SW SUMMER INTERNSHIP REPORT

PROJECT REPORT OF INTERNSHIP AT

COKE OVEN 1 DEPARTMENT IN JSW

SW
JSW STEEL LIMITED, DOLVI WORKS,
DHARAMTAR, TAL-PEN, DIST-RAIGAD, DOLVI,
MAHARASHTRA ,402107

SUBMITTED BY:

NAME: Rahul Kamalakar Bhondakar

COURSE: Mechanical Engineering (Second Year)
COLLEGE: Government Polytechnic, Pen

UNDER THE SUPERVISION OF

Mr. Ajay Kumar Jha

(Coke Oven-1 Maintenance)
 ACKNOWLEDGEMENT

would solemnly like to express my deep sense of gratitude

towards M/s JSW steel Ltd. For giving me the opportunity for
getting industrial Training in their COKE OVEN-1. I am
obliged to my guide and COKE OVEN-1 for providing valuable
guidance and Approving the said training.
‡ am great full to the training & OD department of M/s JSW
Ltd. I Would like to thank MR. PRAVAT KUMAR NAYAK Head of training
& OD Department at M/s JSW steel Ltd.

Mr. Rahul Kamalakar Bhondakar

 CERTIFICATE

This is to certify that the project report titled "Introduction

mechanical equipment in COP1 BPP", submitted to JSW Steel Ltd.
Dolvi Works, Raigad, Maharashtra, of summer training is the bonafide
record of the project work done by Mr. Rahul Kamalakar Bhondakar
Mechanical Engineering from Government Polytechnic Pen, Raigad,
Maharashtra Under my supervision and guidance.

for
Mr. Ajay Kumar Jha
(Guide) Cr
Mr. Harpreet Singh Saini
(G Mechanical Coke Oven 1)

Mr. Pravat Kumar Nayak

(AGM Training)
 TABLE OF CONTENT

1. INTRODUCTION
2. PROCESS FLOW DIAGRAMME
3.
COOLING TOWER
4. BOILERS
66
N AIR COMPRESSOR UNIT
66
=
CHILLER UNIT
WATER PUMP HOUSE
PRIMARY GAS COOLER
ELECTROSTATIC GAS PRECIPITATOR
10.
EXHAUSTER
11. SCRUBBERS
12. GAS HOLDER
13. PLANT SAFETY POLICY
14. CONCLUSION
 ISW OVERVIEW

India's first steel plant to adopt a combination of Conarc

for steel making and Compact Strip Production (CSP) for
hot rolled coils, with thickness as low as 1.2

First choice of prestigious projects is the 5 MTPA integrated steel plant at Dolvi
Advantageously located on the West coast of Maharashtra. Its connected to a Jetty
can handle cargo of up to 15 MTPA. JSW Dolvi Works is India's first to adopt a
combination of Conacre Technology for Both steel-making and compact strip production
(CSP), aiding the production of hot rolled coils. From automotive and industrial
consumer durables, Dolvi Manufactures products that meet the needs of companies
across sectors. The group has strong footprints across various sectors namely, Steel,
Energy, Minerals, Port & Infrastructure & Cement in multiple locations across India. US,
South America and Africa. JSW Steel Ltd, JSW Energy etc are subsidiaries of
GROUP OVERVIEW OF THE
"IF WE WORK HARD AND BE GOOD TO PEOPLE, WE WILL
MR. O. P. JINDAL

At JSW Steel, we are committed to providing a healthy and safe working

for our employees, contractors, business associates, visitors on premises, and above all
communities impacted by our operations. To achieve our zero harm vision, we
stringent safety systems in place.
 Jsw steel Itd facilities

JSW Steel has grown from a single manufacturing unit in early '80s to become
leading integrated steel company with a steel-making capacity of 28 MTPA in India &
the USA, including capacities under joint control & new capacity to be commissioned
Dolvi during this year. Its roadmap for the next phase of growth includes a target
achieving 37.5 MTPA steel capacity by FY25. The Company's manufacturing unit in
Vijayanagar, Karnataka is the largest single location steel-producing facility in India with
a capacity of 12 MTPA. JSW Steel has always been at the forefront of research
innovation. It has a strategic collaboration with global leader JFE Steel of Japan,
enabling JSW to access new and state-of-the-art technologies to produce & offer
value special steel products to its customers. These products are extensively used
industries and applications including construction, infrastructure, automobile,
applications, appliances, etc. JSW Steel is widely recognized for its excellence
business. Some of its key honours and awards include World Steel Association's
Sustainability Champion (consecutively from 2019 to 2021), Leadership Band Rating
(A-) in CDP (2020), Deming Prize for TQM for its facilities at Vijayanagar (2018), and
Salem (2019), DJSI RobecoSAM Sustainability Industry Mover Award (2018) among
others. JSW Steel is the only Indian company to be ranked among the top 10 steel
producers by World Steel Dynamics for 10 consecutive years. As a responsible
citizen, JSW Steel's carbon reduction goals are aligned to India's Climate
commitments under the Paris Accord.
 ABOUT ISW

The US$ 22 billion JSW Group is ranked among India's leading business
Houses.in various sectors including Steel, Energy,
JSW's innovative and sustainable presence
Infrastructure, Cement, Paints, Venture Capital and Sports helping the Group play an
iS
important role in driving India's economic growth.
The Group strives for excellence by leveraging its strengths & capabilities including
successful track-record of executing large capital-intensive & Technically
complex
projects, differentiated product-mix, state-of-the-art manufacturing facilities and greater
focus on pursuing sustainable growth.
With a culturally diverse workforce spread across India, USA, Europe and Africa,
Group directly employs nearly 40,000
It also has a a strong social development focus aimed at empowering local Communities
residing around its Plant & Port locations. JSW Group is known to create value for
its stakeholders by combining its growth roadmap, superior Execution capabilities
relentless drive to be #BetterEveryday.

Key persons
Mr. Sajjan Jindal, ( CMD, Chairman, JSW
Mr. Seshagiri Rao, ( JMD & Group CFO, JSW Steel )
Mr. Jayanta Acharya, ( Dy. Managing Director)
% Following are different plants within JSW DOLVI

Blast Furnance-1&2

Steel Melt Shop (SMS-1 & 2)

Power Plant

Pellet Plant

Coke Oven Plant

Sinter Plant

O Lime Calcination Plant

Slab caster and Bar Mill

Billet Caster

Cement Plant
Company Businesses
Steel
Energy
Infrastructure
Cement
Ventures

JSW STEEL

JSW Steel is the flagship business of the diversified US$ 22 billion JSW Group. As
of India's leading business houses, JSW Group also has other business Interests
sectors such as energy, infrastructure, cement, paints, sports, and Venture capital. JSW
Steel, certified as" Great Places to Work" in 2021, has Emerged as an
with a strong cultural foundation and great potential to be among the Top
companies. Over the last three decades, it has grown From a single manufacturing
to become India's leading integrated steel Company with capacity of 28 MTPA in
& USA (including capacities under Joint control).

Its roadmap for the next phase of growth includes a target of achieving 37.5 capacity
FY25. The Company's manufacturing unit in Vijayanagar, Karnataka is the largest
location steel-producing facility in India with a capacity of 12 MTP.

10
History

The JSW Group's foray into steel manufacturing began in 1982, when It set up
Jindal Iron and Steel Company with its first steel plant at Vasind near Mumbai. The
two decades saw significant expansion and several Acquisitions, following the
of Jindal Iron and Steel Co (JISCO) and Jindal Vijayanagar Steel Ltd (JVSL)in 2005.
Today JSW Steel has plants in six Locations in India - Vijayanagar in Karnataka, Salem
1n Tamil Nadu, and Tarapur, Vasind, Kalmeshwar and Dolvi in Maharashtra. Our global
operations include a plate and pipe mill in the US. In order to securities resources,
company has acquired mining assets in Chile, USA and

About Dolvi Works

The 10 MTPA integrated steel plant at Dolvi is advantageously located on the

coast of Maharashtra. It is connected to a jetty which can handle cargo of Up to 15
MTPA.
JSW Dolvi Works is India's first to adopt a combination of Conacre Technology
both steel-making and compact strip production, aiding the production of hot
coils. From automotive and industrial to consumer durables, Dolvi Manufactures
products that meet the needs o companies across sectors
COKE OVEN 1

By-Product Area

1
PROCESS FLOW DIAGRAME OF
COKE OVEN-1

Coke Oven Plant

COK
OVEN

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 Cooling Tower

There are 5 cooling towers are installed and working IN coke

BPPFunction:
Cooling towers are used to remove heat from a hot water used for process . Air comes in
from the sides of the tower and passes through the falling water.
Working Principle:
Air enters the tower beneath the fill and is drawn up vertically into the tower. Above
fill, hot water is introduced through low pressure spray nozzles to divide the hot water
over the surface of the fill in fine droplets. The cooling air draws heat from the water as
it progresses to the bottom of the tower.

1
 25 TPH Boiler

There are three main important component of boiler

Water - Soft water & De-Mineralize water Fuel
COG & Mix gas (COG+ NG)
Air supply

03

DEAERATOR 3 CSD

PT 0.00 0.2

DEAERATO 0.0 HOOTER

EA

15
There are two types of boiler used
Fire tube boiler
Water tube boiler
Working Principle:
It is simple to understand how the boiler works. To understand it, let us have a look at
The boiler 1S a closed vessel, where the water is stored.
Hot gasses are formed by burning fuel in the furnace. These glasses are made to come
in contact with the water vessel, the point where the heat transfer takes place between
the steam and water. Thus, the boiler's basic principle is to convert water into
with heat energy. There are various types of boilers available to use for
purposes.

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 AIR COMPRESSOR Screw Type Air Compressor Unit

Coke Oven BPP have 5 air compressor units . Those compressors are screw
compressor It is having mechanical parts like air filter, air cooler, oil and
separator,screw and motor. Three of five are used for process air and two are used for
instrument air uses. To demoisturise the air,two driers are also
Working pressure compressed air is around 5 kg/
 Li-Br Vapour Absorption

Coke oven 1 BPP having 5 Li-Br vapour absorption chillers, two are running and
are standby condition. Lithium Bromide (LiBr) has the property to absorb water
(Refrigerant) due to its chemical affinity. It is directly proportional to concentration
and inversely proportional to its temperature. . Diluted LiBr loses its capacity to
water vapour. Thus, needs to be re-concentrated using a Heat Source. When a liquid iS
heated it boils (vaporizes) and when a gas is cooled it condenses ,Lowering the pressure
above a liquid reduces its boiling point .Heat flows from warmer to cooler
The process of absorption cooling iS dependent on a thermochemical 'compressor'.
Two different fluids are used: a refrigerant and an absorbent. The fluids have
"affinity" for each other, which means one dissolves easily in the other.In a
lithium bromide vapour absorption refrigeration system, water is used as the
while lithium bromide (Li Br) is used as the absorbent. In the absorber, the
bromide absorbs the water refrigerant, creating a solution of water and lithium
The refrigerant usually water- can change phase easily between liquid and vapour
and circulates through the
Heat from natural gas combustion or a waste-heat source drives the process. The
affinity of the refrigerant for the absorbent (usually lithium bromide or ammonia)
causes the refrigerant to boil at a lower temperature and pressure than it
would and transfers heat from one place to

1
 Comprehensive water supply system

Coke oven 1 having comprehensive water supply system, which consist of total 12 nos of
centrifugal pumps.
Group 1 pumps chilled water pumps
Group 2 pumps : circulating water
Groups 3 pumps: cooling water pumps
Group 4 pumps : Process water

Centrifugal pump is a type of rotodynamic pump in which mechanical energy of

shaft is converted into pressure and kinetic energy of water. the rotating part of the
centrifugal pump is Impeller. The energy added by the impeller of a centrifugal
to the liquid is largely due to centrifugal effect. the principle of working of
pump is Forced vortex flow which is defined as the when certain mass of liquid
rotated by the external torque(shaft of impeller through motor), there is rise in
head of the rotating liquid. A pump is used to convert the energy of prime mover
kinetic energy and then into pressure energy of a liquid. Centrifugal pumps have
output and efficiency and these are simple In construction as well therefore
pumps have wide spread

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 COKE OVEN-1

This section is broadly classified into following sections

PRIMARY GAS COOLER

ELECTROSTATIC TAR PRECIPITATO
GAS EXHAUSTER
SCRUBBE

COG flow in Coke Oven -1

Extern
consum

Claus

PECS

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 PRIMARY GAS COOLER

Primary Gas Coolers 3 numbers are installed for initial cooling of coke oven gas
temperature of gas before PGC is 80°C while after PGC it
It is a type of shell and tube heat
Circulating water flows in the top portion tubes while chilled flows in the bottom
for effective cooling of gas which flows in the shell part.

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 PRIMARY GAS COOLER

The coke oven gas from the separator is fed to the PGC from the top. The cooler consists
of three zones.isThis a shell and tube heat exchanger in which the CO gas
with service water in the top two zones and with chilled water in the bottom zone the
tubes are inclined in all the zones. The inclinations maintained at 15°c with
horizontal. This provides any naphthalene condensate to drain easily. The main
of PGC is to cool the gas from 90°c to
During this cooling process, the naphthalene and traces of tar present in the gas condense
and this is collected at the bottom of the PGC. The liquid collected at the bottom
1S
to the seal pot by gravity. The level in the seal pot should be maintained constant as this
acts as a seal to the gas in the cooler. Tar at a temperature of 90°c is flushed from the top
of the cooler to remove the condensed naphthalene on the tubes. The tar is then collected
at the bottom of the seal pot. Tar and naphthalene from the seal pot are fed to the storage
tank of the CPH. The CO gas from the bottom of the PGC is fed to the
precipitator.
Gas temperature before PGC-80-95°c
Gas temperature after PGC -
Service water inlet temperature 32-33 I Service water outlet temperature
Gas condensate flow to each PGC - 10-15 Nm3/
Chilled water inlet temperature 11-12°c

22
 ELECTROSTATIC TAR PRECIPITATOR(ETP)

COP1 BPP is having two ETP,one working and one is standby condition. Each one
having capacity of 50,000 m3 capacity.

An electrostatic precipitator (ESP) removes particles from a gas stream by using

electrical energy to charge particles either positively or negatively. The charged particles
are then attracted to collector plates carrying the opposite charge.
An electrical tar precipitator cylinder is provided with insulating boxes and a
holder, the electrical tar precipitator cylinder is internally provided with
electrodes , an upper hanging bracket, aa lower hanging bracket and wire electrodes , the
receiving electrodes are a plurality of regular-hexagon-shaped honeycomb pores, and the
center of each honeycomb pore is provided with the corresponding wire electrode . The
electrical tar precipitator solves the problems that wire electrodes of a traditional
electrical tar precipitator are poor IN discharge property, prone to swing, prone to wire
breakage, low in purification efficiency, unstable in operation and the

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 Blower : -_
Blower is used for suck the gas. The gas which is suck by the blower is coke gas
Blower consists of impeller
Gear Box
Gear box is used to transmit the power.In gear box helical type gear is
Because , vibration is not more Plate type heat exchanger is used gear box
in

Hydraulic Coupler -
Coupler is used to maintain the Speed. At the top of the coupler scoop is attached which
is used to maintain the speed .In hydraulic coupler shell and tube type heat
used
At the top of the coupler scoop 1S attached which
iS used to maintain the. Speed

hydraulic coupler shell and tube type heat exchanger

Induction motor
At the last induction motor is attached. This motor having 2900 rpm something. The
used of inductive motor is to exaust the

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 Overhead Tank- Whenever The power is trapped then overhead tank oil is used.

Precautions
While operating the machine not use
Don't walk IN plant without permission
Always follow safety precautions
Always used safety material like helmet, shoes

Key Specifications
Capacity = 7500n/m^3/ hr
Model No = D/1250
Inlet pressure = 3.5kpa to 5 kpa D Discharge pressure - 25kpa
Voltage = 50 hz
Motor ampere = 110 amp
Oil Tank Capacity = 4000 litre

2
 Scrubber towers

Coke oven gas from exhauster is first fed into the final cooling stage at lower part of H2S
scrubber. Gas is cooled down to ~22°C by spraying with the circulating water. After the
circulating water out of H2S scrubber is cooled with the cooler for circulating water, the
circulating water is sent back again to the final cooling stage at the lower part of H2S
scrubber for circulating cooling. At the upper part of H2S scrubber, H2S in gas is
absorbed with enriched ammonia water from ammonia scrubbing and lean solution from
deacidifier and ammonia stripping unit. At the same time of H2S removal in
scrubber, also CO2, HCN and NH3 are absorbed. Because the absorption process of
H2S, CO2, HCN and NH3 is the exothermic process, therefore both upper stage and
lower stage of H2S scrubber are provided with the coolers for H2S circulating scrubbing
solution.
In ammonia scrubber, ammonia in gas is washed with soft water and the stripped water
from deacidifier and ammonia stripping unit. In addition to these, coal water from coal
water filtering system is added to the bottom of ammonia scrubber after cooled with coal
water cooler so as to increase ammonia scrubbing effect. If the concentration of free
ammonia in coal water is very high, part of or all coal water is directly sent to
stripper. Enriched ammonia liquor out of the sump of ammonia scrubber is first
with ammonia liquor cooler, then sent to the top of H2S scrubber

2
 Gas holder

COP1 is having 50,000m3 capacity dry gas holder installed in area. Gas
holder 1s a large container where industrial gas or town gas iS stored near atmospheric
pressure at ambient temperatures, which is widely used in steel plants to store blast
furnace gas, coke oven gas and converter gas etc. It can stabilize pipe network pressure
so as to keep system stable and balanced.

SPECIFICATIONS;
0 o Height: 50mtr.
O Capacity: 50,000m3
O TYPE: Dry type
o SEAL: Oil seal

2
 SAFETY POLICY OF ISW STEEL LTD
It is jsw Group's vision to achieve zero harm across all our operations. Health and
represents an important part of our Group's values and is core to the JSW way of life.
JSW Steel, we are committed to providing a healthy and safe working environment
our employees, contractors, business associates, visitors on premises, and above all
communities impacted by our operations. To achieve our zero harm vision, we
stringent safety systems in place. These processes are to a large extent tech-enabled and
leverage real-time data, and are guided by the principle of shared responsibility. From a
governance standpoint, our senior management, along with key plant personnel, assumes
overall accountability for ensuring that the appropriate safety policies, procedures and
safeguards are put into practice.

Robust safety performance monitoring and management

Monthly Global Group Health & Safety Performance Report shared with
leadership team with 30+ harmonized leading and lagging performance
across all the JSW Steel
Mandatory individual and site level safety KRAs linked to variable
Safety training
Successfully launched 15 new safety e-learning modules on High Risk
at Group level
Mandatory H&S induction programme for all the employees and
Mandatory H&S e-learning modules for employees in grade L8 and
28,800+ training units completed in FY
A standard training and competency matrix developed for all the plant locations
Hosted monthly learning and sharing webinar sessions on health and safety topics,
with participation from 1,000+ leaders and senior personnel
Group safety online application
A Group Safety Mobile App was launched for Safety Observations (SOs)
Incident Tracking across JSW Group in India
The App enables employees to not only capture the SOs and incidents, but also to
assign it to responsible teams, track the closure of findings, analyse trend and
generate reports directly through their
Launched online safety inspection tool in JSW Safety
SW 10 critical safety rules
Conceptualized and developed '10 JSW Critical Safety Rules' benchmarked
best practices followed across the world
English and Hindi versions of '10 JSW Critical Safety Rules' released across
Group along with FAQs, and developed communications around the

28
Animation-based training modules are being developed in English and Hindi
CoE in process safety
We have begun working on establishing a Centre of Excellence in Process
with DuPont Sustainable Solutions (DSS) at our Dolvi site. All the leaders at
site received extensive training in the Process Safety Management. The site has
also established robust Management of Change (MOC) and Pre Start-up Safety
Review (PSSR).

Contractor assessment and rating for excellence in safety

Each site has a Contractor Safety Management committee headed by a senior
a
leader to improve the contractor safety performance while working for
Each contractor has to undergo mandatory health and safety pre-
assessment (PQA) prior to awarding any contract for work at the sites. Only
who receive more than the threshold PQA score are eligible to work at JSW
Developed the JSW CARES *Contractor Assessment and Rating for Excellence
Safety', a progressive capability building tool for contractors to improve and
in their respective safety management system and performance

Health and safety governance

We have a Health and Safety Governance structure to lead proactively in
and Safety and focus on key issues. The Apex committee, which is chaired by
site head, meets at regular intervals to review and improve plant safety
performance. The information flows from Divisional Improvement Committee
various sub-committee, which aggregates it for the site Apex. Similarly the
Apex committee reviews and submits the site level H&S plan, progress
performance to the Group Safety Council. We regularly benchmark our
practices against international standards. To achieve this objective, in the year
2020-21,
the our
area of Salem
high risk and Dolvi sites were assessed by the British Safety Council
activities. in

Employee involvement in health and safety

Every site within JSW Steel has a Safety Committee which has equal
from Management as well as the workforce. These committees meet at
intervals and discuss health and safety improvements and enhance
health & safety
We promote Safety Kaizen from time to time, where employees at all
participate and contribute to safety improvements
We have : system of Safety Observations (SO), in which all Supervisors
mandatorily participate and highlight safe and unsafe workplace

2
 Every day before the start of work, all employees participate in Toolbox
(TBT) which serve as an informal platform to consult all levels of
regarding safe work practices

3
 CONCLUSION

From training and plant visit,I got the basic knowledge of mechanical equipments
used in coke oven1 bpp area. With the help of guide ,I have learned the operation
these equipments, maintenance, breakdown and working principle.I also
knowledge of preventive maintenance and annual maintenance of these
equipments.
During training I have learned about the safety operation of this equipments and
standard operating procedures.
This training will help me in my academics and future practical knowledge
experience.I would like to thank to all the team members of coke oven 1 for their
great support.

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