INDUSTRIAL TRAINING REPORT

BACHELOR OF
TECHNOLOGY
IN MECHANICAL ENGINEERING

BY

ARVIND KUMAR

DEPARTMENT OF MECHANICAL ENGINEERING

BIT SINDRI
DHANBAD

JULY, 2013
1
 CERTIFICATE

Certified that the Industrial Training report entitled “SUMMER TRAINING ON BOKARO
STEEL PLANT”carried out by Mr.ARVIND KUMAR., bearing Roll No. 10106, a student of VII
Semester, IV year, in partial fulfilment for the award of Bachelor of Tech-nology in
Mechanical Engineering at the BIT Sindri, Dhanbad during the academic year 2013-14.It is
certified that all corrections/suggestions indicated for Internal Assessment have been
incorporated in the Report deposited in the department library. The project report has
been approved as it satisfies the academic requirements in respect of Industrial Training
prescribed for the said Degree.

Signature of the Faculty In-charge Signature of the HOD

Signature of the Examiner

2
 ACKNOWLEDGEMENT

I would like to pay special thanks to Mr. K.K.Jain, General Manager (H.R.D.)
for taking deep pains in organizing such trainings and providing all required
facilities. I offer my sincere thanks to Mr. B.K.Sen, Asst. Manager (H.R.D.) for
guiding me throughout my training schedule.

I would also like to express any my gratitude towards technical staff,

Sr. Superintendents, foremen at various shops for sharing their immense
experience and practical knowledge.

I also want to thank for making my presence an extremely enthusiastic; I have

gained all useful information and practical implication of theory which I had and
given a run in myself. I would like to thanks for your brilliant comments and
suggestions.

I would also like to thank my teacher in charge Mr Vijay Kumar and Mr Naresh
in successful completion of this report with their valuable suggestions.

Also thanks to my Department’s HOD Professor Dr. M.Venu for giving me an

opportunity & all the necessary permission and requests from The College, It
would not have been possible without him.

And lastly, I would like to thank all my group members for their kind co-
operation to complete this training work successfully
3
 ABSTRACT

Though Mechanical Engineering is a vast branch and has unlimited applications,

whole of which cannot be summarized in a single report, but I have tried to
enlighten some of the important aspects and areas of applications of the
knowledge gained within this B. Tech carrier

This report gives the reader a clear idea of the product being produced, the methods
in-volved in manufacturing, and the principles behind the operations. In chapter-1 we
will see a brief history and overview of SAIL and its major units. In the next chapter
we

Will focus on the modernization of the plants, and manufactured product details. We
will see the various units of BOKARO STEEL PLANT one y one along with their
specifications like equipments used, customers, safety, various processes involved,
the reason and the importance of these processes.

It also throws light on the different problems being endured by the plants and
ways the concerned department undertakes to ensure the smooth running of the
plant.

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 CONTENTS
1. CHAPTER 1
1.1. SAIL overview 1
1.2. Background & History 2
1.3. SAIL Today 3
1.4. Major Units 4

2. CHAPTER 2
2.1 SAIL in the Future 11
2.2 Product Details 12

3. CHAPTER 3
3.1. RMHP 13
3.1.2. Introduction 14
3.1.3. Different Raw Materials & Their Sources 15
3.1.4. Material Handling Plant 16
3.1.5.Safety 16
3.2. Coke oven & B.P.P. 18
3.2.1. Introduction 19
3.2.2.Formation of Coal
3.2.3.Types & Sources of Coking Coal 19
3.2.4.Properties of Coking Coal
3.2.5. Coal Handling Plant 20
3.2.6. Carbonization Process 21
3.2.7. Major equipment 22

3.3. Blast Furnace 22

3.4. SMS I & II 23
3.5. CCS 23
3.6. Slabbing Mill
3.7. HSM
3.8. HRCF 24
3.9. CRM
3.10. Hot Dip Galvanizing Complex
3.11. BSP – Product Basket 25
3.12. By Products 26
5
3.13 Process Flow
4. References 27
5. Conclusions 28

6
 CHAPTER-1

STEEL Authority OF INDIA LIMITED

Satisfaction Customer
Aspiration Unlimited
Improvement Continual
Leadership Market

1.1 SAIL OVERVIEW

Steel Authority of India Limited (SAIL) is the leading steel-making company in India. SAIL is
India's largest steel producing company with a turnover of Rs. 47,042 crore, SAIL is among
the five Maharatnas of the country's Central Public Sector Enterprises. It is a fully integrated
iron and steel maker. SAIL manufactures and sells a broad range of steel products that are
used for different purposes like domestic construction, engineering, power, railway,
automotive and defence industries and for sale in export markets. Since its inception, SAIL
has been

7
instrumental in laying a sound infrastructure for the i ndustrial development of the country.
Besides, it has immensely contributed to the development of technical and managerial ex-
pertise. It has triggered the secondary and tertiary waves of economic growth by
continuously providing the inputs for the consuming industry.

1.2 BACKGROUND & HISTORY:

After
independence in the
formative years of
an emerging nation
– India, the builders
of modern India
worked with a
vision to lay the
infra-structure for
rapid
industrialization of
the country.The
steel sector was
one amongst which to propel the economic growth. Hindustan Steel Private
Limited was set up on January 19, 1954. The President of India held the shares
of the compa-ny on behalf of the people of India.

Hindua
n Steel
(HSL)
was in-
itially
de-
signed
to
man-
age on-
ly one
plant that was coming up at Rourkela. For Bhilai and Durgapur Steel Plants, the
pre-liminary work was done by the Iron and Steel Ministry. From April 1957,
the super-vision and control of these two steel plants were also transferred to
Hindustan Steel. A new steel company, Bokaro Steel Limited, was incorporated
in January 1964 to construct and operate the steel plant at Bokaro.

The Ministry of Steel and Mines drafted a policy statement to evolve a new
model for managing industry. The policy statement was presented to the
Parliament on De-cember 2, 1972. On this basis the concept of creating a
holding company to manage inputs and outputs under one umbrella was
mooted. This led to the formation of Steel Authority of India Ltd. The company,
incorporated on January 24, 1973 with an au-thorized capital of Rs. 2000 crore,
was made responsible for managing five integrated steel plants at Bhilai,
Bokaro, Durgapur, Rourkela and Burnpur, the Alloy Steel Plant and the Salem
Steel Plant. In 1978 SAIL was restructured as an operating company.
8
1.3 SAIL TODAY

SAIL today is one of the largest industrial entities in India. Its strength has been
the diversified range of quality steel products catering to the domestic, as well as the
export markets and a large pool of technical and professional expertise. SAIL
produces iron and steel at five integrated plants and three special steel plants, located
principally in the eastern and central regions of India. The company also owns iron
ore, limestone and dolomite mines: domestic sources of raw materials. These mines
are situated close to the eastern and central regions of India giving company
competitive advantages. The company has the distinction of being India’s second
largest producer of iron ore and of having the country’s second largest mines net-
work.

1.4 MAJOR UNITS

Major units of SAIL consist of integrated Steel plant, special steel plant &
Subsidiary units.

Integrated Steel Plants

(i) Bhilai Steel Plant (BSP) in Chhattisgarh

(ii) Durgapur Steel Plant (DSP) in West Bengal
(iii) Rourkela Steel Plant (RSP) in Orissa
(iv) Bokaro Steel Plant (BSL) in Jharkhand
(v) IISCO Steel Plant (ISP) in West Bengal

Joint Ventures

1. NTPC SAIL Power Company Pvt. Limited (NSPCL)

2. Bokaro Power Supply Company Pvt. Limited (BPSCL)
3. Mjunction Services Limited
4. SAIL SCL Limited
5. SAIL-Bansal Service Centre Limited
6. Bhilai JP Cement Limited
7. Bokaro JP Cement Limited
8. SAIL & MOIL Ferro Alloys (Pvt.) Limited
9. S & T Mining Company Pvt. Limited

9
 CHAPTER-2

2.1 SAIL - Into the Future

Modernization

SAIL, is in the process of mod-

ernizing and expanding its produc-
tion units, raw material resources
and other facilities to maintain its
dominant position in the Indian
steel market. The objective is to
achieve a production capacity of
26.2 MTPA of Hot Metal from the
base level production of 14.6 MTPA (2006-07 – Actual).
A new unit coming up at ISP
Orders for all major packages of
ISP & SSP and part packages of BSL,
BSP, RSP &
DSP Expansion have
been placed and these packages are in various stages of implementation. Objective of
Expansion Plan is to expand the production. The production target of hot metal, crude steel
and saleable steel after Expansion is indicated below:

(Million tonne per annum)

Item Base Case After Ex-
(2006-07) pansion
Actual
Hot Metal 14.6 26.2 (23.5)
Crude Steel 13.5 24.6 (21.4)
Saleable Steel 12.6 23.1 (20.2)

TABLE 2.1

10
 Plant Hot Metal Crude Steel Saleable Steel

BSP 7.5 7.0 6.53

DSP 3.5 3.0 2.83

RSP 4.5 4.2 3.8

BSL 7.44 7.00 6.53

ISP 2.91 2.5 2.37

SSP - 0.18 0.34

ASP - 0.48 0.43

VISL 0.33 0.23 0.22

Total 26.18 24.59 23.13

TABLE 2.2

The investment for modernization and expansion programme of SAIL

is estimated at about Rs.54,333 crores.

2.2 PRODUCTS DETAILS:

Products by SAIL can be segregated into different categories-
(1) Long Products
(i) Crane Rails
(ii) Z-Type Sheet- Piling Section
(iii) Bars, Rods & rebars: SAIL TMT
(iv) Wire Rods

(2) Flats Products

(i) Hr Coils ,Sheets
(ii) CR Coils & Sheets
(iii) Plates GP Sheets Coils, GC Sheets: Sail Jyoti
(iv) Tin Plates

(3) Pipes

11
 CHAPTER-3

BOKARO STEEL PLANT

A PARTNER IN NATION BUILDING

Bokaro Steel Plant - the fourth integrated plant in the Public Sector - started taking
shape in 1965 in collaboration with the Soviet Union. It was originally incorporated as a lim-
ited company on 29th January 1964, and was later merged with SAIL, first as a subsidiary
and then as a unit, through the Public Sector Iron & Steel Companies (Restructuring & Mis-
cellaneous Provisions) Act 1978. The construction work started on 6th April 1968.

The Plant is hailed as the country’s first Swadeshi steel plant, built with maximum indig-
enous content in terms of equipment, material and know-how. Its first Blast Furnace started
on 2nd October 1972 and the first phase of 1.7 MT ingots steel was completed on 26th Feb-
ruary 1978 with the commissioning of the third Blast Furnace. All units of 4 MT stage have
already been commissioned and the 90s' modernization has further upgraded this to 4.5 MT
of liquid steel.

12
 Bokaro is designed to produce
flat products like Hot Rolled Coils,
Hot Rolled Plates, Hot Rolled Sheets,
Cold Rolled Coils, Cold Rolled
Sheets, Tin Mill Black Plates (TMBP)
and Galvanized Plain and Corrugat-
ed (GP/GC) Sheets. With the com-
pletion of Hot Strip Mill moderniza-
tion, Bokaro is producing top quality
hot rolled products that are well
accepted in the global market. Bo-
karo has provided a strong raw material base for a variety of modern engineering indus-
tries including automobile, pipe and tube, LPG cylinder, barrel and drum producing indus-
tries.

3.1 Raw Materials & Material Handling Plant

3.1.1 INTRODUCTION:

The Raw Materials and Material Handling Plant receives, blends, stores and supplies dif-
ferent raw materials to Blast Furnace, Sinter Plant and Refractory Materials Plant as per
their requirements. It also maintains a buffer stock to take care of any supply interrup-
tions.
Raw Material Handling Plant or Ore Handling Plant or Ore Bedding and Blending
Plant play a very important role in an Integrated Steel Plant. It is the starting point of
anin-tegrated steel plant, where all kinds of raw materials required for iron
mak-ing/steelmaking are hadled in a systematic manner, e.g., unloading, stacking,
screen-ing,crushing, bedding, blending, reclamation, etc.
Different types of major raw materials used in an integrated steel plant are-
Iron Ore
Lime stone
Dolomite
Manganese Ore
Ferro and Silico manganese
Quartzite and Coal
For Blast Furnace route Iron Making the main raw materials required are-
Iron ore lump
Blast furnace grade lime stone
Blast furnace grade dolomite
Coke
Sinter
Scrap LD
Slag Mn
Ore
Quartzite

The main objective of raw material handling plant/ore handling plant/ore

bedding and blending plant is to

13
 homogenize materials from different sources by means of blending
supply consistent quality raw materials un-interruptedly to different customers
maintain buffer stock
unloading of wagons/rakes within specified time norm
raw material preparation (like crushing , screening etc.).

3.1.2 Different Raw Materials and Their Sources

Raw Materials Sources(PLACES)
1. Iron Ore Lumps Bar sua,Kalta,Kiriburu,Meghataburu,
(IOL) Bolani, Manoharpur, Gua, Dalli, Rajhara, Rowghat

2. Iron Ore Fines Manoharpur,Gua,Dalli,Rajhara

(IOF) Barsua,Kalta,Kiriburu,Mghataburu, Bolani, Rowghat

3. BF grade Lime Kuteshwar, Bhabanathpur,Nandini,Katani

Stone

4. BF grade Dolomite Birmitrapur, Sonakhan, Birsa Stone Lime Company

5. SMS grade Lime
Stone Jaiselmer,Imported lime-stone from Dubai

6. SMS grade Dolomite Belha, Baraduar

7. Manganese Ore Barjamunda, MOIL(Purchased)

8. Mixed Breeze Coke Generated inside the plant (Blast Furnace & Coke Ovens)
9. Mill Scale Generated inside the plant
10. Flue dust Generated inside the plant
11. LD Slag Generated inside the plant

Right quality raw material is basic requirement to achieve maximum output at lowest
operating cost. Quality of raw materials plays a very important and vital role in en-tire
steel plant operation. Quality of raw materials (incoming) and processed
material(outgoing) is monitored by checking the incremental samples collected from
the whole consignment Samples are collected at Auto Sampling Unit or Sampling Unit.
The samples prepared after quarter and coning method are sent for further analysis.

14
3.1.3 Material Handling Equipments
Major Equipments Main Function

1. Wagon Tippler For mechanized unloading of wagons

2. Car Pusher For pushing the rakes inside the wagon tippler
3. Track Hopper For manual unloading of wagons
4. Transfer Car For shifting equipments from one bed to another
5. Screens For screening to acquire desired quality material
6. Crushers For crushing to acquire desired quality material

3.8 Hot Rolled Coil Finishing

15
All the Hot Rolled coils from the Hot Strip Mill are received in HRCF for further distribution or
dispatch. HR Coils rolled against direct shipment orders are sheared and finished to
customer-required sizes and dispatched to customers. The material is supplied as per Indian
specifications and many international/ foreign specifications. The shop has two
shearing lines with capacities of 6, 45,000 Tonnes/ year and 4, 75,000 Tonnes/
year respectively.
3.9 Cold Rolling Mill

The Cold Rolling Mill at Bokaro uses

state-of-the-art technology to produce high
quality sheet gauge material, Tin Mill Black
Plate and Galvanized Products. Cold rolling is
done to produce thinner gauge strips of very
smooth and dense finish, with better
mechanical properties than hot rolling strips.

3.10 Hot Dip Galvanizing Complex

The Hot Dip Galvanizing Complex integrated with the CRM produces zinc-coated Cold
Rolled strips resistant to atmospheric, liquid and soil corrosion The first shop of Bo-karo
Steel to get the ISO-9001 certification way back in 1994, this complex has main-tained a
high-standard of coating quality and its SAILJYOTI branded products enjoy a loy-al market.
This complex made certain innovations for
higher productivity to help re-build earthquake ravaged Gujarat.

Auxiliary Shops
To meet its needs for
maintenance and re-pairs,
Bokaro has a cluster of
engineering shops such as
Machine Shop, Forge Shop,
Structural Shop, Steel
Foundry, In-got Mould
Foundry, Cast

Iron and Non-Ferrous Foundry, Electrical Repair Shop and Power

Facilities Repair Shop in addition to shop-specific Area Repair Shops.
Most of the repairs and maintenance requirements of the plant are
met in-house.
The auxiliary shops and maintenance wings of Bokaro Steel, aided
by in-house design teams, have executed a number of highly
sophisticated procurement-substitution, productivity enhancement and
quality improvement jobs, saving rev-enues and enhancing equipment
availability.

16
 3.11 BOKARO STEEL PLANT - PRODUCT BASKET
Mill Capabilities

Sheets/ Plates
HRCF HR Sheets/ Plates Shearing Line-I - 5-10 1800 2.5-12
HR Sheets/ Plates Shearing Line-II 1.6-4 1500 1.5-4.5
HR Coil Slitting Line
CRM 1660
CR Coils/ Sheets CRM-I complex 0.63-2.5 700-1850
CR Coils/ Sheets CRM-II com- 0.63-1.6 650-1250
plex
Continuous . 6 -
CR Coils/ Sheets, DCR Mill 100 0.22-0.8 650-1040
TMBP
GP Coils & Sheets GC HDGL 170 0.3-1.6 650-1250
Sheets
TABLE 3.3

By-products

Nitration-grade Benzene Anthracene Oil Pitch Creosote Mixture

Nitration-grade Toluene Extra-hard Pitch BF Granulated Slag
Light Solvent Naphtha Hard-medium Pitch (solid/ liquid) Liquid Nitrogen
Still Bottom Oil Ammonium Sulphate Phenol Fraction
Hot Pressed Naphthalene
7. Stackers For stacking material and bed formation

8. Barrel / Bucket wheel For reclaiming material also called blenders

9. Belt Conveyors for conveying different materials to the Destination

18
 Benefits of RMHP/OHP/OB&BP
Provides consistent quality raw materials to its customer and also
controlling the cost by
• Minimizing undersize in iron ore lump & flux by means of screening
• blending
• Input quality over a time period is known
• Metallurgical waste utilization
3.1.4 Safety
It is dust prone department due to handling of various types of fines
hence use of dust mask, safety goggles, safety helmet, safety shoes etc. is
must. Housekeeping is a major challenge in smooth operation in this
department and requires special attention. Spill-age of material, water, oil,
belt conveyor pieces is to be controlled by effective house-keeping. This also
leads to personal and equipment health and safety. It makes the surrounding
area operation friendly.

3.2Coke Ovens & By-product Plant

The Coke Oven Complex at Bokaro converts prime coking coal from
Jharia, Dugda and Moonidih and medium coking coal form Kargali,
Kathara and Mahuda, blended with imported coal, into high quality
coke for the Blast Furnaces, recover-ing valuable by-products like
Anthracene Oil, Benzene, Toluene, Xylene, Light Sol-vent Naphtha,
Ammonium Sulphate and Extra-hard Pitch in the process. Bokaro is
situated in the prime coal belt of the country.

The Coke Oven battery has 8 batteries with 69 ovens each, maintained
meticulous-ly in terms of fugitive emission control, use of phenolic
water and other pollution control measures.

3.2.1 Introduction
Coke making is the process to convert coking coal, through a series of
operations,
into metallurgical coke. The process starts from unloading of the coal at
the wagon
tipplers & ends at sizing & transportation of coke to Blast furnace.

3.2.2 Formation of Coal:

The plant & vegetations buried under swamp bottom during earthquakes or

19
due to other environmental changes were subjected to heat & pressure.
During the initial period plant & vegetations decay to form PEAT. Over a
long period of time water is forced out due to tremendous pressure of the
overburden & due to heat generation mass to LIGNITE. Continuous
compaction & ageing converts the Lignite to Bituminous coal. This process
takes million of years.

3.2.3 Types & Sources of Coking Coal:

All coals are not coking coals, i.e. all types of coal can’t be used for
coke making. Coking coals are classified as:
Prime Coking Coal (PCC) Medium Consistency in chemical & physical
analysis by means of bedding & Coking Coal (MCC)
These are generally known as Indigenous coal, i.e. available in India. In
addition to the above coking coal the following types of coal are also used
for coke making in all SAIL plants.
Imported Coking
Coal (ICC) – Hard
Soft Coking Coal
(SCC)
Coal is extracted from coal mines & processed in the coal washeries to
lower down the ash content to make it fit for coke making. The different
sources of coal are named after the respective washeries and are as
follows:

PCC Bhojudih, Sudamdih, MunidihPatherdih,

Dugda, Mahuda
MCC Kathra, Swang, RajrappaKed-
la,Nandan12
ICC (Hard) Australia, New Zealand, USA
SCC Australia
TABLE 3.1

3.2.4 Properties of Coking Coal

Percentage of Ash: Lower the ash percentage better is the coal.

Indian coal normally contains a high percentage of ash. This is
reduced to some extent by suitable beneficiation process at the
mines.
Volatile Matter (VM): This is the volatile matters present in the coal
which goes out as gas during carbonization.
Free Swelling Index (FSI): This shows the agglomerating nature of coal
on rapid heat-
ing.
LTGK: This is another test for agglomerating behaviour of coal. However
this is done at a slower rate of heating. Inherent Moisture: This gives a
very good idea. the rank of the coal with advancement of rank the
inherent moisture generally comes down. Mean Max Reflectance: Rank
of coal is determined by measuring the reflectance of coal, which is
determined by MMR value. MMR is directly proportional to the strength
of COKE.
20
Coal Ash VM FSI LTGK Inherent moisture
MMR
PCC 19.0 21-23 >3.5 >E 2.5-3.0 1.10
MCC 18.5 23-25 >3.0 >E 2.5-3.0 0.85
Soft 8-10 25-30 >5.0 >G 2.5-3.0 0.87
Aust Hard 8-10 18-20 >5.0 >G 2.5-3.0
1.25 NZ 3-4 25-28 >5.0 >G 2.5-3.0 1.25
USA 8-10 25-30 >5.0 >G 2.5-3.0 1.00
3.2.5 Coal Handling Plant:

Coke is one of the most important raw materials used to extract iron from the iron ore.
The success of Blast Furnace operation depends upon the consistent quality of coke,
which is used in Blast Furnace. The quality of coke depends upon the precarbonisation-
technique, carbonization & post-carbonisation techniques used in Coke
ovens. Precarbonisation technique is controlled by Coal handling Plant.

Unloading & lifting of coal:

Washed coals from washeries are received at the Coal Handling Plant by Railways
wagons. Generally 58 wagons, called a rake, are brought to the plant at one time.
These wagons get unloaded in wagon tipplers. Here the wagons are mechanically
clamped &turned through 180° to 360° to discharge the coal onto down below
conveyors. Then through a series of conveyors the coal is stacked in coal yard through a
Stacker. The coal yard is divided into separate segments where different types of coal
can be stacked in respective earmarked areas. It is very important to stack different
types of coal separately so as to avoid mix up of two types of coal. Mix up of coal is
highly detrimental for coke making. From the coal yard, coal is reclaimed through Re-
claimer & by a series of conveyors gets transported to either crushers or silos as per
prevailing system in different SAIL plants.
Crushing & Blending:
The sequence of crushing & blending is different in different SAIL plants. The system of
crushing the coal & then blending is followed is RSP where as blending is done before
crushing in BSP.
Importance of Crushing:
Fine crushing of coal is essential to homogenize the different inherent constituents of
coal otherwise the coke produced will have different coking behaviour depending on its
original coal structure. Crushing of coal is done by hammer crusher. Crushing also adds
to improve the bulk density of coal charge in the ovens. Bulk density is the compactness
or close packing of the coal charge in the oven. Higher the bulk density better is the coke
strength. Bulk density can also be increased by addition of briquettes This facility exists
in RSP & BSP only. It has been observed that the same coal blend,

21
 after crushed to afineness of 70% against the normal requirement of 82%, will result
in deterioration instrength, denoted as M-10, by 1.5% to 2.0%. It is desirable to have
80% to 82% of -3.2mm size coal after crushing. This is known as crushing Index. How-
ever over crushingis not desirable as this reduces the bulk density & increases micro
fines, which causesproblem in battery operation.

Importance of Blending:

Blending plays a vital role in producing good metallurgical coke. Blending is a process of
mixing the different types of coal, i.e. PCC, MCC, Soft & Hard, in a predetermined ratio to
reduce the ash percentage of the blend coal, keeping the other coking prop-
ertiesintact. As evidenced from the table under properties of coal the Indigenous coals
containa relatively higher percentage of ash & Imported coals contain a relatively
lowerpercentage of ash. Hence a proper mixing, i.e. blending of both types of coal is nec-
essary.However blending is to be done in a very accurate manner so that required coke
propertydoes not get adversely affected. Blending is generally done by adjusting the dis-
charge ofdifferent types of coal from bunkers or silos to a common belt. The different

type of coalsgets thoroughly mixed during crushing where blending is done before crush-
ing. In casewhere blending is done after crushing proper mixing takes place at several
transfer points,i.e. during discharge from one conveyor to another conveyor through a
chute, duringtransportation to coal towers or service bunkers.

QUALITY OF COAL BLEND CHARGE:

ASH 12% to 14 %
VM 24% to 25%
MMR 1.12 to 1.16
SULPHUR < 0.6 %
FSI > 6
MOISTURE 8 % approx.

3.2.6 Carbonization Process:

The process of converting blend coal to metallurgical coke is known as carbonization.

It is defined as heating the coal in absence of air. It is also the destructive distillation of
coal. The carbonization process takes place in a series of tall, narrow, roofed cham-
bersmade of refractory bricks called ovens. A specific number of ovens constitute a Bat-
tery.
The ovens are mechanically supported by Structural & Anchorage.
A battery can be classified as per size & design. The most common classifications are:
a. Tall Battery – 7.0 mt. height.
Small Battery – 4.5 mt. height.
b. Recovery type battery – Gas formed during carbonization is converted to fuel &
again reused. By-products are obtained during cleaning of the gas.
Non-Recovery type battery – No by products are formed as the generated gas
Acts as the fuel.
c. Top charge battery – Conventional battery with charging from the top.
Stamp charged battery – A cake like mass is formed by ramming the coal. This
type is only installed at Tata Steel.
Blend coal from coal tower is charged from top to the ovens. Each oven is sand-
wiched
22
 between two heating walls from which heat is transmitted to the coal charge in-
side theoven. When coal is charged inside an oven, the coal nearest to both the walls
get heatedup first, melts & resolidifies to form coke. The heat passes to the next layer
of coal & soon till they meet at the canter. During the process of carbonization the
coal charge firstundergo de moisturization (drying) up to a temperature of 250°C.
Then it starts to soften ataround 300°C. It then reaches a plastic or swelling state dur-
ing 350°C to 550°C. Theentrapped gasses are then driven out at 400°C to 700°C. The
calorific value (CV) of Cokeovens gas is around 4300 kcal/m3.The gas is cooled to
800Cby ammonia liquor/ flushingliquor. The mass inside the oven then re-solidifies
(shrinkage) beyond 700°C. Finallycoke is produced as a hard & porous mass at around
1000°C.The total time taken for fullcarbonization is called coking time or coking peri-
od. The hot coke is then pushed out from the ovens. The hot coke is then cooled by
water spray or dry nitrogen purging. Thisprocess is called quenching of coke. General-
ly coke is cooled by water spray for a periodof 90 seconds. The cooled coke is then
sent to Coke Sorting Plant for proper sizing &then to Blast Furnace.

3.2.7 Major Equipments:

Major equipments/machines used in the process of coke making are:
Charging car: It collect the blend coal from coal tower & charges to empty ovens.
Pusher Car or Ram Car: Its functions are to level the charge coal inside the oven during
charging & to push out the coke mass from inside the oven after carboniza-
tion.
Coke Guide Car: It guides the coke mass during pushing to the Quenching car.
Quenching Car: It carries the hot coke to quenching tower & dump in the wharf
after cooling.

Role of Coke in the Blast Furnace:

Coke plays a vital role in Blast Furnace operation. For stable operation of the furnace
consistent quality of coke is most important. Variation in coke quality adversely af-
fects
the Blast Furnace chemistry. The roles of coke in Blast Furnace
are: It acts as a fuel.
It acts as a reducing agent.
It supports the burden inside the furnace.
It provides permeability in the furnace.

3.3 Blast Furnaces

Bokaro has five 2000-cubic metre Blast Furnaces that produce molten iron - Hot Metal -
for steel making. Bell-less Top Charging, modernised double Cast Houses, Coal Dust Injec-
tion and Cast House Slag Granulation technologies have been deployed in the furnaces.
The process of iron-making is automated, using PLC Charging System and Computer Con-
trolled Supervision System. The wastes products like Blast Furnace slag and gas are either
used directly within plant or processed for recycling / re-use.

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3.4 Steel Melting Shops

Hot Metal from the Blast Furnaces is converted into steel by blowing 99.5% pure Oxygen
through it in the LD converter. Suitable alloying elements are added to produce different
grades of steel.
Bokaro has two Steel Melting Shops - SMS-I and SMS-II. SMS-I has 5 LD converters of
130T capacity each. It is capable of producing Rimming steel through the ingot route.
SMS-II has 2 LD converters, each of 300 T capacities, with suppressed combustion system
and Continuous Casting facility. It produces various Killed and Semi-Killed steels.

3.5 Continuous Casting Shop

The Continuous Casting Shop has two double-strand slab casting machines, producing
high quality slabs of width ranging from 950 mm to 1850 mm. CCS has a
Ladle Furnace and a Ladle Rinsing Station for secondary refining of the steel. The Ladle
Furnace is used for homogenizing the chemistry and temperature. The concast
machines have straight
Page moulds, unique in the country, to produce internally clean slabs.

CCS produces steel of Drawing, Deep Drawing, Extra Deep Drawing, Boiler and Tin Plate
quality. It also produces low alloy steels like LPG, WTCR, SAILCOR and API Grade.

3.6 Slabbing Mill:

Slabbing Mill transforms ingots into slabs by rolling them in its 1250 mm Universal Four-
High Mill. The rolling capacity of the Mill is 4 MT per annum. The shop has Hot and Cold
Scarfing Machines and 2800 T Shearing Machine. Controlled heating in Soaking Pits,
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close dimensional accuracy during rolling and hot and cold scarfing help produce defect-
free slabs.

3.7 Hot Strip Mill

Slabs from CCS and Slabbing Mill are

processed in the state-of-the-art Hot
Strip Mill. The fully automatic Hot Strip
Mill with an annual capacity of 3.363
million tonnes has a wide range of
products - thickness varying from 1.2
mm to 20 mm and width from 750 mm
to 1850 mm. The mill is equipped with
state-of-the-art automation and con-
trols, using advanced systems for pro-
cess optimization with on-line real time
computer control, PLCs and technologi-
cal control systems.

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3.13 PROCESS FLOW
Page | 19

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4. CONCLUSIONS

According to my personal goal of amassing through knowledge about the

power systems, their workings, breakdowns, precautions, tests I conclude that
the public sector is the best sector for a stable job.

The perks of being an engineer here in Bokaro Steel Plant are infinite. The
com-pany itself is run by the central government with a stable and fixed
salary which ensures a stable life and a decent one for you and your family.

Coming back to the task at hand, another interesting conclusion drawn

from my training here is that to survive in this field the personnel must keep his
eyes and ears open and his pride and ego in the dustbin along with the
everlasting sup-ply of eagerness to learn something new in their pockets.
Otherwise nothing is possible.

Also the kind of job in this industry forces you to stay awake sometimes all
throughout the night ensure that the plant runs smoothly. Thus labor is
something which this job demands.

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 5. REFERENCES

SAIL ANNUAL JOURNAL 2009-10

ANNUAL REPORT: 2009-10
WORKING NOTES HRD DEPARTMENT
CR(E) DEPARTMENT
WEB SITE OF SAIL www.sail.co.in
OTHER SITES: - www.google.com
www.wikipedia.com

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