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Project MMSM
Project MMSM
MAR`1992
Installed Capacity:8,50,000tonnes.50,000
Tons/Year
TYPE OF MILL :High Speed Continuous Two High
Hot Rolling Mill.IGH SPEED CONTINUOUS TWO
HIGH HOT ROLLING MILL
UNIQUE FEATURE: Rolling of Parallel flanged I
and H beams using universal cassettes.
ROLLING OF PARALLEL FLANGED H AND I
BEAMS USING UNIVERSAL CASSETTE
MAXIMUM MILL SPEED : 9 m/s9
999 m9m/sec
ROLLING RATE : 222 tonnes/hr2 Tons/H22r
Products of MMSM
Merchant products like Squares, Rounds and Flats
which are further processed by customers.
Structural products like Angles, Channels and Beams
etc.
PRODUCTS
SPECIFICATIONS
Rounds
40-80
Squares
40-90
Channels
100-180
Equal Angles
Unequal Angles
Flats
T-bars
100X100
H-E Beams
I-Beams
GRADES ROLLED
MILD STEEL
MEDIUM CARBON STEEL
HIGH CARBON STEEL
ALLOY STEEL LIKE:
a)Spring Steel
b)Manganese Steel
c)Chromium Steel
d)Copper Steel
SALIENT FEATURES
3 Charging grids of 90t/hr. capacity.
Charging conveyors to transfer the blooms.
Bloom pusher for charging the blooms into the
furnace.
SALIENT FEATURES
RE- HEATING FURNACE
SUPPLIED BY M/S STEIN HEURTEY OF FRANCE
2 x 130 T/hr top and bottom fired walking beam type reheating furnaces .
4 moving and 4 fixed skids for transfer of blooms.
Input bloom size: 250mm X 250mm Cross section, 6 -12
meters length and weighs 2780-5560 kgs (approx).
Furnace effective length: 20 metres
Furnace inside width : 13 metres
Furnace effective area: 240 m2
Chimney height :80 metres
Type of burners: Flat flame and Long flame type
Number of burners: 59
Number of zones: 5 zones (top and bottom fired)
2 top heating + 1 bottom heating
1 top soaking + 1 bottom soaking
Fuel used: Mixed gas (coke oven gas + BF gas + LD gas) of
calorific value 2000kcal/mm3
Evaporative cooling system for skids cooling.
Convective and cross flow type air and gas recuperators for
pre-heating gas and air.
MILL PROPER:
Supplied by M/S ZDAS of CZECH Republic
MILL PROPER
MILL STANDS
ROLL MATERIAL
SHEARS
8000 KN Shear: Placed before roughing mill stand and serves to crop badquality bloom front end and for dividing 12 metre long blooms into halves
2500 KN Shear: Crank type flying shear located after roughing mill train
to crop the front end and scrap the rolling stock in to pieces in case of failure
in the following mill trains
800 KN Shear: Crank type flying shear located after intermediate mill train
to crop the end portions and scrap the rolling stock in to pieces in case of
failure in the following mill train or cooling bed equipment
500 KN Shear: Crank type flying shear located after finishing mill train to
crop the end portions and to cut the rolled bars into cooling bed length.
COOLING BED:
120 metre long double side rake type cooling bed.
EQUIPPED WITH:
ROLLER SRAIGHTNER
PLACED BEHIND EACH SIDE OF THE COOLING BED FOR
STRAIGHTENING ROLLED PRODUCTS
Total no of rolls :9
No of top rolls: 4 (Only axially adjusted) and motor driven
No of bottom rolls : 5 (Axially and vertically adjustable) and
friction driven
Straightener speed: 2.5 to 12 m/sec
BATCHING OF PRODUCTS
FINISHING SHOP
COLD CIRCULAR SAWS:
2 Cold saw lines each consisting of one stationary and 2
mobile saws for cutting the finished products to customer
lengths
Blade diameter 1600 to 1450mm
Blade thickness: 8 to 10mm
Peripheral speed of saw blade 145 m/sec
Max layer width 1400mm
Pressure water for saw blade : 8MPa
AUXILLIARY SYSTEMS
Hydraulic and lubrication cellars for all mill plant.
Cellar for water station of De-scaling equipment.
High pressure water station for cold saw blades cooling.
3 Electrical control rooms (ECRs) for electrical equipment
control.
Ventilation systems for ECRSs and Cellars.
Fire protection systems.
13 nos of Electrical Overhead Travel cranes.
Scale flushing systems.
Pipe line distribution systems for water, compressed air,
Nitrogen Oxygen and Steam etc.
STACKING
Hydraulics
Hydraulics is a topic in applied science and engineering dealing with
the mechanical properties of fluids. On a very basic level Hydraulics
is used for the generation, control, and transmission of fluids in
order to produce some mechanical work or in general as a part of
river engineering.
B) CLOSED TANK
hydraulic cylinder are connected to pump, one end (A) through the
2 / 3 way DCV and the other end (B) directly. The operation of the
cylinder during the retraction stroke is the same as that of a regular
double-acting cylinder. Fluid flows through the DCV zero
position from the actuator A side during retraction. In this position,
fluid from the pump directly enters the rod end of the cylinder
(direct connection). Fluid in the blank end drains back to the tank
through the DCV as the cylinder retracts. When the DCV is shifted
to 1 position due to manual actuation, the cylinder extends. The
speed of extension is greater than that for a regular double-acting
cylinder because flow from the rod end (QR) regenerates with the
pump flow (QP) to provide a total flow rate (QT), which is greater
than the pump flow rate to the A side of the cylinder. ( Area of
blank end is more than rod end, thereby blank end provide least
resistance )
REGENERATIVE SYSTEM
C= Double-acting cylinder
P = Pump
E = Electric Motor
T = Tank
F = Filter
R = Relief Valve
D =2-position, 3 way , Manually operated and
Spring return DCV
Expanded table:
VALVES:
CYLINDERS:
Boosters:
BOOSTERS CONTINUED:
FLUID MOTORS:
VANE PUMPS:
HYDRAULICS SYSTEM:
Plant Details
2. Long Product
a. Medium Merchant Mill
b. Light Merchant Mill
c. LD shop
d. Rebar mill
e. Wire and Rod Mill
3. Secondary Products
a. Benzene Plant
b. Ammonium Sulphate Plant
c. Tar Plant
d. Slag Plant
4. Shared Services
a. Power Plant
b. Blowers and Pump Houses
c. Industrial Gases
d. Fuel Management
e. Waste Recycling Plant
f. Environment and Occupational health
5. Miscellaneous
g. Hospital
GENERAL DESCRIPTION
Low carbon steels used to make car bodies, whereas high carbon
steels are used to make cutting tools and rails.
Steel often is mixed, or "alloyed," with other elements (e.g.,
chromium, nickel, manganese, molybdenum, selenium, tungsten,
titanium or vanadium) to give it special properties, such as
increased strength, durability or resistance to heat and corrosion.
Steel alloys contain from 5% to 50% of one or more alloy metals;
alloys with less than 50% iron content are considered ferro-alloys
rather than steel. The most common steel alloy is stainless steel (a
combination of basic steel, chromium and nickel), a corrosionresistant metal that has a variety of applications.
Integrated steel mills are typically vast complexes with three major
sections:
A. blast furnaces that transform iron ore, coke (a purified form
of coal) and limestone into iron;
B. steel-making furnaces that refine iron into semi finished
steel; and
C. finishing mills that turn semi finished steel into basic steel
products (e.g., bars, pipes, sheets, rods or wire).
Process Description
The steel-making process at VSP entails the following processes:
1. Sizing of Iron Ore, Coke, Dolamite, Limestone, etc
The raw materials are stored in material yards. The raw material is
picked up using conveyer belts and sent for crushing. Using 2 levels
of crushers (primary and secondary) the ore is crushed to the
required grain using filters. Similarly, coal, limestone and Dolomite
is also crushed to the required grade. Using a magnetic separator
ferrous impurities are separated out.
2. Refining coal into coke
The first step in steel making is the transformation of coal into a
purer form known as coke. Coke provides heat, provides
permeability, supports burden materials and also acts as a reducing
agent. Coke is a hard, dark grey material that burns longer, hotter
and cleaner than coal and is the fuel used to smelt iron ore into
iron.
channels in the lower part of the cooling chamber. The gases flow
upward and coke moves downward in the cooling chamber. The
heated gases coming out from the cooling chambers at about 750
800OC go to primary dust catchers, waste heat boilers and
secondary dust catchers. The temperature of cooled coke is in the
range of 180 200 OC.
d. Coke Chemicals Recovery
The chemicals that need to be removed from coke oven gas are
benzene, ammonia and benzol hydrocarbon. Tar is removed first by
cooling of the coke oven gas by spraying liquor over coke gas.
Nearly 60% of the tar gets condensed and is separated out. The
remaining gas flows to Primary Gas Coolers (PGC), where it is
subjected to cooling water and the gas is cooled to 25C and nearly
all the tar gets removed. The gas is then passed through saturators
where 5% sulphuric Acid solution is maintained. Then the gas
bubbles through it, ammonia reacts to form ammonium sulphate
and is separated out and dried. The gas is then passed through
final gas coolers that removed naphthalene and then passed into
benzol scrubbers that remove benzol from the gas which is distilled
to remove benzene, toluene, Sol-110 and CB-II. Passing hydrogen
gas of required purity does this. Hydrogen is extracted from coal
gas by using a molecular sieve.
e. Coke Sorting Plant
Coke is crushed and sorted to make it of size 25-70mm which is
used in the blast furnace.
3.
Sintering Plant
4.
Blast Furnace
The raw materials for iron making (iron ore, limestone and coke)
are stockpiled in outdoor storage yards. The charge travels along a
conveyor belt, up a ramp, and finally is dumped into a blast furnace
to smelt the charge into molten iron and slag. The 2 blastfurnaces
are called Krishna and Godavari with a rated capacity of 3.4 MT
annually. Before the charge is dumped into the blast furnace, a
series of tank-shaped stoves next to the furnace are heated. In
these stoves, air is heated to 2,000 degrees Fahrenheit and
5.
There are 4 BOF at VSP. In the first step of the basic oxygen
process, the BOF is tilted toward a charging platform where scrap
steel is charged into the furnace. Then, a ladle of molten iron is
moved by crane and poured into the BOF; the molten iron will make
between 60% and 80% of the total charge. Fully charged, the BOF
is returned to an upright position, and a long, water-cooled pipe
called an "oxygen lance" is lowered into the furnace near the
surface of the molten charge. Once in place, the oxygen lance
blows pure oxygen into the furnace at extreme pressure and speed
(in excess of the speed of sound). The molten charge, saturated
with oxygen, begins to burn at a very high temperature. A
measured amount of lime is then released into the furnace; the
lime reacts with the charge's impurities and forms a slag, which
rises to the top of the molten charge and is discarded. After the
oxygen "blow" has ended (usually after 20 minutes), the BOF
is tilted toward the "teeming platform" where the refined molten
charge rushes through a taphole into a rail-mounted ladle. Carbon
and other alloying agents (e.g., tungsten, titanium, molybdenum)
are added to the charge to create molten steel. The steel moves
through the curved casting machine to a horizontal position, it
solidifies throughout, and roller machines flatten the steel to a
predetermined thickness. Finally, at regular intervals, mechanical
shears cut the continuous strand of steel into "blooms, LD gases,
emitted from the mouth of the converter are collected and cleaned.
Each converter is provided with a separate gas cleaning system.
The gas is extracted at the converter mouth through an adjustable
skirt, movable cooling hood and a fixed cooling hood where the gas
is cooled down to temperature of about 1100 deg. C and then led to
a two-stage venturi scrubber where the gas is cleaned and further
cooled to about 70 degC with dust content below100 mg/m3 . With
6.
Blooms are reheated in walking beam furnace and steel slabs are
shaped into rods, bars, rails, angles, channels etc of different sizes.
Steel wire is wound around the coiler into a tight coil.
Utilities
The major utilities, which are critical for the manufacturing process,
are Steam, Power, Water, Air, Oxygen, Argon and Nitrogen.
a. Power
The power requirement of VSP is around 221 Mw at full load. The
captive power generation of VSP is 270 Mw i.e VSP is self sufficient
to meet all the power need of the plant under normal working. In
case partial power failure of the of captive power plant due to break
down or under maintenance there is an agreement with APSEB to
supply the power. At VSP power is generated through steam
turbines. Steam is produced for power generation by burning coal
in four boilers boilers. Superheated steam at a pressure 107
kg/cm2 is supplied to steam turbines for generation. There are 3
turbines of 60 megawatts and one of 67.5 mw. Power generated at
6.6 kv is stepped up to 220KV.through outdoor transformers in
switch yard. Power is received from Andhra Pradesh Electricity
Board at 220 KV from 2 lines fed to 220 kv bus. Power is also
generated by waste heat recovery in CO & CCP plant & BF plant.
Thermal Power Plant(TPP) 3x60 MW
- 1x67.5 MW
Back pressure turbine(CO &CCP) -2x7.5 MW
Gas expansion turbine (BF plant) 2x12 MW
The entire plant load of plant is divided in five blocks (LBSS 1 to 5).
In each LBSS, power is stepped down to 33/11/3.3 kV
Power is supplied to the various department and machinery at
230V, 440V, 6.6KV and DC supply. Most of the transformers are
indoor in separate cubicles. Transformer has its outdoor baffle wall
is constructed between the transformers. There is a separate
central maintenance department to look after maintenance of H.T.
motors, L.T. motors and D.C. motors above 200 kW.
b. Fuel
There are 3 major fuels used in the manufacturing process
namely Blast Furnace Gas(BF gas),
Coke Oven Gas (C.O. Gas) and
L.D. Gas.
All the three fuels are generated inhouse and are used as heating
medium at various points in the plant.
Fuel
BF Gas
L.D. Gas
C.O. Gas
Generating Source
1 and 2 blast Furnaces
L.D. Shops
Coke Plant
c. Water
The water is received from Yelluru reservxoir about 150kms from
the plant site through gravity channel. There is a reservoir inside
the plant that has 45 days storage capacity. Daily water
requirement is 3000 metric tonnes.
d. Air
There is adequate generation of Instrument Air in the works with
redundancy and storage to cater to the requirement of the works.
e. Industrial Gases
There is an air separation plant at VSP for generating Oxygen,
Nitrogen and Argon. The air is compressed and chilled. Various
gasses are then separated out. Oxygen requirement is 3000 tonnes
per day. Oxygen is stored in tanks and supplied. Nitrogen is used
for cooling in COCP and SMS plant. It is supplied via pipeline. Argon
is used in the Steel Making process. Acetylene is generated by
reacting calcium carbide with water. Acetylene is required for gas
cutting of steel.
INDUSTRY-RELATED HINDRANCES TO
PRODUCTION IN RINL
Foregoing analysis shows that India has made sufficient
achievement in industrial development during the last five decades
and has emerged as the tenth largest industrialized country of the
world. But considering the size of the country this development is
far from satisfactory.
Visakhapatnam Steel Plant (VSP) is the only shore-based Indian
integrated Steel Plant, with a rated capacity of 3.4 Mt Hot Metal,
3.0 Mt Liquid Steel and 2.656 Mt Saleable Steel. The plant was
commissioned in the year 1990. VSP has 7 M tall Coke Ovens with
Dry Quenching facility, the 3,200 cu.m Blast Furnace and the 100%
Bloom Casting technology and fully computerized Rolling Mill.
Presently the Plant is operating at higher efficiency levels
surpassing the rated capacities.
Current capacity is as below:
Hot Metal 4.15 Mtpa
Liquid Steel 3.6 Mtpa
Saleable Steel 3.2 Mtpa
RINL is a Navratna company
MOU performance over the decade:
Excellent
: 7 years
Very Good : 3 years
ONLY INTEGRATED STEEL PLANT AMONG PSEs HAVING NO
CAPTIVE IRON ORE AND COAL MINES.
Long products manufacturer Market leader in Bars & Rods
Product
DPR
Capacity
As
Achieved
Hot
Metal
3.4
4.0
Liquid
Steel
3.0
3.5
Saleable
steel
2.6
----
The situation becomes acute when fresh loans are taken to pay the
installments of the old loans. Due to liberalization, the foreign
exchange reserve position has improved in recent years and flow of
foreign capital has started in industrial sector. These foreign
investors also do not like to invest in such industries which require
large capital, need long gestation period and where recovery is slow
or more risk is involved. Instead of depending on foreign capital we
have to place more reliance on indigenous capital with greater
emphasis on the development of priority industries.
3. License Policy
The license policy approving the site, capacity, type and expansion
of industries is a typical example of excessive state interference
and red tapes which hinder the industrial development. Recently
some examples of political vendetta have come to surface whereby
central government over delayed the approval of industries from
such states where hostile political party is in power. Ministers and
influential political leaders are pressurizing industrialists to install
industries in their electoral area so as to approve their licenses.
With the introduction of liberalization policy many of the
shortcomings of the license policy have been removed.
ROLLING STAND