bhutan, Salwari

Dolomite Chips

50

Sources of Raw Material

Material No. of Beds (240 M) Stock No of Days Source

Manganese Ore Imported Coal Prime Coking Coal Medium Coking Coal Coal Middlings for Power Plant 38 M high, 12mm dia

Barbil, Banspani Autralia, NewZealand , Haldia, Paradeep, Vizag

46 Silos 2500T 7

Dugda, Munidih, Jamadoba, Belatand Kathara, Kedla, Rajrappa, Mahuda, Swang Kathara, Rajrappa, Kedla, Swang, Giddi, West Bokaro, Kargali, Mahuda, Dugda, Katrasgarh etc.

Coke Oven Battery

Quenching of Coke

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

Coke Ovens

Desired Analysis vs Indian Coals:

Desired Analysis Indian Coals Imported Coals

Ash% Volatile Matters% Moisture% Sulphur% Phosphorus%

< 16 > 25 7-9 < 0.05 < 0.05

19-24 24-26 7-8 0.56 0.09

3-12 (Av 9) 19-28 (Av 23) 8-11 (Av 9) < 0.05 < 0.05

Material Flow Diagram : Coal & Coke

Coking Coal From Various Source

Wagons

Coal Handling Plant

Coke Sorting Plant

Coke

Battery ( 8 Nos.)
Coke Oven Gas By Product Plant

Blast Furnace Coke

+ 25 -80 mm Blast Furnace

Nut Coke Sold

Coke Breeze -15 mm Sinter Plant

By-Product Plant
It consists of : Gas Condensate Section Ammonium Sulphate Plant Benzol Recovery Plant Tar Distillation Plant Sulphuric Acid Plant

Products produced from by product plant. N G Benzol N G Toluene Xylene L S Naptha S B Oil PCM Road Tar Coal tar wash oil Extra hard pitch Hard medium pitch Hot Pressed naphthalene All by products of By Product Plant are sold through e- auction.

Tech-economic factors
CO Gas yield : 325.0 Nm3 / TDC

Coke Rate

---

:
: : : :

505.0 Kg / THM
0.583 Gcal / TDC 29.50 KWh /Ton of BF Coke 10.50 Kg/ TDC 30.80 Kg/ TDC

Sp. Heat Consumption Sp. Power consumption Ammonium Sulphate yield Crude Tar yield

A view of Sinter belt

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 Sections a) Raw Material Section b) Stock Bin & Proportioning Section c) Sinter Machine Section

Hot Rolling Mill Mill Scale Lime Dust Coarse Waste Bins Section

Refractory Mat Plant

Ore Handling Plant

Coke Ovens

Iron OreFines, LimeStone,Dolomite, Lime Dust Sand Raw Mat Section Fine LimeStone Fine ,Coke Fine, Dolomite Fine Stock Bins Mixed Raw Charge Palletizing/Balling Drums

Coke Breeze Slime Thickening Section Lime Sludge

Mill Scale, Flue Dust, Lime Dust Coarse

Cleaned Water

Material Flow Diagram Sintering Plant

Flue dust to waste bin

Raw Charge (Moist & Balle) Sinter Machine Building Sinter Hot Sinter Return Cold Sinter Return

Blast Furnace Deptt Return Sinter to Stock Bin

Raw material sinter Screened coke return to raw material section

Technical Specifications of some critical equipments

Sl.no 01 02 03 04 05 06 07 08 Name Hammer crushers Coke crusher Flux Screen Sinter Machine Sinter area Pallets Vacuum chambers Exhausters Quantity 05 08 10 03 252 square metre 130 in each m/c 26 in each m/c 6nos(2nos/m/c) Capacity 250 ton/hour 16 ton/hour 150 ton/hour 300-450 ton/hour Installation Area Raw material Raw material Raw material M/c building M/c building M/c building M/c building M/c building

12000 m3/minute

Technical Specifications of some critical equipments

Sl.no Parameters 01 02 03 04 05 Specific fines consumption Specific flux consumption Specific Coke consumption Specific Power consumption Specific Heat consumption Norms 1093kg/t of hot metal 255 kg/THM 85 kg/THM 45KWH/Tgross sinter 0.024Gcal/TGS Actual in 2007-08 1025kg/THM 244kg/THM 86kg/THM 48.33KWH/TGS 0.025Gcal/TGS

A view of Blast Furnace

A Closer view of 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

Blast Furnace

MATERIAL FLOW DIAGRAM FOR BLAST FURNACE

Sintering Plant
Flue Dust Raw BF gas
Dust catcher In BF Partially Cleaned BF Gas Gas Cleaning Plant Cleaned BF Gas For Distribution

Iron Ore Lime Stone

Mn Ore
Quartzite

Sinter Coke

Charging Section of Blast Furnace

Iron Ore (Lump) RM Lime Stone, Mn Ore, Quartzite

& MHP

Sinter

SP

Coke Coke Ovens

Blast Furnace
Process Steam Hot air

Process Steam Net work

For Sale

Cold Pig Pig Casting

M/C
Mixer of SMS

Hot Metal
Slag

Stove of BF

Cold air TBS

Slag Dump Yard

IMF

BFCHSG /SGP

Slag Granules for Sale

Hot Metal being charged into the converter

BF SSD RMP BMS FAS

O2 Plant

HOT METAL SCRAP LIME IRON Ore, BAUXITE, Mn Ore, Lime Stone Fe-Mn, Fe-Si 99.5 % pure O2

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 suppresed consumption system

Lining life :
SMS-I = 800 1000 heats SMS-II = 2000 2500 heats

Concast 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 Sections a) Ingot Storage Yard b) Soaking Pit C) Mill Proper d) Slab Storage Yard

Reheating Furnace of HSM

Strip Coming out of Finishing stands

Hot 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 Strands

Hot Strip Mill

4 Hydraulic Coilers with automatic strapping & Robot marking Capacity: 3.955 MT of HR Coils
Coil Dimensions Strip thickness Strip Width mm Coil inside dia Max Coil outside dia Max coil weight Rolling Speed: 1.6 to 16.0 mm 910 to 1,850 650 mm 2,300 mm 32 T 20 m/sec Max.

Material Flow Diagram of HSM

Slab yard

Furn aces

Furn aces
VSB

Roughing Stands
F. Shear R1 R2 R3 R4 R5

C Finishing Stands

Coilers

Hot Roll Coil Finishing (HRCF)

Functions : To shear the coils into plates and sheets Facilities : Shearing Line I : 5-10x1800 mm, 2.5-12 mtr. plates capacity 6,45,000 T/year Shearing Line II : 1.6-4x1500 mm, 1.54.5 mtr length sheets capacity 4,75,000 T/year Slitting Line : 1.5x8x1800 mm, 150mm Min. width capacity 4,00,000 T/year Maximum Pkt. Wt.: 15 T

5-Stand Tandem Mill

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 & SPMII, 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

GC Sheets

Services Department
PPC & SC R&C Lab Engg. Shops Energy Mgmt. Envt. Mgmt. : Coordination of plant operation and prodcution plant as per demand. : Machine Shop, Structural Shop, Forge Shop, SF, IMF, ICF : CDI in BF, CCS, Walking Beam Reheating Furnace : Installation of ESps in SP, BoD Plant Recycling of Flux, Dust. Mill Scale, Lime Dust, LD Slag Plantation of 42 lakh trees BSL certified under ISO 1400 : 2004 EMS market

: Chemical, Metallurgical, Inspection, R&D, a Network Testing Lab

Safety and Fire Services Quality Assurance SA 8000

: BSL certified under OHSAS 18001 : Major Units, Shops, Non-Works Deptt. Certified for ISO 9001 :2000 QMS : Social Accountability Certification

Services Department
HRD : Management and Technical Development In-house and External Training Training for Safety, Housekeeping, Maintenance Operation, Project, QC Communication Exercises Quality Circle Other HRD Activities Suggestion Scheme etc.

CSR

: Peripheral Development (Bokaro Steel Gramin Vikas Yojana) Free Health Check up (Bokaro Steel Sarva Swastha Yojana) Free Education and Scholarship (Bokaro Steel Shiskha Protsahan Yojana)

 Bokaro Industrial Area Development Authority (BIADA) Various Concessions/Exemptions in

253 SSI Units registered with BSL 81 accepted as Ancillary Units

Ancillary Development

Tender cost, earnest money, security deposit etc. Price matching and purchase preference BSL Laboratories offers testing facilities, help in developing new designs and products and awareness on ISO 9000 System

 Last Modernization

Con-cast facilities integrated with SMS-II Up-gradation of Hot Strip Mill including

Ladle Furnace & Ladle Rinsing Station for Secondary Refining Two Double Strand Slab Caster

Next Phase Modernization (by 2010-11)

New SMS-III with 3.8 MT Capacity

Change of Pusher Type Reheating Furnaces to Walking Beam Type Quick Work Roll Change System Addition of fourth Coiler

New CRM-III with 1.2 MT Capacity

3 x 160T Converters with 3 x 160T Ladle Furnaces & Degassing facilities 2 Single Strand Thin Slab Casters (1.2 MT each) & 1 conventional Slab Caster (1.4 MT) 7- Stand Compact Strip Mill & new Coil Yard Coupled Pickling and Tandem Mill ECL, Bell Annealing Furnace (100% Galvanizing Line with Galvanneal facilities

Hydrogen

Annealing)

 Up gradation of 3 BF to 4900T/day capacity by enhancing volume from 2000 to 2365 M3 and installing CDI & CHSGin all BFs (presently 4&5 only) Sintering Area 252 m2 to 312m2 and productivity 1.2T/m2/hr Rebuilding of 3 CO batteries, computerised combination control system etc. Conversion of H2S04 PL-I to HCL Pickling Line Enhancing capacity of SMS II from 2.16 to 3.12 MT by schemes Addition of O2 generating capacities

Result of Expansion
Sl. No. 1. Description Hot Metal (MT) Capacity 7.44

2.
3. 4. 5.

Crude Steel (MT)

Saleable Steel (MT) Yield of Saleable Steel from Liquid Steel (%) Specific Energy consumption (Gkcal)

7.00
6.53 91.4 5.5

6.

Coke rate Kg/THM

395

Comparative Statement of Purchase/Production Cost

Ingredients 2006-07 (Rs/Ton) 2007-08 (Rs/Ton) % Change 2008-09 (Rs/Ton) % Change (from 07-08)

Imported Coal
Indigenous Coal Coke Ferro Alloy

6970
3844 11977 42000

6346
4159 11584 49000

-9
8 -3 16

16700
6500 30000 87600

163
56 158 79

Thank You