Harish Reddy

An Industrial Report
On
RASHTRIYA ISPAT NIGAM LIMITED

Visakhapatnam
An Industrial training report submitted to GICE, Visakhapatnam.

In partial fulfillment for the award of
Diploma in Chemical Engineering (Oil Technology)
By
MUDUNDI PARDHIV VARMA
21065-CHOT-029
DEPARTMENT OF CHEMICAL ENGINEERING (Oil Technology)

GOVERNMENT INSTITUTE OF CHEMICALENGINEERING
VISAKHAPATANAM-530007
GOVERNMENT INSTITUE OF CHEMICAL ENGINEERING

AN INDUSTRIAL REPORT ON STEEL PLANT
Pride of steel
RASHTRIYA ISPAT NIGAM LIMITED

VISAKHAPATNAM
CERTIFICATE
This is to certify that MUDUNDI PARDHIV VARMA (21065-CHOT-029)
bonified student at Government institute of Chemical Engineering, Visakhapatnam has
undergone sandwich industrial training in RASTRIYA ISPAT NIGAM LIMITED,
Vishakhapatnam. During the period of FEBRUARY-2024 to MAY-2024.
During the period of training his conduct is found to be .
MR.M.GANESH BABU,
AGM,Training Incharge.

INDUSTRIAL REPORT ON STEEL PLANT .
ACKNOWLEDGEMENT
The satisfaction that accompanies the successful completion of any task would be
incomplete without mentioning the people who made it possible and whose constant
guidance and encouragement grown all the efforts with success. This acknowledgement
transcends the reality of formality when we like to express deep gratitude and respect to all
those people behind the screen who guided, inspired, and helped us for the completion of the
report.
We are thankful to the Mr.M.GANESH BABU,AGM,Training incharge;
Dr.A.MURALI MOHAN,DGM(Trg) ;Mrs.N.BHANU,HOD for their concern in
giving the opportunity to pursue Industrial Training and for providing guidance.
We take pleasure in thanking Mr.S.MURALI KRISHNA , Sr.Manager

(QATD); Mr.K.SAMBABU,GM(UTILITIES)I/C;Mr.A.BAPUJI, DGM(CO&CPP)/ Mr.
M.K. SINHA GM(CO&CCP)-CCP(O)/Mr.S.A.LAKARA, DGM (CO&CCP); Mr.
P . RAVI K U M A R Sr.Manager(WMD) I/C; Mr.MADHUSUDAN DGM(TPP) I/C
for their excellent perception and sparing valuable time despite his busy schedule
and also to all staff members of RINL who were engaged with us during the period
of our training.
The encomium goes to the Dr.K.V.RAMANA, Ph.D. Principal;
MR.D.DAMODAR,M.Tech, Senior Lecturer, Training incharge& HOD (OT);
Mr.V.SRIKANTH(M.Tech),Senior lecturer& Training incharge (OIL
TECHNOLOGY) ; DR.P.KRISHNA REDDY (M.Tech, pH.D); Mr.CH.VINODH
KUMAR(M.Tech) for giving us this opportunity for the successful completion of
industrial training.
On conclusion, we will remember our experiences during this industrial training and put
of presenting the training experience to prove our ability and work for pride of the organization
in all respects wherever we get an opportunity.
MUDUNDI PARDHIV VARMA

21065-CHOT-029

INDEX
❖ Introduction of “VSP”
❖ Modern Technology & Major Plant Facilities
❖ Safety in industry
❖ Fire safety
❖ Personal protective equipment
❖ Profile on “VSP”
1. Coke Ovens &Coal Chemical Plant:
• Coke Oven
➢ Coal Preparation Plant
➢ Coke Oven Batteries
➢ Coke Dry Cooling Plant
➢ Coke Sorting Plant
• Coal Chemical Plant:
➢ Primary Gas Coolers
➢ Ammonium Sulphate Plant
➢ Final Gas Coolers
➢ M.B.C (Mechanical biological chemical)
➢ Tar Distillation
➢ P.C.L.A(Pitch cooling loading area)
➢ Naphthalene Fraction Crystallization
➢ Benzol distillation plant
2 .Utilities:
➢ Air Separation Plant
➢ LPG ( Liquified Petroleum Gas)
➢ Compressor House
➢ Chilled Water Plant
3. Quality Assurance & Technology Development:

➢ Thermal power plant lab
➢ Central Lab
➢ Coke oven lab

4. Thermal Power Plant:

➢ Clariflocculator
➢ Pressure sand filter
➢ Activated carbon filter
➢ Ultra filtration
➢ Reverse osmosis
➢ Strong acid cation
➢ Strong base anion
➢ Mixed bed
5. Water Management Department:

➢ KBR(Kanithi Balancing Reseviour)
➢ Pump House-1,Pump House-18
➢ Steel Melt Shop, Blast furnace
INTRODUCTION
The role of ferrous metals in general and of steel in particular in national economy is
enormous. One cannot name an economic branch where ferrous metals find no applications.
The economic power of country is determined by its output of steel, since it determines the
progress in the principle economic branches, be it mining, transport, manufacture
engineering or agriculture implements is unthinkable without steel.
An additional impetus for increasing the scope of steel manufacturers had been the vigorous
progress in chemical engineering. It has turned out that steel can be very profitable combined
with certain novel materials for instance plastic combined with stainless steel are excellent
materials fore making furniture, decorating automobiles internal lining of houses and
building purposes. As a result the manufacture of stainless steel has been appreciably
increased in order to cover these new demands in recent years. The world for the steel rises
continuously and is expected to reach the level of thousand million tons per year by the end
of this century. The steel will obviously remains the principle structural material in for stable.
To meet the above requirements the following iron and steel companies were established:
➢ Tata iron and steel company is the first ever-integrated steel plant in India in 1908 at
Jamshedpur.
➢ TISCO in Bihar
➢ IISCO in Burnapur
➢ Bhadravathi steel in Karnataka
➢ Hindustan steel plant at Bhilai , Rourkela and Durgapur
➢ Visakhapatnam steel plant at Visakhapatnam

VISAKHAPATNAM STEEL PLANT:

Visakhapatnam Steel Plant, the first coastal based Steel Plant of India is located, 16m South west of city of
Destiny i.e., Visakhapatnam. A great emphasis has been made on total automation, seamless integration and
efficient up gradation, which results in wide range of long and structural products to meet stringent demands
of discerning customers within India and abroad. VSP Products meet exalting International Quality
Standards such as JIS, DIN, BIS, BS etc.
VSP has become the first interacted steel plant in the country to be certified to all the three
international standards for qualify (ISO-9001) for Environment Management (ISO-1400) & for occupational
health & safety (OHSAS-18001) The certificate covers quality systems of all operational, maintenance,
service units besides purchase systems, Training and Marketing functions spreading over 4 Regional
marketing officers, 23 branch offices and 22 stock yards located all over the country.
In order to increase the steel production reasonably high in the nation and remove the regional
imbalances in industrial developments, the government of India took a great step in setting up the coastal-
based steel plant of India is Visakhapatnam steel plant in Andhra Pradesh.
This has resulted in a great demand for Visakhapatnam steel plant product in India and abroad
which are having international standards. Visakhapatnam steel plant is considered to be the first integrated
steel plant in India to become fully ISO-9002 certified company. This certificate covers quality systems of
training and marketing functions over four regional marketing functions and 22 stock yards located all over
the country. The decision of the government of India to set up an integrated steel plant at Visakhapatnam
was announced by the Prime Minister Smt.Indira Gandhi. The plant was inaugurated formally on 20th
January 1971 by the prime minister.
The project was estimated to the cost of rupees 3,897.28 crores based on process on 4 th quarter of
1981 but during the implementation of VSP is has been on served that the project cost as increased
substantially over the sanctioned coast mainly due to this and the approved concept were studied in 1986 the
rationalization has basically been from the point of view of obtaining maximum output from the equipment
already installed paneled for procurement, achieving the higher level of operation efficiency and
procurement over what was envisaged earlier under the rationalized concept. 3.0 million tons of liquid steel
is to be produced in a year and the project is estimated to cost 5,822 crores based on 4th quarter of 1987.
VSP’S FRUITFUL ACHIVEMENTS:
 It has crossed many milestones in the fields of production, productivity and exports.
 Coke rate at an order of 543kg/ton hot metal
 Average converter life of 649 heats.
 An average of 11.5 heats per sequence in continuous bloom caster.
 Specific energy consumption of 7.51 Kcal/ton of liquid steel.
 Specific refractory consumption of 15.2kg.
 A labor productivity of 192-ton/man yr.

MODERN TECHNOLOGY & MAJOR PLANT FACILITIES:-

MODERN TECHNOLOGY:
Visakhapatnam steel plant is the most sophisticated and modern integrated steel plant in the country.
Modern technology has been adopted in many areas of production, some of them for the first time in the
country.
 Selective crushing of coal
 Dry quenching of coke
 On ground blending of sinter base mix
 Conveyor charging and bell less top blast furnace
 Cast house slag granulation for blast furnace
 100% continuous casting of liquid steel
 Gas expansion turbine for power generation utilization blast furnace top gas pressure
 Computerization for process control
THE MAJOR PLANT FACILITIES:

→ Coke oven batteries of 67 ovens each having 41.6 cu.m volumes.
→ Sinter machines of 312 m2 area.
→ Blast furnace of 3200m3 useful volume.
→ Steel melt shop with three L.D converters of 150 ton capacity each and 6 nos. of 4 strand continuous
bloom casters
→ Light and medium merchant mill of 710,000 tons per year capacity
→ Wire rod mill of 850,000 tons per year capacity
→ Medium merchant and structural mill of 850,000 tons per year capacity.
GOVERNMENT INSTITUTE OF CHEMICAL ENGINEERING

SAFETY IN INDUSTRY
Introduction:
Industrial safety is a broad area of workplace safety, covering several issues and topics,
including:
• General safety (issues and concerns that are common across all industries) • Site-specific
safety issues
• Process and production safety
• Material safety
• Fire safety
• Electrical safety
• Building and structural safety (including temporary installations) •
Environmental safety
The Importance of Industrial Safety:

Although every workplace and job task carry some safety hazards, industrial hazards are often
higher risk and have the potential to cause severe injury, extensive property damage, or
devastating environmental harm. Given the highly specialized nature of the work, many of the jobs
are carried out by trained and skilled employees. Workers who sustain lost time injuries can be
difficult to replace, even temporarily. Because of this, injuries can have significant effects on a
company's production output, shipping schedules, fulfillment, vendor relationships and customer
satisfaction. Good safety practices, then, not only keep workers safe but also help maintain
employee, vendor, and client satisfaction.
Industrial Safety Objectives:

• Preventing work-related fatalities, disabling injuries, illness, and damage to machinery or
materials
• Ensuring continued production by preventing disruptive incidents • Reducing workers
compensation costs, maintaining lower insurance rates, and minimizing indirect costs associated
with accidents.
• Strengthening safety culture and increasing employee morale • Meeting vendor and client expectations
Industrial Safety Planning

An Industrial Report on STEEL PLANT
Industrial safety takes place long before the work begins. In fact, it should be part of the job planning and
site design. Some important early and ongoing considerations include:
• Plant layout
• Fire prevention systems
• Health and hygiene
• Safety training
• Adequate lighting in work areas and corridors

• Flooring and working areas that are easy to clean and organize. • Insulation
• Signboards and written safety instructions
FIRE SAFETY
Introduction:
Fire is a chemical in which combustible material combines with oxygen in atmosphere to give
heat and flame except for spontaneous ignition, the process can only begin with a source, once it
has begun, the heat produce may often be sufficient to support or even accelerate the process. The
materials involved in the combustion process are hydrocarbons, other organic
compounds, cellulose carbonaceous materials which may be in solid, liquid or gaseous state.
Fire results from the combination of fuel, heat, and oxygen. Whenever a substance undergoes a
chemical change by combining with oxygen, it usually liberates certain amount of heat. The
chemical change is called as ‘OXIDATION’ this oxidation is accompanied by evolution of heat
is
called as combustion. In fire service parlance and uncontrolled combustion is a ‘FIRE’.
Three factors must be considered in occurrence of fire:
Fire safety is a set of practices intended to reduce destruction caused by fire. Fire safety measures
include those that are intended to prevent the ignition of an uncontrolled fire and those that are
used to limit the spread and impact of a fire. Fire safety measures include those that are planned
during the construction of a building or implemented in structures that are already standing and
those that are taught to occupants of the building. Threats to fire safety are commonly referred to
as fire hazards. A fire hazard may include a situation that increases the likelihood of a fire or may
impede escape in the event a fire occurs. Class of Fire Example Method to Extinguish
Extinguishing media A Solids (wood, paper, glass) cooling or starvation sand, water, soda acid
extinguisher B Hydrocarbon,Oil (Styrene, Pentane ,Ethyl Benzene, Diesel) Blanketing
or starvation Dry Chemical Powder (DCP),Foam Extinguisher, CO2 Sand C Gas Fire (LPG)
Blanketing Co2 fire extinguisher D Metal Fire Blanketing Co2 & DCP Fire extinguisher E
Electrical Fire Blanketing Co2&DCP extinguisher.

PERSONAL PROTECTIVE EQUIPMENT

Introduction:
Personal Protective Equipment (PPE) refers to protective clothing for the eyes, head, ears, hands,
respiratory system, body, and feet. It is utilized to protect individuals from the risks of injury and
infection while minimizing exposure to chemical, biological, and physical hazards. PPE serves as
the final line of defense when engineering and administrative controls are insufficient in reducing
or eliminating risks.
Importance:
According to the hierarchy of controls by the National Institute for Occupational Safety and
Health (NIOSH), PPE (sometimes also referred to as PPE equipment)—is recommended to be the
last level of defense to prevent occupational injuries, illnesses, and fatalities, but some businesses
combined it with other control measures to ensure a safe and healthy environment for
their workers. Here are some benefits of using PPEs:
• Prevent unnecessary injury in the workplace;
• Protect employees from excessive chemical exposure;
• Prevent the spread of germs and infectious diseases including COVID-19; • Help businesses
comply with regulatory requirements(e.g., The Personal Protective Equipment at Work
Regulations 1992 that’s recently been extended to limb workers); and
• Improve employee productivity and efficiency.
Personal Protective Equipment:

However, even the strictest controls will not necessarily eliminate all the risks associated with
most job tasks and this is where the need for PPE must be evaluated. A hazard assessment can help
identify which specialized PPE will be required. There are numerous types of workplace safety
equipment available depending on the hazard exposure and work conditions.
The following are basic PPE that can help protect employees:

Face and Eye Protection:

PPE includes safety goggles and face shields and should be used for tasks that can cause eye damage or
loss of vision, sprays of toxic liquids, splashes, and burns.
Safety Tips:
• Check if safety glasses comply with the ANSI Z87.1 eye protection standard.
• Ensure that there are no cracks or deformities on the lenses.
• Clean and disinfect after use.
• Ensure the strap is in good working condition and is firmly sealed to the cheek and forehead.
Respiratory Protection:
PPE includes full-face respirators, self-contained breathing apparatus, gas masks, N95 respirators,
and surgical masks are used for a task that can cause inhalation of harmful materials to enter the
body. This includes harmful gas, chemicals, large-particle droplets, sprays, splashes, or splatter
that may contain viruses and bacteria such as COVID-19, viral infections, and more.
Safety Tips:
• Ensure that the equipment is fit-tested and the employee has undergone proper training before
wearing one.
• Carefully read the instructions to determine if it is designed to help protect against the hazards
you may face.
• Change filters on half-mask or full-mask respirators frequently. • Replace disposable respirators
with every use.
• Surgical masks are not to be shared with anyone. An Industrial Report on STEEL PLANT
Government Institute of Chemical Engineering Page 90 • Avoid touching the surgical mask after
wearing it.
• Change surgical mask timely and should be disposed of after use. • Replace the
mask immediately if it is damaged or soiled.
Skin and Body Protection:

: PPE includes the following categories to protect employees from physical hazards
Head Protection:
PPE includes hard hats and headgears and should be required for tasks that can cause any force or
object falling to the head.
Safety Tips:
• Ensure that there are no dents or deformities on the shell and connections are tightened inside.
• Do not store in direct sunlight as extreme heat can cause damage. • Choose appropriate cleaning
agents as it can weaken the shells of hard hats and may eliminate electrical resistance.
• Always replace a hard hat if it was used for any kind of impact, even if the damage is
unnoticeable.
Body Protection:
PPE includes safety vests and suits that can be used for tasks that can cause body injuries from
extreme temperatures, flames and sparks, toxic chemicals, insect bites and radiation.
Safety Tips:
• Ensure that they are clean and free from cuts and burns.
• Always get a good fit to ensure full body protection.
• Ensure bodysuit is heat-resistant clothing when working with high temperature hazards.
Hands Protection:
PPE includes safety gloves and should be used for tasks that can cause hand and skin burns, absorption of
harmful substances, cuts, fractures or amputations.

Safety Tips:
• Ensure hand protection fits perfectly with no spaces and is free from cuts, burns and chemical
residue.
• Always replace them if any sign of contamination was observed. • Use rubber gloves when
working with heat and electricity to reduce the risk of burn or electrical shock.
Foot Protection:
PPE includes knee pads and safety boots and should be used for tasks that can cause serious foot
and leg injuries from falling or rolling objects, hot substances, electrical hazards, and slippery
surfaces.
Safety Tips:
• Ensure boots have slip-resistant soles that can protect against compression and impact.
• Ensure the sole plate is in good condition to prevent punctures.
Fall Protection:
PPE includes safety harnesses and lanyards and should be strictly used for tasks that can cause
falling from heights and serious injury or death.
Safety Tips:
• Ensure that the straps are free from tears, deformities and burn marks. • Check the
buckles if connected securely and tightly.
• Dispose of the equipment if used after a falling incident.
Hearing Protection:
PPE includes ear muffs and plugs and should be used for tasks that can cause hearing problems
and loss of hearing.

Safety Tips:
• Ensure the equipment fit the ear canal perfectly.
• It is recommended to use formable earplugs to fit on different sizes of ear canals. • Use protectors that
reduce noise exposure to an acceptable level to have a room for communication.
• Ensure earplugs are clean and in good condition. Learn more about hearing protections.
INTRODUCTION
PROFILE OF VISAKHAPATNAM STEEL PLANT:
Rashtriya Ispat Nigam Limited - Visakhapatnam Steel Plant (RINL- VSP) popularly known as
'Vizag Steel' the 'Pride of Steel', a leading Central PSU under the Ministry of Steel is the first shore
based Integrated Steel Plant in the country.
Visakhapatnam Steel Plant (VSP) is an integrated public sector steel plant owned by Rashtriya
Ispat Nigam (RINL), built with an annual production capacity of about 3.00 million tons per year of
liquid steel with provisions for future expansion. It is the only coast based integrated steel plant in
India. The detailed project report was prepared by the Principal Consultant, M.N. Dastur &
Company (P) Ltd in 1980. The project had envisaged iron making capacity of 3.4 MTPY, liquid steel
production of 3 MTPY and rolled capacity of 2.66 MTPY including 0.246 MTPY of saleable billets.
The iron and steel making facilities were generally based on the utilization of Soviet equipment, while
rolling mills were from other sources.
VSP has been able to achieve hot metal production of about 4.0 million tons per year from its
two blast furnaces and in line with the hot metal production, steel melt shop has also been able to
produce about 3.5 million tons of liquid steel. The plant is also producing about 3.17 million tons per
year of saleable steel, out of which billets for sale constituted about 0.18 million tons.
BACKGROUND:
With a view to give impetus to industrial growth and to meet the inspirations of the people
from south India, decided to establish integrated steel plant in public sector at Visakhapatnam (AP)
and Hospet (Karnataka) besides a special steel plant at Salem (Tamil Nadu).
The announcement was made in the parliament on 17th April 1970 by the then prime minister
of India late Smt. Indira Gandhi. A site was selected near Balacheruvu Creek near Visakhapatnam city
by a committee set up for the purpose, keeping in view the Topographical features, Greater
availability of land and proximity to a future port. The foundation stone for the plant was laid by Smt.
Gandhi on 20.01.1971.Seeds were thus sown for the construction of a modern & sophisticated
steel plant having an annual capacity of 3.4 million tons of hot metal. An agreement was signed
between government of India and the erstwhile USSR on June 12th, 1979, for setting up of an
integrated steel plant to produce structural & long products on the basis of detailed project report
prepared by M/s M.N. Dastur & company.

A comprehensive revised detailed project report jointly revised by Soviets & M/s Dastur
Company was submitted in Nov' 1980 to Govt. of India.
The construction of the plant started on 1st February 1982. Government of India formed a new
company called Rashtriya Ispat Nigam Ltd. (RINL) on 18th Feb '82 and transferred the responsibility of
constructing, commissioning & operating the plant at Visakhapatnam from Steel Authority of India Ltd.
to RINL. Due to poor resource availability, the construction could not keep pace with the planned cost.
In view of the critical fund situation and need to check further increase in the costs, a rationalized
concept was approved which was to cost Rs.6849 Crores based on 4th quarter of 1988.
The rationalized concept was based on obtaining the maximum output from the equipments
already installed, planned /ordered for procurement, and achieving higher levels of operational
efficiency and lab our productivity. Thus, the plant capacity was limited to 3.0 million tons of liquid
steel per annum. In the process, one steel melt shop and one mill were curtailed.
The availability of resources continued to be lower than what was planned, and this further
delayed the completion of the construction of the plant. Finally, all the units were constructed and
commissioned by July 1992 at a cost of Rs. 8529 crores. The plant was dedicated to nation by the
then prime minister of India late Shri. P.V. Narasimha Rao.
MAJOR SOURCES OF RAW MATERIALS:

RAW MATERIAL SOURCE
Iron ore lumps & fines Bailadilla, MP
BF limestone Jaggayyapeta, AP
SMS lime stone UAE
BF dolomite Madharam, AP
SMS dolomite Madharam, AP
Manganese ore Chirupalli, AP
Boiler Coal Talcher, Orissa
Coking coal Australia
Medium coking coal Gidi/Swang/Rajarappa/Kargali

MAIN PRODUCTS OF VISAKHAPATNAM STEEL PLANT:

STEEL PRODUCTS BY-PRODUCTS OTHERS
Angles Nut Coke Granulated slag
Billets Coke dust Lime fines
Channels Coal tar Ammonium sulphate
Beams Anthracene
Squares HP naphthalene
Flats Benzene
Rounds Toulene
Re-bars Xylene
Wire Rods Wash oil
UTILITIES & SERVICES:

✓ Utilities Dept.
✓ Water Management
✓ Power Generation and Distribution
✓ Traffic Dept.
✓ Quality Assurance and Technology Development (QA & TD) ✓ Production
Planning and Monitoring (PPM)
✓ Calcining & Refractory Material Plant (CRMP)
MODERN TECHNOLOGY:
Visakhapatnam steel plant is the most sophisticated and modern integrated

steel plant in the country. Modern technology has been adopted in many areas of production, some of
them for the first time in the country. Among these are:
▪ Selective crushing of coal
▪ Dry quenching of coke
▪ On ground blending of sinter base mix
▪ Conveyor charging and bell less top blast furnace
▪ Cast house slag granulation for blast furnace
▪ 100% continuous casting of liquid steel
▪ Gas expansion turbine for power generation utilization blast furnace top gas
pressure
▪ Computerization for process control
INTRODUCTION TO STEEL
Steel is an alloy of iron and carbon with improved strength and fracture resistance
compared to other forms of iron. Many other elements may be present or added. Stainless steels that
are corrosion- and oxidation-resistant typically need an additional 11% chromium. Because of its high
tensile strength and low cost, steel is used in buildings, infrastructure, tools, ships, trains, cars,
bicycles, machines, electrical appliances, and weapons.
Iron is the base metal of steel. Depending on the temperature, it can take two crystalline forms
(allotropic forms): body-centered cubic and face centered cubic. The interaction of the allotropes of
iron with the alloying elements, primarily carbon, gives steel and cast iron their range of unique
properties. In pure iron, the crystal structure has relatively little resistance to the iron atoms slipping
past one another, and so pure iron is quite ductile, or soft and easily formed. In steel, small amounts
of carbon, other elements, and inclusions within the iron act as hardening agents that prevent the
movement of dislocations. The carbon in typical steel alloys may contribute up to 2.14% of important
in steel: phosphorus, sulfur, silicon, and traces of oxygen, nitrogen, and copper.
Further refinements in the process, such as basic oxygen steelmaking (BOS),

largely replaced earlier methods by further lowering the cost of production and increasing the quality
of the final product. Today, steel is one of the most commonly manufactured materials in the world,
with more than 1.6 billion tons produced annually. Modern steel is generally identified by various
grades defined by assorted standards organizations. The modern steel industry is one of the
largest manufacturing industries in the world, but also one of the most energy and greenhouse gas
emission intense industries, contributing 8% of global emissions.[2] However, steel is also very
reusable: it is one of the world's most recycled materials, with a recycling rate of over 60% globally.
VARIOUS DEPARTMENTS IN STEEL PLANT:
1. RAW MATERIAL HANDLING PLANT (RMHP):

VSP annually requires quality raw materials like iron ore, fluxes (dolomite, limestone) coking
coal and non-coking coal. It requires 12-13 million tons of raw materials, which produces three million
tons of liquid steel.It is provided with unloading, stacking and reclaiming facilities, which include
wagon, tippler, ground and track hoppers. The various features are:
• Peripheral unloading system for railway wagons
• Blender reclaimed for blending of ores and fluxes.
• Storage yards to facilitate comfortable storage and
supply ofraw materials.
• Ring granulators for crushing boiler coals.
• PLC control of all systems
• Mixer for mixing lime is purchased and generated fines.
• Cone crushers for the crushing of lump ore.

2. COKEOVEN AND COALCHEMICALPLANT(CO & CCP):

Coke is manufactured by heating crushed coking coal in absence of air at a
temperature of 1000oC and for about 16-19 hrs. A coke oven comprises of two hallow chambers
namely coal chamber and heatingchamber. In the heating
chamber, gaseous fuel such as gas, coke oven gas is burnt. The heat so generated is conducted
through the common wall to heat & carbonize the coking coal placed in the adjacent coal chamber.
Number of ovens built in series one after the other form a coke Oven battery. At
VSP, there are four Coke Oven Batteries. 7 meter tall and having 67 Ovens each. Each oven has a
volume of 41.6 Cu.M & can hold up to 31.6 tons of dry coal charge. Carbonization takes place at
1000-1050 degree centigrade in absence of air for 16-18 hours.
Red hot coke is pushed out of the oven and sent to Coke Dry Cooling plants for
cooling to avoid its combustion. There are 4 Coke Dry Plants (CDCP) each having 4 cooling
chambers. The capacity of each cooling chamber is 50-52 TPH. Nitrogen gas is used as the Cooling
medium. The heat recovery nitrogen is done by generating steam and expanding in two back pressure
turbines to produce 7.5 MW power each.
Sintering is an agglomeration process of fine mineral particles into a porous

mass by incipient fusion caused by heat produced by combustion within the mass itself. Iron ore
fines, coke breeze, limestone, and dolomite along with recycled metallurgical wastes are converted
into agglomerated mass at the Sinter Plant, which forms 70-80% of iron bearing charge in the Blast
Furnace.
Sinter is hard, porous ferrous material obtained by agglomeration of iron fines,
coke breeze, limestone fines, metallurgical waste like dust, mill scale, LD slag. Usage of sinter in B.F
increase productivity by decrease in the coke rate and imposing the quality of hot metal produced.
Parameters of the machines are:
• Effective area 312 m2
• Sintering area 276 m2
• Capacity 450 m2
• Sinter bed height 300mm
4. BLAST FURNACE:
Iron is produced in the Blast Furnace by smelting iron bearing materials with the help of
coke and air. The solid charge materials like sinter, sized iron ore, coke etc. are charged in the vertical
shaft of the Blast Furnace from top and hot air blast is blown through tuyeres located at the bottom. The
oxygen present in hot air combines with the carbon of coke and generates heat and carbon
monoxide (reducing agent). The reducing gases, while ascending upwards comes into contact with the
descending charge materials. Eventually the charge gets reduced and hot metal, slag and BF gas are
produced. Hot metal and slag is tapped from tap hole. The Blast Furnace gas which comes out from top
of the furnace is cleaned and used as fuel in the plant.
Hot metal is produced in blast furnace, which are tall and vertical. Raw
materials are Iron Ore, Coke, Dolomite, and Limestone. It is charged from the top and hot blast at
1100 c-1300 c.
There are two B.F’s each with a volume of 3200m3, each with 4 tap holes and with a daily
production of 9720 tons of liquid steel. The technical parameters are:
• Effective volume - 3200m3
• Capacity - 4860TPD
• Height - 33.1m
• Number of tap holes- 4
Each furnace is facilitated with two Cast Houses, Slag Granulation Plants.
There are 4 Pig Casting Machines to handle the pig iron to cast into PIGS.
5. STEEL MELT SHOP:

Steel is made in steel melting shopsin the refractory lined vessels called LD
Converters by blowing oxygen through the hot metal bath. While iron making is a reduction process,
steel making is an oxidation process. The oxygen reacts with impurities like carbon, silicon,
phosphorus, Sulphur etc. present in hot metal to produce steel. No external fuel is required as the
silicon & carbon releases huge amount of heat energy. Also, the carbon reaction releases large
quantities of gas rich in carbon monoxide along with huge amounts ofdust. The gases released from
the converter are collected, cooled, cleaned, and recovered for use as fuel in the steel plant. The entire
molten steel at VSP is continuously cast at the radial type continuouscasting machines resulting in
significant energy conservation and better quality steel. 100% Continuous casting on such a large
scale has been conceived for the first time in India.
Steel is an alloy of iron with carbon up to 18%. Hot metal produced in B.F contains impurities such
as carbon (3.5-4.25%), silicon (0.4-0.5%, manganese (0.3-0.4%), sulphur (0.04%max) and
Phosphorous (0.14%max). To improve the quality of steel, the impuritieshave to be removed by
oxidation process which is done in convertershophaving 3 LD converters. Operational parameters are:
• Useful Volume - 133m3
• Capacity - 150 tons
• Temporary Lining - Tarred Dolomite
• Permanent Lining - Chrome magnesite
• Oxygen Working Pressure-16kg/cm2
6. ROLLING MILLS:
Blooms produced in SMS-CCD do not have as much application astheyare.
So, they are shaped into Billets, Rounds, Squares, Angles,Channels,Wire Rods, Rein Forced Bars
etc. by rolling them in 3 sophisticated highcapacity, high speed, fully automated rolling mills namely
LMMM, WRM, MMSM.
a). LIGHT AND MEDIUM MERCHANT MILL:
The cast blooms from the continuous casting department are heated and rolled
in the two high speed and fully automated rolling mills namely Light & Medium Merchant Mill
(LMMM) and Medium Merchant & Structural Mill (MMSM). The billets produced in LMMM are
further rolled

in Bar Mill / Wire Rod Mill (WRM). The finished products include wire rods & long products like
reinforcement bars, rounds, squares, flats, angles, channels, billets etc.
Blooms from Continuous Casting Division are rolled into billets, someof which
are sold, and rest are sent to Bar Mill/WRM. The continuous two-line Bar Mill comprises of an 8
Stand Double Strand roughing train,2 nos. of 4 Stand Single Strand intermediate train & 2 nos. of 4
Stand Single Strand finishing train. Loopers are provided in between the finishing standsfor tension
free rolling to obtain good surfacequality and tolerances. Housings are of closed top type. Roll necks
aremounted in anti friction bearings.
It is a unique rolling mill; it consists of Billet Mill and Bar Mill. It is facilitated with 2 walking
beam furnaces of 200 TPH heating capacity and 2 stand roller hearth furnaces. The roller hearth
furnace connects the billetwith the bar mill.
b). WIRE ROD MILL:
WRM-1: - The Mill is a high speed 4 strand No-Twist continuous mill designed to produce
850,000 Tons of wire rod coils per year. Rolled billets of 125 mm x 125 mm square cross section,
length ranging from 9.8 m to 10.4 m and weighing approximately 1250 kgs are used. The mill is
designed to roll steel stock of 0.9% max. Carbon content.
WRM-2: - The Mill is designed to produce 6,00,000 tons per year of rounds in coil form. The Mill is
designed to roll low, medium, and high carbon steel, case hardening steel, cold heading quality steel,
electrode steel, spring steel, bearing steel and free cutting steel. The mill shall use continuous cast billetsof
150 mm X 150 mm square cross section, 12 m length and weighing 2100 kgs approximately, are used as
input material. It is a 4-stand mill and is fully automated. The mill has 4 zone combination type preheating
furnace of 2100 TPH capacity. The mill products include rounds and ribbed wire in size of 5.5mm-12.7mm
dia. Wirerods are made in coil from having maximum weight of 1200kg. The mill is equipped with
retarded still more lines for improving the quality of wire rods.
c). MEDIUM MERCHANT & STRUCTURE MILL:

The Medium Merchant and Structural Mill (MMSM) is one of the modernrolling mills of Visakhapatnam
Steel Plant. This is a single strand continuous mill having a production capacity of 850,000 tons per
year. Theimportant feature of this mill is that Universal beams (both parallel and wide flange) have been
rolled for the first time in India using Universal stands. Parallel flange beams have an advantage over
conventional beamsbecause, for the same weight, the section is stronger and stiffer due to greater moment
of inertia and higher radius of gyration.
This mill is installed at ground level and has the capacity of roll 8,50,000 tons of medium merchant
products per annum. The feed materialsto mill are 250mm x 250mm blooms. MMSM is a high-
capacity continuousrolling mill consisting of 20 stands arranged in 3 train i.e., roughing, intermediate
and finishing trains.
d). ROLL SHOP & REPAIR SHOP (RS&RS): Roll Shop & Repair Shop caters to the needs
of three Mills in respect of roll assemblies, geographically this dept. is in three areas as Roll shop-1,
Roll shop-2 and Area Repair shop. The main activity of this shop is roll pass design, grooving of roll,
assembly of rolls with bearings, preparation of guides and their service and manufacture/repair of
Mill maintenance spares. For the first time in the country, VSP has adopted CNC technology
for grooving steel rolling Mills rolls. High constant accuracy, higher productivity, use of standard
tool for any groove turning elimination of the use of different templates, easier to incorporate groove
modification etc. are some of the advantages of CNC lathes over the conventional one.

Roll pass design section takes care of design of grooves for development of new
sections, modification of existing pass designs for improving the productivity and quality. Preparation
of rolling schedules, groove detail and distribution and template drgs, parts programming for
grooving of rolls on CNC lathes. This section also looks after procurement of rolls, establishment
and improvement of their performance, failure analysis of rolls etc.

Coke oven and coal chemical plant
COKE OVENS :-
Coke is an important raw material in the production of steel. It is produced by heating coal in the absence of
air to remove volatile compounds and moisture. Coke is used as a fuel and reducing agent in the blast
furnace process, which is the most common method for producing steel. The coke reacts with the iron ore to
remove impurities and produce carbon monoxide, which is used to reduce the iron oxide to molten iron.
Coke also provides the necessary heat and chemical energy to keep the blast furnace process running
efficiently. Without coke, steel production would be much more difficult and expensive.
ORIGIN OF COAL:
Coal originated from the arrested decay of the remains of trees, bushes, mosses, vines and
other forms of plant life, which flourished in huge swamps and bogs millions of years ago,
during prolonged periods of humid, tropical climate and abundant rainfall. Streams into the
swamps and lake basins to form the coal beds carried an enormous amount of vegetations.
Owing to pressure, the streams have generally been crushed to an elliptical section and
formed coal.
USE OF COAL IN VSP:

Coal is used in the form of coke to serve the purpose of iron ore reduction in blast
furnace. It also serves as a heat source.
TYPES OF COAL:
There are 2 types of coal:
(1) Coking Coal. (2) Non-Coking Coal.
The different coking coals used in VSP are:

1)M.C.C - Medium coking coal - BENGAL,
BIHAR
2)I.C.C - Imported coking coal - AUSTRALIA
3)I.S.S.A.C - Imported coking coal - AUSTRALIA
4)SOFT - Imported coking coal - AUSTRALIA
In VSP coking coal is used for producing metallurgical coke where as non-coking coal is used for
producing thermal power (in boilers).

TYPES OF COAL AND PROPERTIES:
S.NO. TYPE OF % MOISTURE % ASH MEAN MAXIMUM

COAL REFLUTANCE
1. M.C.C 25-28 17-22 0.9
2. I.C.C 24-26 8-10 1.10-1.3
3. I.S.S.A.C 23-25 8-10 1.16-1.3
4. SOFT 30-34 8-10 0.9-1.0 COKE:

It is a strong
porous hard mass that is obtained by heating of the coal in the absence of air at high
temperature. It is a reactive fuel and satisfies the need for blast furnace.
FUNCTIONS OF COKE:
1. It acts as heat producer in blast furnace
2. It acts as reducing agent by carbon reduction in blast furnace with oxygen reaction.
3. It gives a permeable bed and also as a slag carrier.
CARBONIZATION OF COAL:
Heating of coal in the absence of air at high temperatures to produce residue coke, coke
oven gas is called “CARBONISATION OF COAL” or “DESTRUCTIVE DISTILLATION”.
Its main purpose is to produce coke and the by-product known as coke oven gas from which
various products are obtained and this is used as fuel of high calorific value.
NEED FOR MANUFACTURE OF COKE FROM COAL:

1. Natural coal is too dense and fragile to be used as a fuel in the furnace.
2. Coal is not strong enough to withstand nearly 25meter of burden lying on it inside the furnace.
3. Coal is nearly “VOLATILE MATTER FREE” so it does not create problems of hot shortness and
coal shortness.
4. As compared to coal coke is of high quality and is highly reactive.
5. Coke is highly porous mass and it equalizes the blast coming from the bottom of the charge.
6. As coke is a rigid hard mass it does not create the problems of dust nascence.
7. As coke is a rigid hard mass it does not create the problems of dust nascence.

The ASH CONTENT in coke is very low i.e.) around 10%. So it does not arise problems of striking on the
grates The ASH CONTENT in coke is very low i.e.) around 10%. So it does not arise problems of striking
on the grates
The coke oven and coal chemical plant is mainly divided into the following department:
1. Coal Preparation Plant (C.P.P)
2. Coke Oven Batteries
3. Coke Dry Cooling Plant (C.D.C.P)
4. Coke Sorting Plant (C.S.P)
5. Coal Chemical Plant (C.C.P)
SIMPLIFIED FLOW SHEET FOR COKE OVEN PLANT :

COAL PREPARATION PLANT:-

PURPOSE OF COAL PREPARATION PLANT:
The main purpose of this plant is to prepare the coal by removing the foreign matter and
bringing to the size suitable for carbonization or coking process.
COAL BLEND COMPOSITION:

1.M.C.C - 15%
2.I.C.C - 40%
3.I.S.S.A.C.C - 35%
4.SOFT - 10%
PROPERTIES:
➢VOLATILE MATTER:
It is the matter which is unstable at high temperature and converts itself into gaseous state
like tar, benzene compounds etc. it is around 20-25%.
➢MEAN MAXIMUM REFLUCTANCE:

It is a coal ranking. It decides the properties of coal. It is around 1.12-1.14.
➢CRUSING INDEX:
% of -3mm size particles which should be around 70% - 75%
➢FIXED CARBON:
The carbon left behind after the removal of the volatile matter is fixed carbon.
➢ASH CONTENT:
The % of ash present in coal. It can known by testing in the laboratory. It is around 17-22 in
Indian coking coal & 8-10 in imported coking coal.
➢TOTAL MOISTURE:
The amount of total moisture present in coal. There lies some internal moisture also.
CONTENTS IN 1 TON OF COAL:

1.Coke - 746 kgs
2.Crude Tar - 32 kgs
3.Crude Benzol - 6.9 kgs
4.Ammonia - 4.1 kgs
5.CO Gas - 150 kgs
6.Losses - 61 kgs

COAL PREPARATION PLANT CONSISTS OF FOLLOWING

SECTIONS:
• Foreign material separation section Dogimeters.
• Mixing bins
• Coal blending
• Hammer mill
• Screening .
FOREIGN MATERIAL SEPERATION SECTION:

The coking coal is taken from coal yard by using bucket elevators on the conveyors. Then it
is sent to foreign material separation section. In foreign material separation section the
following equipment exists:
1. 2 Cylindrical screens.
2. 2 Suspended iron separators.
3. 2 Self unloading suspended iron separators for separating the magnetic particles in the coal.
PROCESS:
First the suspended iron separators separate the iron particles in the coal. After it is
demagnetized, the separated coal falls on self-unloading suspended separators. It works for
19 seconds. After that coal is separated into +150 mm & -150 mm sized particles in rotary
screens. +150 mm sized particles fall in the chute and are sent back for crushing. Whereas -
150 mm particles are transferred to reversible conveyors. There are further connected to
shuttle conveyors for filling the bins. There are a total of 16 bins, equally divided into 2
rows. All the odds like 1, 3, 5, 7, 9, 11, 13, 15 & the evens 2, 4, 6, 8, 10, 12, 14, 16. The
capacity of each bin being 800 T and a height of 20 mts.
Specifications of cylindrical screen:
Inclined angle - 8°
Feed end length - 1.5 m
Discharge end length - 0.8 m
Mesh size - 150 mm
DOGIMETERS:
These are arranged under each bin for blending the coal to produce quality of coke. Mixing
of different coals depending upon blend composition does blending of coal.

In the old dosimeters the doors at the chute were operated and coal discharge was controlled.
There occurred some jamming of coal. So vibrators were used to clear the jamming which is
removed now. In the new dosimeters the chute is made uniform and “RATE OF
DISCHARGE IS EQUAL TO SPEED AT WHICH THE ROTOR OF THE CONVEYOR
ROTATES”
MIXING BINS:
Coal mixing bins are large containers used to store and blend coal from different sources
or grades. The bins are typically located near a coal preparation plant or a power plant and are used to
ensure a consistent supply of coal with the desired characteristics. Coal mixing bins can be used to
store different types of coal separately, or to blend coal from different sources to achieve a desired
quality or consistency. The coal is typically stored in bins until it is needed, at which point it is
transported to the processing or combustion facility.
Mixing bins are used to store different types of coal which are screened in the FOS section.
-150mm size coal from foreign object separation unit gets stored in the conical shaped bins, there are
22 mixing bins each have capacity 800tons.
COAL BLENDING:
Coal blending is the process of mixing coals from different sources or grades to
achieve a desired quality or consistency. The goal of blending is to create a coal with the desired
characteristics, such as a specific energy content, ash content, sulfur content or moisture content.
Blending can also help to reduce the
environmental impact of coal by reducing emissions of pollutants like sulfur dioxide and nitrogen
oxides. Coal blending is an important tool for optimizing the use of coal as an energy source and
ensuring that it is used efficiently and responsibly.
Coals of different types stored in mixing bins gets blended together as ratio i.e.,
60% Australia coal and 10% of India-A, India-B, India-C and India-D each.
HAMMER CRUSHER:
A hammer crusher is a machine used to crush coal into smaller pieces. It is

commonly used in coal handling plants and coal preparation plants to process coal for use in power
generation or other industrial processes. The hammer crusher works by using a series of hammers to
crush the coal into a fine powder. The coal is fed into the machine from the top and is crushed by the
hammers as it falls down towards the bottom of the machine. The crushed coal is then screened
to separate the fine and coarse particles, with the fine particles being sent to the combustion chamber
or other processing equipment. The crushed coal is send to screening.

SCREENING:
The crushed coal from hammer mill is screened to +3mm and - 3mm size coal.
The +3mm size coal is recycled to hammer crusher and -3mm size coal is sent to coal tower.
COAL TOWER:
-3mm size coal from screens are stored in coal tower. Coal tower consists of 8
pockets each have 1000 Tons capacity. Coal from coal tower is used for charging.
COKE OVEN BATTERIES:
Coal is converted into coke by high temperature carbonization in the ovens of the battery.
There are 3 batteries working and the Battery – 4 is being constructed for more production of
hot metal.
CONSTRUCTION:
The total length of the battery is 100 mts. It consists of rectangular chambers of
length 16 meters, 7 meters high and 0.14 meters width with removal door ends. Coke oven
battery is a combination of ovens and heating chambers in alternatively. There are 67
ovens and 68 heating chambers in a battery. These ovens are OTTO-HOFFOMEN’S by-
product oven type. On the roof there are metal lids for the sake of charging purpose. The
width of the coke discharge side is slightly more than the pusher side for easy transport of
coke outside. Heating flues are arranged in the walls between the ovens. There are
regenerators underneath the battery. The oven walls are lined with silica bricks of high
thermal conductivity. There is no shrinkage in the refractory walls. These bricks ensure
long life. All doors are sealed with refractory clay and water mixture.
Battery has 4 machines:
1. Pusher car
2. Charging car
3. Door extractor car
4. Loco car

TYPICAL CROSS SECTION OF A COKE OVEN:-
PROCESS:
Coal is transported from coal preparation plant to coal tower above the battery. A charging
car travels on the battery and under the coal tower. 32 T of coal is charged in each oven up to
a height of 6.7 meters out of 7 METERS by charging position in each oven.

Since the coal drops by gravity, it should be levelled which is done by a levelling bar fixed to
the pusher car. After levelling all lids and doors are replaced and coking process is continued
until most of the volatile
matter is removed. This process takes a coking period of 17-18 hrs by indirect heating with
coke oven gas or mixed gas (CO gas + BF gas) in absence of air at 1150°c.
After complete carbonization, coke oven gas is collected by hydraulic main that is
connected to the ovens, which are sent to recovery plant for cleaning of gas. Later it is sent to
recovery plant for cleaning of gas. After cleaning CO gas is recycled back to the battery for
heating purpose. The product is 1-3% moisture contained coke. Yield of coke by HIGH
TEMPERATURE CARBONIZATION at 900°c - 1200°c is 65-75%.
Calorific value of di3fferent gasses used for heating purpose:
CV of Coke oven gas - 4200 K Cal /Nm3

CV of Blast furnace gas - 750 K Cal /Nm3
CV of Mixed gas - 1000 K Cal /Nm3
The walls start after 5 m level. Until 5 m level it is called the regenerator. The regenerators serve
the purpose of recovering heat by heat exchange between hot flue gasses and bricks. The air
coming in. thus air gets preheated in the regeneration section takes this heat. In the first cycle fuel
gas flows through one set of flues and flue gas goes out through other set of flues. There are 136
waste heat boxes through which air is supplied form one section and flue gas leaves through other
section.
As hot air is of low density and by the density difference suction is created by which flue
gas rises up out of the chimney. Checker bricks made of silica are placed in the regeneration
section so that the contact area and time for regeneration increases and maximum heat is
recovered.
SPECIFICATION:
➢ Total no of Batteries - 3
➢ No of ovens in each Battery - 67
➢ Heating walls - 68
➢ Height of each oven - 7 mts
➢ Length of each oven - 16 mts
➢ Width of each oven(P/S,C/S) - 38.5 / 43.5 mm
➢ Heating wall thickness - 0.105 mts
➢ Coal charging in each oven - 34 ton’s
➢ Output coke from oven - 25 ton’s
➢ No of vertical flues - 32
➢ No of waste heat boxes - 136
➢ Heating gas used in Battery 1&2 - CO gas
➢ Heating gas used in Battery 3 - CO + BF gas in 1:9 ratios.

➢ Coking period - 17-18 hrs
Coke temperature - 1050°c
➢ Coke fluidity temperature - 400-500°c
➢ Capacity of battery - 97 pushing/Battery/day
➢ Coking Period Determination (C.P.D)
COKE DRYING COOLING PLANT

After pushing the coke from the Battery with a temperature of 1050°c, it is transferred into C.D.C.P
for cooling purpose.

The C.D.C.P technology is adopted only in VISAKHAPANAM STEEL PLANT only because
in wet cooling the strength of the coke is reduced.
The advantages of DRY COOLING are:
1) Waste heat recovery (by producing steam)

2) Pollution control (done by closed circuit)
3) Better Coke strength (there is no thermal shock as in wet cooling) 4)
PROCESS
Coke form Battery falls into loco on the coke side, which is brought into C.D.C.P. The loco
is lifted up and coke is charged into the cooling chambers. Later the chambers are closed by
lid and N2 gas is passed inside through a temperature of 55°c by a mill fan. The hot coke is
cooled from 1050°c to 180°c-200°c. There occurs no chemical reaction, as N2 is an inert gas.
The heated gas is utilized for producing steam in boilers. These boilers are water tube
boilers, which are of capacity 25 T/hr. the temperature and pressure of the steam, are 440°c
and 40 Kg/cm2. Cooled coke i3s convey6ed to C.S.P and the steam is used to run back
pressure turbine station for producing power of 15 MW.
SPECIFICATIONS OF C.D.C.P:
➢ No of C.D.C.P - 3/3 Batteries

➢ No of chambers - 4 Chambers/each C.D.C.P
➢ Capacity of each C.D.C.P - 50-52 T/hr
➢ Coke temp before cooling - 1050°c
➢ Coke temp after cooling - 180°c-200°c
➢ Coolant used - N2 gas
➢
COKE SORTING PLANT:

PROCESS:
Coke from C.D.C.P enters the C.S.P section. Here coke is crushed, screened and later conveyed
to different consumers. In C.S.P dust will be removed from the coke with the help of dedusting
fans. After that coke is sent to crushing section to crush into 80mm size particles. There B.F
coke (25-80mm) is separated through 14- roll screen and sent to Blast Furnace. The remaining 0-
25 mm fractions will be sent to vibrating screen. Here 0-10 mm particles called BREEZE COKE
is conveyed to Sinter Plant and 10-25 mm called NUT COKE to Blast Furnace.

COAL CHEMICAL PLANT:

Many by products are extracted from the coke oven gas at this department. It consists of the
following sections:
1. Exhauster house.
2. Ammonium sulphate plant 3. M.B.C plant.
4. Tar distillation plant.
5. P.C.L.A
6. Naphthalene fraction crystallization.
7. Benzol plant.
8. Benzol distillation plant.
.
EXHAUSTER HOUSE:
The coke oven gas from the separator is fed to the PGC from the top. The cooler
consists of three zones. This is a shell and tube heat exchanger in which the CO gas
exchanges 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 inclination is maintained at 15°c with the
horizontal. This provides any naphthalene condensate to drain easily. The main purpose of
PGC is to cool the gas from 90°c to 30°c.

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 is sent 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 in the seal pot. Tar and
naphthalene from the seal pot is fed to the storage tank of the CPH. The CO gas from the
bottom of the PGC is fed to the electrostatic precipitator.
Gas temperature before PGC - 80-95°c
Gas temperature after PGC - 27-30°c
Service water inlet temperature - 32-33°c
Service water outlet temperature - 43°c
Gas condensate flow to each PGC - 10-15 Nm3/hr
Chilled water inlet temperature - 11-12°c

Chilled water outlet temperature -20°c
Total number of tubes - 409
ELECTROSTATIC PRECIPITATOR:
The CO gas enters the ESP from the bottom. Electrostatic precipitators a cylindrical
vessels with a conical bottom. Each ESP is provided with a seal pot.

A round disk having electrodes in suspended state is present inside the precipitator.
Electrodes are nothing but SS metal rods. Three are present at the top of precipitator, which
supplies the necessary power to each ESP. high voltage of about 50,000 volts is supplied to
each electrode. Due to high voltage the fine and foggy stick to the walls of the electrodes and
they fall down due to gravity. The liquid thus collected at the bottom is fed to the seal pot.
Each electrode is covered to prevent the connection between any two electrodes.
Capacity 30,000 Nm3/hr
Voltage 70KV
Number of electrodes 148
ESP insulator boxes temperature 80°C

EXHAUSTERS:
These are centrifugal fans necessary to drive the gas from the batteries itself to various
plants like ASP, Benzene recovery and finally to the main header of the coke oven gas.
Exhauster sucks the CO gas from the batteries. The pressure at the suction side of the
exhauster is -350mm WC and the discharge side is +2500mm WC. Due to increase in the
pressure the temperature is increased to 55-60°c. The flow of gas is controlled by Askania
valve, which is a butterfly valve. The function of this valve is to control the flow of gas to the
exhauster. When the quantity of gas is low then the valve is closed and when the gas quantity
is high valve is opened.
Capacity 67,000-76,000Nm3/hr
Power 1250KW
Maximum suction at inlet 500mm WC g
Maximum pressure at delivery 2700mm WC g
CONDENSTE PUMP HOUSE:

Flushing liquor separated from the separators is fed to the condensate pump house. This
consists of decanters and storage tanks. The tar and flushing liquor collected from the
exhauster house is stored in the storage tanks.
DECANTERS:
Decanters are used to settle the flushing liquor by gravity. These are mechanical
decanters provided with scraper mechanism. This scraper is a chain like arrangement
provided at the bottom.
The flushing liquor is fed at the middle of the decanter. In decanters due to density
difference, flushing liquor, tar & sludge form as three layers from top, and the flushing liquor
is then sent to the storage tanks.
A telescopic valve provided to the decanter removes the tar settled in the middle layer. The
valve works on the principle of ‘U’ tube manometer. Sludge removed by scraper mechanism
provided at the bottom of the decanter. The scraper then dumps the sludge into a bunker provided at
the end of the scraper. A motor provided with a gearbox runs the scraper. The sludge from the
bunker is removed periodically.
Tar collected from the flushing liquor decanter is stored in the tar storage tanks. Then it is
pumped to tar decanters. The tar from the tar decanters contains less moisture and sludge.
Flushing liquor from the decanter is stored in the storage tank and again pumped to batteries.
If the flushing liquor is excess then 60% is sent to excess flushing liquor tanks.
.
AMMONIUM SULPHATE PLANT:-
Coke oven gas with a pressure of 2500mm WC from exhauster is fed to the ASP. Ammonia present in
the CO gas is recovered in ASP as ammonium sulphate fertilizer.
PROCESS:
The CO gas from the exhauster is fed to the pre-heater to preheat the gas to 6070°c. But
according to our atmospheric temperature, this temperature is obtained after the exhauster.
So the gas is directly fed to the saturator.
1. SATURATOR:
Saturator is a cylindrical vessel with conical bottom. It is provided with a bubbler hood,
which is duct prolonged to the middle of the saturator. The duct has a hood at the bottom
provided with vanes like arrangement. Another ring like structure with small openings is
provided at the conical portion, which is used for nitrogen feeding. Hot water rings are
provided at the top of the saturator. Saturator is always maintained with acid bath called
mother liquor, which contains 4-5% of sulphuric acid.
The CO gas enters through the bubbler hood which is dipped in the bath. The gas rises
through the mother liquor. During this period, the ammonia present in the gas reacts with the
sulphuric acid in the liquor.
NH3 + H2SO4 NH4 (HSO4)

NH4 (HSO4) + NH3 (NH4)2 SO4
Ammonium sulphate thus formed settles at the bottom of the saturator. Pure nitrogen is purged into the
saturator through N2 rings at 4-5 kg/cm2. N2 purging increases the crystal growth. Pure sulphuric acid (98%)
is fed to the saturator to maintain the acidity in the saturator. The gas collected at the top of the saturator is
fed to the acid trap. As the gas rises up, some of the crystals may be carried with the gas and they get stacked
to the walls of the saturator at the top. Then the hot water is sprayed to the rings provided. The crystals
attached to the walls of the saturator are washed away. When hot water is sprayed the concentration of the
liquor decreases. So inlet acid concentration increases to 6-7% at that period. After the reaction mother
liquor is continuously drawn to the circulating tank provided at the side of the saturator. This acts as a seal
for the saturator. From the circulating tank, mother liquor is fed to the mother liquor tank. The crystals
collected at the bottom are fed to the crystal receiver tank by using pump.
2. ACID TRAP: The outlet gas of the saturator carries some acid mist. In order to remove the acid mist,
the gas is sent to the acid trap. It is a hollow cylindrical vessel. The coke oven gas from saturator enters
tangentially to the trap. Due to the centrifugal motion, the acid mist gets separated. The acid collected at
the bottom is fed to the circulating tank. The CO gas is fed to the Benzol recovery.

3. CRYSTAL RECIEVER TANK:

Ammonium slurry from the bottom of the saturator is pumped to the crystal receiver
tank with conical bottom. The ammonium sulphate crystal settled at the conical portion of
the tank, which is wet with liquor. The mother liquor from the top of the receiver is fed to the
saturator. The slurry from the bottom is fed to the centrifuge.
4. CENTRIFUGE:
Centrifuge is a horizontal cylindrical structure having two drums inside it. One drum
moves with rotary motion and the other in reciprocating motion. The feed enters at the center
of the rotation drum through pipe known as cone pipe. Crystals present in the slurry are
separated by the centrifugal force of the rum. Hot water is sprayed into the centrifuge to
wash of the free acidity that is the acid layer on the crystal.
The cleaned crystal is discharged into the outer drum which is reciprocating. The
reciprocating drum pushes the material into the discharge chute. The liquor seper4ated is
then sent to the saturator. The discharge chute of crystals opens onto a conveyor.
5. DRIER:
Drier is fluidized bed type. The principle is based on the loose materials property to
acquire fluidity in the airflow under a definite air velocity. The crystal from the centrifuge
contains some amount of moisture. To remove this moisture crystals are to be dried. The
drier is provided with a screen at the bottom, ceramic rings are arranged at the bottom of the
screen. The drier is provided with forced draught fan and air, heated in the duct. A spreader
at the feed chute of the drier spreads the feed in all directions. Forced draught fan sucks the
atmospheric air and feeds to the drier. The discharge chute of the fan is divided into 2
sections .One for hot air and the other for cold air. The hot air duct is provided with a steam
heater. The air is heated to 120-150°c by using steam and this hot air is fed form the bottom
of the screen. The ceramic rings distribute the air in all directions and allow the crystals in
fluidized state. The temperature of the air is sufficient the moisture of the crystals. At the
discharge end of the drier, cold air is passed which cools the crystal. When the pressure level
of the fluidized bed reaches the set point (300-400 mm Wc) an automatic discharge feeder
discharge the dry ammonium sulphate to the bucket elevator .The elevator discharges the dry
product into the bunker, which in turn feeds the product to the bagging machine. The zone
above the fluidized bed is kept under 5-10 mm Wc in order to avoid carryover of the
ammonium sulphate particles out of the dr4ying unit to the dust catcher.
6. CYCLONES:
The air form the drier is sucked by the suction fan and fed to the cyclone separators.
Cyclone separators separate fine ammonium sulphate crystals in the air and feed to the
bunker. The air from the cyclones is fed to the dust collecting tank which contains flushing
liquor up to certain level. The dust – laden air is then fed to the bottom of the tank. The
crystals then dissolved in the water and the air is vented into the atmosphere.

7. MOTHER LIQUOR TANK:

The excess liquor from the saturator enters the mother liquor tank. Each saturator is
provided with two mother liquor tanks. One is vertical and the other is horizontal. First the
liquor enters the horizontal tank. As the liquor has less density than the tar it floats. Then the
clear mother liquor from the bottom is fed to the vertical tank. Form the bottom of the
vertical tank mother liquor is fed to the saturator through the pumps provided. The
concentration of the liquor is maintained 10-12%. If the concentration decreases, the density
of the liquor decreases and it may be contaminated. Then crystals may become back.
8. AMMONIA COLUMN:
During carbonization of coal ammonia gets vaporized and flows along with flushing liquor in gas
collecting mains, a little amount of ammonia gets absorbed in flushing liquor. The excess ammonium
liquor after separation of tar, containing free and fixed ammonia, phenols, pyridine bases and cyanides,
rodents are pumped to the fourth plate of the ammonia column for distillation of free ammonia. The
column consists of 24 bubble cap trays. 40% of liquor level is maintained in the column. Steam is
injected at the bottom by steam coils. The purpose of steam is to supply the necessary heat required for
distillation. As the liquor is distilled, free ammonia present in the flushing liquor evolves and rises to the
top of the column. The distilled liquor from the bottom of the column is fed to the pitch tank. Certain
level of the flushing liquor is maintained in the tank and the over flow from the tank is fed to the M.B.C
Plant for treatment. The pH of the flushing liquor at the discharge end of the column should be 7-7.5 and
the free ammonia should be less than 50 PPM.
The ammonia vapours collected at the top of the column are fed before primary gas coolers. The
gases are not fed to the saturators directly as the temperature of the vapours is high and secondly the
vapours contains not only ammonia but also some traces of rhodanides and cyanides. These chemicals
should not be present in the ammonium sulphate fertilizer. To remove some content of fixed ammonia in
the liquor, dilute NaOH solution is injected at the inlet of the ammonia column. The NaOH reacts with
the fixed ammonia compounds and forms as ammonia gas.

BENZOL RECOVERY
FINAL GAS COOLERS:
Coke oven gas after ammonia recovery consists of 0.8-1.12 mg/lit of naphthalene. These naphthalene
particles are removed by spraying tar.
Temperature at the bottom of FGC 50-60°c
Naphthalene in CO gas after FGC 0.4 g/Nm3
FGC tar temperature 80-90°c

Specific gravity of FGC tar moisture 5%
GAS PRE-COOLER:The gas at 30-35°c is fed to the pre-cooler, which is indirect contact cooler. The gas
is cooled by chilled water (150°c), which passes through the tubes. The gas is cooled to 25-27°c so that
any particles condensed are received in the seal pot.

SCRUBBERS:
Scrubbers are long towers consisting of aluminium packing or wooden sheets provided with three
layers. The main drawback of wooden sheets is that it requires large cross-section and more height, while
aluminium is efficient. But the condensate should not have muggy materials, which stick to the plates
and scrubbing cannot be done efficiently.
The CO gas from the gas pre-coolers is sent to the first benzol scrubber at the bottom. Solar oil or
de-benzolized oil is used for scrubbing the gas to recover benzol. Large amount of the benzol is absorbed
in the first scrubber. At the bottom of the first scrubber a certain level of benzolised oil is maintained. CO
gas from the top of the first scrubber is fed to the bottom of the second scrubber in which it comes to
contact with fresh de-benzolised oil, which removes the traces of benzol remaining in the gas. The
benzol free CO gas is sent to custo
Capacity 58,000Nm3/hr
Oil flow rate 150m3/hr
Benzol content in gas after benzol scrubber 3 g/Nm3
Specific gravity of solar oil 0.8428
Molecular weight of solar oil 230
Flash point 132°c
Initial boiling point 270°c
PROCESS:
Air from the atmosphere is fed to the suction side of the compressor through filters for removing the
dust particles.
COMPRESSOR:
Reciprocating compressors are used to compress the air up to 6 kg/cm2. This is double acting piston type,
which consists of low-pressure side and high-pressure side. A motor drives the compressor. An inter
cooler is provided between the LP side and the HP side. An after cooler is provided to cool the air.
Air initially fed to the low-pressure side where it is compressed to 2 kg/cm2. Due to compressor the
temperature of the air is increases and it is cooled in the inter cooler. This avoids decrease in the
compression efficiency on the OIL CYCLE:
The DBO from benzol distillation unit is fed to the top of the second scrubber. Benzolised oil from
the bottom of the second scrubber is pumped to the top of the first scrubber through the distribution
nozzles. The benzolised oil collected at the bottom of the first scrubber is sent to the benzolised oil tank
from where it is pumped to the benzol distillation section.

COMPRESSOR HOUSE:
Compressor house provided in the recovery plant is used to supply the plant air and instrument air. Air is
compressed up to 6 kg/cm2 in the HP side. The compressed air is fed to the after cooler. The purpose of
this cooler is to remove the moisture in the air. The air from the after cooler is fed to air receiving tanks.
Air in the receiving tanks contain moisture and oil particles. So this air cannot be used for instruments.
This air is used for cooling and other purposes. In the compression of air the lube oil is used for
compressor bearings. In this process, some oil is mixed with air. To remove this oil the air is fed to the
oil filter. The air is then fed to the coke filters where coke layers are placed. This removes moisture and
dust particles in the air. Then the air is fed to the dryers in which a bed of activated alumina is placed.
This eliminates complete moisture and from dryers the air is fed to the candy filters in which very fine
particles of moisture and dust is removed. Then the air is again fed to the buffer vessels, which is an
intermediate storage. The dried air is supplied to the instruments and its pressure is in the range of 4
kg/cm2.

MECHANICAL BIOLOGICAL AND CHEMICAL TREATMENT

PLANT
PROCESS:
Toxic effluents generated in various sections of coke oven and by-product plant are collected and
pumped to the treatment plant from two pump houses. One at ammonium sulphate section and the other
at tar distillation section. Excess flushing after removal of ammonia in ammonium stripping unit is also
fed to this treatment plant. The combined effluent contains large amount of tar and oils and toxicants like
phenol, cyanide, thiocyanides etc. The effluent plant is designed to remove tar and oils with the help of
mechanical separation methods followed by biological treatment at effluent namely two stage activated
sludge process to remove other toxicants.
Phenolic effluent from two phenolic water pump houses located in CO & CCP are directly fed to pre-
aerators of tar settling plants. Excess flushing liquor ammonia stripping is also pumped to the same pre-
aerators to the double pipe heat exchangers where it is cooled from 90°c with the help of recalculating
cooling water. Water inlet temperature is 34°c and outlet temperature is 45°c. Mixed effluent at a
temperature of about 50°c is distributed in equal positions in tar settling tanks by gravity. In pre aerators
effluent mixed thoroughly with the help of air. The tar settling tanks are provided with steam heating coil
and scrapper mechanism at the conical hopper bottom. Tar collected at the bottom of each tank is
pumped out in the tar collecting tanks ones in 3-5 days time. Tar settling tanks are provided for removing
tar and oil form the effluents. Oil floated on the surface of water and tar settles down in the conical
bottom. Floated oil removed with the help of scrapping device and flows to oil collecting tanks by
gravity.
Over flow from the tar settling tank is collected in vertical steel tanks named phenolic water collecting
tanks from where it is pumped to the oil flotation tank through pressurized head tank. Air (5% by volume
of water) is injected in the suction line of the pumps before it is pumped to the pressures tank. In the
flotation tank air bubbles through the water as the water is depressurized and the oil is entrained by air
bubbles and floats at the water surface. The entrained oil is skimmed with oil skimmer mechanism of the
flotation tanks and collected to the oil discharge to a tank called tar and oil collecting tank. After oil
flotation tank, water goes to the second phenolic water collecting tank, with the help of pump collected
water is send to second flotation tank to pressurized tank. Tar and oil from the collecting tank are finally
pumped to tar acid utilization plant. After removal of tar and oil the effluent is collected in averaging
tank.
The averaging tank consists of two chambers and each chamber is having one over flow tank. In this tank
adding ortho phosphoric acid and bacteria nutrient. 73% strong ortho phosphoric acid at the rate of 20
g/m3 of water to be purified. From these tanks effluent is pumped to aeration tank of first stage
purification through shell and tube heat exchangers to maintain effluent temperature between 35-38°c.
Cold circulating water is used for this purpose. In this first stage purification is done with the help of
phenol destruction bacteria. To maintain their vital activity, compressed air from the air blower is applied
to the aeration tank.

Phenolic water after the first stage of purification is collected in a tank from where it is pumped to
aeration tank of second stage purification. In second stage of purification rodents and cyanides are
destroyed with the help of rodents destructing bacteria. With each aeration tank (both 1 & 2 stage) of
purification sludge settling tank regeneration are attached. The over flow from each tank first goes to the
settling tank where sludge settles down and the super latent water overflows to the collecting of first
stage purified water collecting tank.
The settled sludge then flows to the attached regeneration from where it is recycled back to the
aeration tanks with the help of air lifting pump. Volumetric flow rate of sludge in each tank it’s about
80% of the volumetric flow rate of water being purified, to treatment unit for further treatment. Inlet to
the treatment plant as well as excess sludge is taken from the bottom of the settling tank and taken to
sludge disposal facilities having sludge-drying beds. Treatment effluent from the second stage of
purification is collected on a tank from where it is pumped to l sewage treatment plant for further
treatment and dilution. Further culture of bacteria their accumulation two separate bacteria culture tanks
requisite facilities are also provided which can be utilized and when required.
Two MS tanks each of capacity 800m3 are provided as balancing tanks. Water can be pumped from any
of the equipment, provision is there to take this water back treated water from the collecting tank after
second of purification can also be directed to a balancing tanks.

TAR DISTILLATION PLANT:

Tar is a viscous fraction obtained by the cooling of coke oven gas with ammonia liquor. During this
cooling coke dust particles mixed with liquor and forms coal tar. It consists of large chain aromatic
compounds, which can be distilled into light oils, phenols, naphthalene oil, wash oil and pitch. Coal tar in
coke oven gas is collected from CPH and final gas a cooler of benzol recovery is transferred to tar and oil
storage. From there it is pumped to mechanized decanter in tar distillation plant.
COMPOSITION OF COAL TAR COMING TO TDS:
Light oil - 0.5%
Phenol fraction - 1-1.5%

Naphthalene - 5-6%
Wash oil - 8-9%

Anthracite oil - 18-19%
Moistur4e - 5-6%
PROCESS:
The tar from the condensate pump house is fed to the tar and oil storage of the TDP. The tar to the
tar distillation section is fed from the tar and oil storage tanks. This tar contains 5% of moisture, which
can be removed in the decanters.

DECANTERS:
The tar from the TOS is fed to the decanters. It is provided with a scraper conveyer to remove the
sludge collected at the bottom and transferred to a bunker in the decanter small quantities of water and
flushing liquor collects at the top of layer which are continuously removed.
The tar from the decanters flows through two strainers to remove suspended matter to a common suction
header of liquor plunger pumps for first stage. A plunger pump consists of three piston, suction and
delivery valves, which pump with high pressure. Tar initially consists chloride salts and acid, which
causes corrosion and damages the piping present in the furnace and the plant. To prevent the soda ash
solution of 8% concentration is injected at the suction side of the pumps.
2NH4Cl + Na2CO3 ---------- 2NaCl + 2NH3 + CO2 + H2 O

2HCl + Na2CO3 ---------- 2NaCl + H2O + CO2
The ammonia formed from the above reactions vaporizes along with water vapour and light oils.
FURNACE:
It consists of two zones one is convection zone and the other is radiation zone. Furnace is having four
burners where CO gas is used as fuel. Air draught is taken from the bottom of the furnace. The tar from
the filter is pumped to convection zone, which is at the top of the furnace. Here the temperature increases
to 120-130°c. Controlling the airflow can control the flame length more the air longer the flame and vice
versa. This arrangement helps in controlling the temperatures of tar in both the zones.
In radiation zone dehydrated tar is circulated which is pumped from second stage plunger pumps. The
temperature of the tar is increased to 400°c. The temperature of the tar should not increase beyond 400°c
as this cause the formation of B.F grade pitch.
The flue gas from the furnace is sent to the atmosphere through the chimney. It is provided with a baffle
plate in order to assure complete combustion of the gas.
I STAGE EVAPORATOR:
Evaporator is a cylindrical vessel having baffle plates, which change the direction of gases. Evaporator
is designed for the evaporation of water and light oils from the crude tar, which are fed at the middle of
the evaporator. The temperature of the tar at the inlet is about 120-130°c. Due to this temperature, the
moisture in the tar is evaporated. These vapours from the top of the evaporator are fed to the twin
condensed coolers. From the bottom dehydrated tar having less than 2% moisture is fed to the dehydrator
tar tank and pumped to the radiation zone of the furnace.
Pressure in the evaporator 0.3 kg/cm2
Temperatures of vapours 102-105°c
Temperature of DTT <110°c
Baffle plates 3
GOVERNMENT INSTITUTE OF CHEMICAL ENGINEER

DEHYDRATED TAR TANK:
Tar from the evaporator is fed to the DTT tank, which is used as an intermediate storage. The tank is
always maintained 100% and the over flow tar from the DTT is fed to the decanter4. Tar is fed to the II
stage tar pump from the bottom of the DTT. The pump discharges this tar to the radiation zone of the
furnace where it is heated up to 380-400°c. This tar is fed to the second stage evaporator at the rate of 10
m3/hr.
II STAGE EVAPORATOR:
In second stage evaporator oil vapours and pitch are separated. Dehydrated tar from the radiation zone is
fed to the evaporator. Two baffle plates are arranged below the vapour inlet and five above the vapour
inlet. Four bubble cap trays are also arranged at the bottom of the evaporator. This arrangement
completely separates tar fraction form pitch. A protective plate is also installed as in first stage
evaporator. The oil vapours from the top of the evaporator are fed to the distillation column. The tar at
the bottom of the evaporator is called as pitch and is supplied to the pitch cooling section.
Pressure in the evaporator 0.5 kg/cm2
Number of bubble cap trays 4
No. of baffle plates 7
Temperature of the fractions 400°c
DISTILLATION COLUMN:
Fractionating column is designed to separate different fractions from tar. The column is provided with
59 trays out of which 56 are bubble cap trays and the remaining three baffle plates. Each tray has 42
bubble caps. Mixed oil vapours from the top the second stage evaporator are fed to the third tray of the
fractionating column at a temperature of 360-380°c.
As the vapours rises to the top of the column different fractions are obtained from different trays.
Initially vapours enter at about 360-400°c. Pure light oil is supplied as reflux to the top plate rectification
column to maintain top temperature of the column. Reflux is fed as the top temperature increases. All the
fractions are continuously drawn from the column. The vapours, which are not condensed are collected
from the top of the column and fed to the twin condenser cooler of the second stage.

LIGHT OIL:
Light oil is obtained from the column, which is lighter than all of the fractions the top
temperatures of the column are maintained at 100°c. The light oil consists of phenol and phenol
containing water (PWC). The light vapours are cooled in twin condensed coolers and fed to the separator
II.
PHENOL:
Phenol fraction obtained is not in pure state at 160-180°c. It contains 22% phenol and 10-15%
naphthalene. Three tapings are provided on 44.46 and 48 trays.
NAPHTHALENE:
Naphthalene fraction can be trapped from 24, 26, 28 and 30 trays. It is obtained at a temperature of
190-200°c. Steam jacketed lines are provided because decrease in temperature results in crystallization of
naphthalene.
WASH OIL:
There 5 tapping for wash oil on 12, 14, 16, 18, and 20. Normally wash oil will be tapped at a
temperature of 280-290°c. It is tapped from 6 & 8 trays. Anthracite II is heavier than all fractions. So it is
obtained from 1 s tor 2 trays at 320-330°c.

TWIN CONDENSED COOLERS I & II STAGES:

These are shell and tube heat exchangers to condense the vapours. First stage coolers condenses the gas
coming from I stage evaporator and the II stage cooler condenses the gas leaving the column. The
vapours pass through the shell and service water is used to cool the vapour passing through the tube side.
The vapours of I stage cooler are cooled from 102-50°c. The vapours of second stage coolers from 100-
40°c. After condensation the vapours from both I & II stage condensers enter into separators I & II
respectively.
SEPERATORS I &II:
Separators are used to separate light oils from other fractions (NH3 water and phenolic water)
obtained fm the top of the first stage evaporator and distillation column in separator I & II respectively.
Light oil obtained from the top the two separators flow to light oil tanks by gravity. At the bottom of the
separator I ammonia water will be settled and at the bottom of the separator II phenolic water will be
settled. Both of them are removed through dip tubes to prevent light oil mixing with them.
SUBMERGED COOLERS:
Submerged coolers contain a coil inside the coolers through which the fractions from the column
are passed. This coil is submerged in the water. The vapours are cooled from 80-50°c are sent to the
collected tanks.
START UP TANK:
During initial starting of the plant, the temperature of the tar does not reach up 400°c in second stage
evaporator will be diverted to start up tank until it reaches the temperature of 290°c similarly column
bottom liquid will also be diverted to start up tank until the temperature of the column reaches to 330°c.
Tar then overflows to the decanters.
USES OF DIFFERENT TAR FRACTIONS:

LIGHT OIL:
It can be further processed to produce crude tar basis can be used to prepare pyridine and heavy basis.
Light oil can be fractionized to produce small amounts of benzene, toluene, xylene and heavy solvent
naphtha.
PHENOL:
• It is mainly used in plastic industry.
• In thermosetting resins made with formaldehyde.
• In pesticides preparation.
• Insecticides and pharmaceuticals.
• Dye stuffs and carpolactum for fibers.

AN INDUSTRAIL REPORT ON STEEL PLANT
NAPHTHALENE:
• Used in manufacturing of pthallic anhydride.
ANTHRACENE:
• It is purified to produce pure anthracite.

• It is used to produce carbozole and phenanthracene.
PITCH:
• Pitch cake.
• Industrial pitches.
• Road tar.
• Refined tar
PARAMETERS:-
TEMPERATURES:
Tar in decanters 75-80°c
Tar after first stage furnace 120-130°c
Tar after DTT 100°c
Vapours from first stage evaporator 105-110°c
Tar after II stage furnace 380-400°c
Vapours after II stage evaporator’s 300-330°c
Pitch after II stage evaporator 330-350°c

Distillation column top temperature 100°c
FLOW:
Tar in first stage 9-10 Nm3/hr
Tar in second stage 10 Nm3/hr

ANALYSIS:
Water content in I stage tar 5-6%
Water content in II stage tar <1%
PRESSURES:
Tar after I stage pump 2.3 kg/cm2
Tars after II stage pump 4.5 kg/cm2
CO gas before furnace >100 mm WC
I stage evaporator top 0.14-0.5 kg/cm2
I stage evaporator bottom 0.24-0.25 kg/cm2
II stage evaporator top 0.35 kg/cm2
II stage evaporator bottom 0.4 kg/cm2
Distillation column top 0.04-0.06 kg/cm2

PITCH COOLING AND LOADING AREA:-

Pitch is a mixture of resins and straight chain aromatic compounds and oils. Pitch from the
bottom of II stage evaporator is fed to the storage a tank of PCLA by gravity mainly produces.
1. Pitch creosote mixture
2. Medium hard pitch

3. BF grade pitch
The main consumers are BALCO, NALCO, and INDALCO & HINDALCO. This pitch is mainly
used in manufacturing electrodes in aluminium industries.
PITCH CRESOTE MIXTURE:-

The pitch from TDS is stored in the storage tanks. The softening point of this pitch is about 65-70°c.
Anthracite oil, wash oil and pitch are mixed in respective proportions in PCM tanks. Initially, anthracene
and wash oil are mixed in 1:1 ratio. The tank is filled up to 1.8m with this mixture and the soft pitch is
filled up to 4m heights. Then the mixture is allowed to mix properly by keeping in continuous circulation
through a pump from bottom. This PCM is used as fuel in CRMP section, which produces refraction
bricks in VSP.
MEDIUM HARD PITCH:

The softening point of the soft pitch is 65-70°c. To increase the softening point of the pitch up to 95-
110°c the pitch is fed to a series of reactors.
REACTORS:
Reactors are cylindrical vessels with conical bottom. A bubbler is provided inside, which is fed
with air at a pressure of 5 kg/cm2. An outlet provided at the top removes the air injected. A cylindrical
small vessel on the top of the reactor is provided with baffles to remove any heavier particles present in
the vapours. The vapours mainly contain anthracene and wash oil fractions.
PROCESS:
Initially the pitch at 360°c from TDS is fed to the middle of the first reactor. Air is injected through
the bubbler, which is provided with a ring having small holes. As the air passes through the pitch, it
entrains any oil present in the pitch. The overflow from the first reactor is fed to the second and similarly
to the third. Aeration is done in all the three reactors to increase the softening point up to 110 °c
depending on the requirement. Airflow to all the reactors increases up to 400°c. The MH pitch after
obtaining the required softening point is fed from the third reactor to electrode pitch tank. From ETP the
tar is pumped to the overhead tanks. All the ETP and overhead tanks are provided with steam coils to
keep the pitch in liquid state. The pitch from overhead tanks is pumped to the bay, which is a large
rectangular area where the pitch is allowed for atmospheric cooling. After complete cooling the pitch in
small pieces is packed in bags. The vapours from all the reactors and storage tanks contain some
entrained oil particles. The vapours are first condensed in a shell and tube heat exchangers (water in

AN INDUSTRIAL REPORT ON STEEL PANT
tubes and vapours on shell side). The condensed vapours are sent to the washer. In the washer, the
vapours are scrubbed with the light oils. The condensate collected called pitch distillates are fed to the
pitch distillate tank. The washer is provided with steam jet ejector at the top to draw the oil free vapours
and is let out to the atmosphere.
PITCH COOLING AND LOADING AREA FLOW DIADRAM:-
CHEMICAL PROCESS DURING ARERATION:

Pitch is a mixture of high polymers, straight chain organic compounds and oils. Due to aeration and
effective mixing in the reactor, the polymer oil bond breaks and resin bonds progressively increase
causing softening point elevation. Due to effective agitation, new polymeric bonds formation and bond
breakage large amount of heat is evolved. This increase in temperature leads to the formation of optically
sensitive isomers i.e. optical isomers; which causes the pitch increase in optical activity. The increase in
aeration in the reactor increases the softening point of pitch to required levels and increases the porosity,
which will affect the strength and binding properties of the pitch. The aluminium industries require
various concentration of resin in the pitch, which plays main part in the bonding property of pitch.
Quinolone insoluble and benzene insoluble determine this.

BF GRADE PITCH:
BF grade pitch is used for preparation of BF mass for Blast Furnace tapping. This requires high
softening point of 170-180°c. So it is prepared separately in fourth reactor. Initially, pitch from TDS is
charged for three and a half hours and air is injected through bubbler at the rate of 150 Nm3/hr for 10-12
hours. After softening point is attained to the bay by gravity for cooling purpose.
PARAMETERS:
Pressure Temperature Air flow
(mm HG) (°C) (Nm3/hr)
Reactor 1 300 to 325 50
Reactor 2 310 to330 80
Reactor 3 320 to 340 120
NAPHTHALENE FRACTION CRYSTALLIZATION:-

Naphthalene fraction obtained from the distillation column is 75-80% pure. This is purified up to
99% in NAFC section. Crystallizing out naphthalene from the melt obtained from TDP does this
purification.
PROCESS:
Naphthalene oil from tar distillation plant at 70-80°C is pumped to the overhead tanks of the NAFC
section. The tanks are provided with steam coils. The temperature of the naphthalene oil is maintained at
85-90°C. One tank receives oil from TDS and the other from melting pot. The naphthalene oil is then fed
to the drum crystallizer.
DRUM CRYSTALLIZER:
Drum crystallizer is a hallow cylinder with ribbed surface over its entire perimeter. The drum is
rotated at an rpm of 0.3 by an electric motor and reducer. The rotating drum is partially submerged in oil
bath. Two jackets are provided at the bottom of the drum one for naphthalene oil and the other for hot
water. The oil form the over head tank is fed to the oil jacket. Hot water is circulated under the oil jacket
to prevent the solidification of naphthalene. Inlet and outlet to the service water is provided to the side of
the drum.
Service water is circulated inside the drum to cool the naphthalene layer formed on the surface of the
drum. Knifes are provided on the surface of the drum to cut the layer formed on the drum. The flakes are
then collected in a screw conveyor and fed to the press mixer.

capacity 25 T/hr4 of fr4action
Rotation per minute 0.3
Temperature of hot water in jacket 90-100°c
Cooling water temperature 18-20°c
Temperature of fraction in bath 80-90°c
Naphthalene temperature 60°c

HYDRAULIC PRESS:
It consists of a mixer and a press. Flakes from the conveyor are fed to the mixer in which agitator
mixes the crystals homogeneously. The temperature in the mixer is maintained at 60-65°c by circulating
hot water in the jacket.
PRESS:
It consists of three filters mounted in a rotary table. This system is operated by hydraulic pressure at
a pressure of 160 kg/cm2. Oil is compressed and fed to different parts of the press. The press consists of
squeezing device, pushing device and table stopper. Squeezing device is provided with shift to compress
the naphthalene into a cake. The filters are at an angle of 120 ° to each other. The naphthalene mass from
the mixer is fed to the filter through the charging neck of the mixer the press is operated by six
operations.

CLAMPING:
The filter coincides with the axis of charging neck of the mixer. The mixer discharges the feed into
the filter. Then the table rotates.
SQUEEZING OR PRESSING:
After clamping the filter moves to the squeezing device. The squeezing device consists of two
cylinders, which compresses from top and bottom with 160-180 kg/cm2 pressure. The oil present in the cake
will be separated from the holes provided in the filter. This is collected at the bottom. Then the cake is
formed.
PUSHOUT:
This operation is done after squeezing. A cylinder from the bottom of the filter lifts the cake forward
up.
PUSH OFF:
An arm like device pushes the cake into a chute. At this position, the lifted cylinder is in the same
position. Push out and push off operations is done in the third position of the filter.
RETURN STROKE:
In this operation all the cylinders return to their original position.
TABLE ROTATION:
After all the cylinders reach to their original positions, the table rotates so that the filter again
comes to the first position i.e. charging position. All these operations are done automatically by gear
mechanism. The temperature inside the filter is maintained by supplying steam. All these six operations
are completed in three & a half minutes. The naphthalene cakes formed are conveyed to the jaw crushers.
The weight of the cake form is about 40 kgs and 98% pur4e. The jaw crusher crushes the cakes and the
crusher pieces are conveyed to the bagging machine through a chain conveyor.
Naphthalene bags weighting 50kg each are stored in the go down.
PRESSED OIL:
The oil separated from the filter is further processed to recover naphthalene present in the oil as the
oil contains 60-65% naphthalene. This pressed oil collected in the ground floor is pumped to the
overhead tank. This oil is processed in mechanical crystallizes.
MECHANICAL CRYSTALLIZERS:
These are horizontal cylindrical vessels with the shaft running through the crystallizer. The shaft is a
propeller type agitator, which is fixed with a number of vanes. The shaft is run by a motor, which
connected by a gearbox. There is a provision for spraying of water on the drum. The water is collected in

the water jacket under the drum. The de-naphthalene oil from the overhead tank is fed to the mechanical
crystallizer. Half of the volume of the crystallizer is fed with the DN oil. Due to slow and continuous
agitation of the shaft, high retention time and slow cooling the oil in the crystallizer thickness. Small
nucleuses of the crystals are formed and the oil forms as the slurry. Constant agitation of the melt results
in the breakage of weak small crystals originally formed which then act as nucleus to new crystals.
Cooling is done by natural convention by atmosphere for 16 hours. After 16 hours of atmospheric
cooling, 8 hours water-cooling is done by spraying water on the drum. After the completion of
crystallization, the valve open and the slurry is transferred to mixer through screw conveyor.
MIXER:
The slurry enters into the mixer through a filter, which filters any suspended particles in the slurry.
Mixer is a horizontal cylindrical drum provided with agitator. Mixer acts as a storage drum as well as
maintains the uniform mixture by agitating the slurry. Then the slurry flows by gravity to the centrifuge
by controlling the valve.
CENTRIFUGE:
The centrifuge used in the NAFC is of basket type. It is a batch wise centrifuge operating at a rate of 400
liters of naphthalene slurry per batch. The retention time of each is 2 minutes. The centrifuge consists of
a basket rotated by a motor. Feed enters through a feed chute, which aids provided with an automatic
valve. There is a knife arrangement, which collects the naphthalene powder into a basket type chute. The
slurry is discharged from the rotating basket tangentially through the holes arranged.
The centrifuge does three operations.
CHARGING:
During this period (20seconds) the material is fed into the basket after a flow rate of 400 liters, the
valve is closed.
DRYING:
The power is separated from the slurry and the basket is rotated without slurry for about 1 minute. The
naphthalene powder is allowed to dry during this period.
DISCHARGE:
After the material is dried, the knife collects all the powder into a chute that is fixed to the door. The
oil separated contains 40-60% of naphthalene. The soil is again recycled till its concentration reaches
below 30%. After this DB oil is pumped to the tar and oil storage section. The naphthalene powder so
obtained is about 98-99% pure and this fed to the melting pot through a belt conveyor.

MELTING POT:
This is a horizontal cylindrical drum, which consist of steam coils inside it. LP steam is circulated in
these coils. The naphthalene powder gets melted due to high temperature and the liquid thus obtained is
fed to the main naphthalene friction overhead tank to increase the purity of the naphthalene oil coming
from the distillation section.
BENZOL PLANT:
Benzol plant is provided to produce pure benzene, toluene and solvent naphtha. Benzol plant
consists of three sections:
• Benzol distillation plant • Hydro refining unit • Extractive distillation unit
Crude benzol recover from the coke gas is fed to benzol distillation plant. Various chemicals in the benzol
are recovered by distillation. BENZOL DISTILLATION PLANT (BDP): In BDP the benzolised oil from
final absorption is pumped to the storage tanks of the benzol distillation. The BO is then stripped of steam to
get the crude benzol and DBO. This DBO is again pumped to benzol recovery section. Makeup solar oil is
added continuously to compensate for the losses in the equipment. The BO is initially preheated in three
preheaters, which are shell and tube heat exchangers. Preheating is first done in oil dephlegmators, oil-oil
heat exchangers and finally in steam preheaters. The temperature slowly decreased in order to prevent
chemical decomposition of BO. The temperature of the BO fed to the stripping column is about 130-1350C.
Stripping Column: Pre-heated BO from the exchangers is fed to seventeenth tray of stripping column.
The column consists of bubble cap trays. Low pressure (LP) of stream at a temperature of 1800C and 3.8
kg/cm2 is injected through BDO at the bottom of the column. Crude benzol in the BO is recovered by steam
distillation. Steam distillation is done so that the partial pressure of the benzol decreases and easily get
vapourized. LP steam injected at the bottom not only maintains temperature of the column but also decreases
the temperature of the crude benzol. The crude benzol vapours along with steam from the top of the column
are fed to the oil dephlegmators. The BDO from the bottom in which crude benzol is recovered is pumped to
the decanter through oil-oil heat exchangers. The crude benzol vapours are partially condensed in the oil
dephlegmators. The partial condensation removes any higher fraction present in the vapours which further
increases the purity of the vapours. Three sets of dephlegmators are provided, two sets for oil and one set for
water. The vapours are cooled to 92 – 950C in oil dephlegmator by pre-heating the feed to stripping column
and further cooled to 840C in water dephlegmator. The condensate collected in the heat exchanger is called
‘PHLEGMA’. The phlegma from the exchangers, which contains water is collected in a separator. Water is
separated and phlegma overflows to the phlegma collecting tank, from which tank phlegma is sent to
stripping column as reflux.
Regenerator: The continuous circulation of BDO forms some polymer due to heating and cooling. This
polymer must be removed from the BDO by regeneration. A regenerator is a hollow tank in which steam
coils are arranged. Medium Pressure (MP) steam is circulated through these coils. Part of the stripping
column is fed to the regenerator. Due to the pressure, CB vapours are collected at the top which in turn to the
stripping column. The bottom liquid from the regenerator is pumped out and stored in crude and finished
product storage (CFPS).

Crude Benzol Column – I: The vapours containing crude benzol from the top of the stripping
column is fed to the crude benzol column – I (CB-I) through water dephlegmator where the crude benzol is
separated to heavy crude benzol (HCB – used as furnace oil) and light crude benzol (LCB – contains
fractions of benzene, toluene, xylene). This column consists of 16 bubble cap trays. Simple distillation is
carried out in this column. A re-boiler provided at the bottom of the column supplies the necessary heat. MP
steam is used as a heating medium. A CB vapour at a temperature of 80 – 850C is fed to the 6th tray of the
column. The lighter components are vaporized, and these are collected at the top of the column, which are
then condensed into condenser by water. The condensed vapours are then fed to separator where the
moisture present in the vapours is separated and the LCB obtained is stored in CB – I tanks. Part of the LCB
is fed as reflux to the CB – I column. The bottom product obtained from CB – I column is fed to CB – II.
Top Temperature 70 – 800C Bottom Temperature 115 – 1200C
Crude Benzol Column – II: CB – II consists of 6 bubble cap trays. The bottom product of the
CB – I, which mainly contains HCB with small amounts of CB – I column is fed to CB – II column. To
recover the CB – I the liquid is to be distilled. The CB – I vapours An Industrial Report On RINL
Government Institute of Chemical Engineering Page 76 obtained from the top of the CB – II are fed to CB –
I column as reflux. The bottom product obtained from CB – II is called HCB. Top Temperature - 1060C
Bottom Temperature - 1100C
De-benzolised Oil: The DBO from the bottom of the stripping column is pumped through oil-oil
heat exchanger to DBO cooler. In DBO cooler, it is cooled to 45 – 500C. Due to high temperature exposure
part of the solar oil may get decomposed. This decreases the absorption efficiency of solar oil. To remove
this decomposed matter of DBO is fed to the decanter.
Decanter: It is a horizontal cylindrical tank unlike mechanical decanters BDO is fed to decanters
at a temperature of 45 – 500C. A small amount of water is fed to the decanter which provides better removal
of sludge or muck form of oil. Water settles at the bottom carrying sludge with it. Oil layer is formed above
the muck layer. The residence time in a decanter is 3 – 4 hrs. Water is continuously drained from decanters.
Oil after 3 – 4 hrs is fed to BDO tank. Muck from the decanter is drained and sent to the emulsion beaker.
Due to contact of oil, water and muck oil-water emulsions and muck-water emulsions are formed. These
emulsions float on the surface of the water, which is fed to emulsion beaker along with the muck
Emulsion Beaker: This is a horizontal cylindrical vessel provided with insulation. Medium
pressure steam is fed through a coil into the beaker. The residence time for settling the oil, muck and water
in the beaker is 2 hrs. Due to heating of emulsion, oil and water gets separated which is called as ‘De-
emulsification’. Emulsion thus formed is broken and muck will float on water. This muck is fed to muck
tank and water is drained. The temperature inside the beaker is 80 – 900C.
HYDRO REFINING: In this unit hydrogen gas purifies the light crude benzol. Hydrogen is
recovered from coke oven gas and CB – I from benzol distillation plant. CB – I consists of benzene, toluene,
xylene, solvent naphtha, non-aromatics and residue. Initially the CB – I is purified from sulphur, non-
aromatics and other compounds. This consists of the following sections:
• De-fronting section
• Reaction section
• Purification section
De-fronting Section: In this section carbon disulfide is removed from the crude benzol and this is
called de-fronted crude benzol. CB – I from the storage tank is pumped to a surge tank which is meant for
intermediate storage and then it is pumped to distillation column through feed pre-heater. The feed enters the
column at a rate of 3 ton/hr. at 700C, 0.5 kg/cm2 . Sulphur content fed will be 2000 – 1800 ppm. This
decreased to about 1200 ppm in the column. The distillation column consists of 30 bubble cap trays of which
17th tray is the feed tray. Steam is fed into re-boiler, which heats the bottom product recycled to the column.
The remaining bottom is called de-fronted crude benzol, is fed to the reaction section through feed pre-
heater. The sulphur is removed in the form of CS2 vaporizer. Part of it is fed to the column as reflux and the
other part is stored. The DCB obtained is at 700C and this is fed to the intermediate storage.

Reaction Section: This section consists of reactors and evaporators. Here hydro refining takes
place in the reactors provided which remove the oxygen, nitrogen, and Sulphur content in DCB. The de-
fronted crude benzol is pumped to the de-fronted storage tank (V – 401) through a filter. The filter is
provided to remove the solid particles and polymers, which may be present in the crude benzol. The benzol
filter is an edge type filter and consists of a slotted tube inside a shell with a specified filter fineness, which is
determined by the slots and scrappers. This is agitated by a hard crank. The particles are retained at the edges of the
slots and must be scrapped off. If the pressure difference between the inlet and the outlet streams is too high the
concerned filter must be opened and cleaned. filtered DCB is stored in the surge drum (V – 401). The drum is set to
approximately two bars split range controlled by feeding N2and venting gases. From surge drum, the DCB is fed to
pre – vaporizer at a pressure of 30 bars using 32 stage centrifugal pumps.
Pre – Vaporizer: It is nothing but a vertically mounted shell and tube heat exchanger. The feed is mixed
with a part of cycle gas (containing H2 approximately 15% of the total gas) before it is fed to the vaporizer. This feed
is pre – vaporized to about 160 – 1650C by means of the main reactor effluent passing through shell side. The feed at a
temperature of 160 – 1650C is fed to the third mixing nozzle of stage evaporator. This vertical heat exchanger is
provided with turbulence promoters in the tube side to achieve high turbulence so that more heat exchange will occur,
and no scale formation is attained. This arrangement is provided as the feedstock is in partial vapour stage (gas –
liquid stage) and so fouling of the tubes will occur rapidly. This arrangement also provides easy cleaning of tubes by
simply pulling the turbulence promoters.
Stage Evaporator: The stage evaporator is a long cylindrical vessel provided with three stages, which
are separated by two plates. Demister pads are provided at the top of the evaporator. Each stage is provided with a
mixing nozzle. Two re-boilers (E – 402 and E – 403) are provided for the second and first stage respectively. A gas
preheater (E – 404) is also provided in which the rectangle gas (85% of the total gas) is pre-heated to 2100C by the
main reactor effluent. E – 402 and E – 403 are heated by hot oil through tubes at a temperature of 2500C. Rectangle
gas mixed with feed is passed through the shell side. Down comers are placed so that the liquid in the third stage will
enter the second and from second to first. Pressure inside is about 20 kg/mm3 . The DCB mixed with 15% rectangle
gas is fed at the third mixing nozzle of the evaporator. The vapours coming from the second stage and the feed are
mixed thoroughly and fed to the third stage. Lighter vapours are passed through the demister pads and to the pre –
reactor. The liquid containing lighter and heavier substance is passed through down comers to the second stage. Here
the fed is mixed with the vapours from first stage in the mixing nozzle II and heated in re – boiler (E – 402). This is
fed to the top of the second stage. Liquid from 2nd stage flows to 1st stage. This liquid is pre – heated in E – 403 and
mixed with 85% of the rectangle gas in the first mixing nozzle and again fed to the first stage. The temperature at the
bottom of the evaporator is 2100C. Due to heating of the feed the vapours are sent to the top and any residue or
polymers in the feed are collected at the bottom. Part of the liquid from the first stage is fed to the residue flash drum
(V – 406) from where they are recycled to benzol distillation plant. The lighter vapours from the flash drum are fed to
the surge drum (V – 401) nearly this residue would be 3 – 4% of total feed The vaporization of feed (DCB) in the
evaporator is done by reduction of partial pressure of DCB, which is manipulated by addition of the rectangle gas.
This results in lower operating temperature even at higher pressures. Vaporization of feed in heat exchanger should be
avoided to reduce fouling of surfaces.
Pre – reactor: The vapors from the top of the evaporator at 2000C are heated in a heat exchanger (E –
406) to 200 – 2250C by passing main reactor effluent through shell side. The reactor is provided with a bed of catalyst
i.e., NICKEL MOLYBDENUM. In this pre – reactor such as di-olefins, styrene and CS2 are removed by
hydrogenation. Feed enters from the bottom of the reactors through catalyst bed. Hydrogenation of di-olefins, styrene,
takes place in the presence of catalyst. The temperature at the inlet of the reactor is 200 – 2250C and this depends on
the life cycle of the catalyst. Due to the exothermic reaction the outlet temperatures increase to 210 – 2350C. Due to
continuous operation of the catalyst bed polymerization products like coke will deposit on the bed resulting in lower
efficiency. This can be overcome by increasing the inlet temperature of the reactor. Catalyst activity can be
determined by the temperature difference between inlet and outlet, which should be more than 100C. Catalysts
can be regenerated by heating the bed with steam and air. The reactions in the pre – reactor is.
Di-olefins (CnH2n-2) + H2 Mono olefins (CnH2n)
Cyclopentadiene (C5H6) + H2 Cyclopentane (C5H8)
Styrene (C8H8) + H2 Ethyl benzene (C9H10)
Carbon disulfide (CS2) + H2 Methane (CH4) + H2S
Main Reactor: In the main reactor treated pre – reactor effluent is hydrogenated on special sulphide
molybdenum catalyst. The main reactor consists of two beds of catalyst makeup gas i.e., pure H2 gas from the
compressor at pressure of 18 bars provided more hydrogenation and hence complete saturation of olefin hydrocarbons.
The inlet temperature is about 2700Cand the outlet temperature is 3300C due to exothermic reaction. Mainly
desulphurization, densification and olefin saturation feed stock occur in the main reactor. The hydrogen is fed through
a distributor below first bed of catalyst oxygen content in H2 gas should be very low so that no polymerization occurs
in the reactor. Hydrogenation of aromatics should be prevented. Catalyst deactivation can be determined by the
amount of thyophene content at the outlet of the reactor. If this increases hydrogenation of aromatics, coke formation
increases. So, the temperature of the reactor should be increased or other regenerations should be done.
Main reactions are:
Mono olefins + H2 →Paraffin
Ethyl mercaptans + H2→ Ethane + H2S
Thyophene + H2 → Butane + H2S
Coumarone + H2→ Ethyl benzene + H2
Pyridine + H2 →Pentene + H2
Pyridine + H2 →Butane + H2
Benzene + H2 →Cyclohexane
Toluene + H2→ Methyl Cyclohexane
Hence required to maintain a heater to which part of the effluent is passed. Heated and fed to the main reactor supplies
the temperature. Coke oven gas is used as fuel in the heater. The effluent from the main reactor collected at the
bottom, which is at 3300C. This effluent is passed through (E – 407, E – 406, E – 404, E – 401) and finally cooled in
water cooler (E – 408). This condenser effluent is fed to the separator. Before water cooling hot water is dosed into the
effluent. This dissolves the deposits of salts such as NH4HS2 and NH4Cl. The cooled effluent at 500C is fed to the
separator. A water leg provided separates the dosed water. The water free effluent is fed to the stripping column. The
gases i.e., unreacted hydrogen gas and other gases are sucked by recycle gas compressor and are recycled part of the
gas is purged out through vent provided. The heat demand of the process is supplied by a separate hot oil system. The
hot oil is used as a heating medium for several heat exchangers in hydro refining unit and extractive distillation unit. A
horizontal furnace is used to heat the oil, the furnace is fired using coke oven gas. Hot oil is pumped into the coils into
the furnace. The temperature of the oil increases to about 340 – 3500C. The hot oil is pumped by a pump. This is again
recycled to the suction side of (P-404).
Reassure Swing Adsorption Unit: The required hydrogen gas to HR units is supplied from this section. The
clean coke oven gas after benzol recovery is fed to filter at a pressure of 800mmWC. Moisture and carbon particles
present in the gas are filtered and the filtered coke oven gas is fed to reciprocating compressor, which compresses the
gas to about 2.5 kg/cm2 . The compressed gas is again fed to the other compressor where the pressure of the gas
increases to 6.5 kg/cm2 . The gas is then fed to another filter, which removes moisture in the gas. From the filter the
gas is fed to the pressures in the adsorption unit. It consists of 4 cylindrical vessels in a bed of molecular sieves placed
on. The coke oven gas passed from the bottom of the bed. And the molecular sieves absorb the hydrogen present in the

gas. The hydrogen thus collected is fed to the makeup gas compressor. The gas is passed through one catalyst
bed only. Currently, the remaining beds are being regenerated. This is because the catalyst for 180 sec only. Then it
must be regenerated. This is done by using pure H2 gas. The regeneration of bed is done automatically. The H2gas is
collected from the top of the bed and is fed to the makeup gas compressor. This is a vertical reciprocating compressor
of double stage. The H2 gas is compressed to about 30bar. The recycled gas from gas separator is fed to the recycle
gas compressor, which is a horizontal single stage compressor. Purification Section: This section consists of a
stripping column in which the Sulphur content as H2S and any dissolved gases in the DCB are removed. Process: The
liquid part from the separator is fed to the stripping column through a preheater, which is heated by BTX solvent from
the stripping column fed at a temperature of 1350 c is fed to the column the column consists of sieve trays. The top
temperature is 125-1350C and bottom temperature is 1500C. Pressure is about 4.3 kg/cm2 . A re-boiler is provided
which supplies the required heat to the column. MP steam is fed to the shell side of the re-boiler. The gas from the
column contains H2S. These are condensed in the condenser where water is issued. This condensate (700 C) is fed to
the reflux drum. Part of the condensate is refluxed to the column. Moisture present in the gas is removed from the
water leg and the off gases are fed to the off-gas mains.
The bottom product called BTX solvent raffinate is passed through preheater where it is cooled and finally raffinate is
cooled in the raffinate cooler which is cooled by water. This is stored in intermediate storage
Extractive Distillation Unit: In this unit, the BTX raffinate is processed to separate benzene, toluene and xylene
solvent. Further benzene and toluene are also separated. Using ‘Extractive Distillation’ in which N-Formyl
Morpholine (NFM) is used as solvent does separation of BTX into BT and X. Non-aromatic compounds present in
BTX are removed by pressure distillation solvent is recovered in solvent recovery column. Benzene and toluene are
separated in BT separation column. The total heat required for the unit is supplied from various means pressure
distillation receives heat from hot oil. The aromatic separation column and solvent recovery column receives heat
from the vapours of the pressure distillation column. The BT column receives heat from the LP steam.
MANOJ KUMAR SINHA A.LAKARA

GM(O),CO&CCP DGM(O),CO&CCP

UTILITIES DEPARTMENT
INTRODUCTION:
Utilities (Water, Electricity and Gas) are essential services that play a vital role in
economic and social development. In steel plant, utilities play an important role in the
production and supplies basic requirements to corresponding units.
AIR SEPARATION PLANT
• Liquid storage and distribution
• Cylinder filling station
AUXILLARY DEPARTMENT
• Compressor house
• Chilled water plant
• L.P.G plant

AIR SEPERATION PLANT
Air separation plant is one of the major production units in utilities department which produces oxygen,
nitrogen, argon. Atmospheric air consists of oxygen, nitrogen, argon, moisture, carbon dioxide, carbon
monoxide and hydrocarbons. The main constituents are separated from air in the Air Separation Plant.
PRODUCTS BOILING POINT QUANTITY
Nitrogen - 195.8oC 78%
Oxygen - 183Oc 21%
Argon - 185.8oC 0.9%
✓ Oxygen is used in steel making in LD converters and for general purposes.
✓ Nitrogen required for the BF high top cleaning systems, in dry quenching of coke, gas line purging as a
purging medium for LD converter cleaning.
✓ Argon is used for homogenization of liquid steel in continuous casting and is required for welding in the
repair shops.
STEPS INVOLVED IN THIS PROCESS:
▪ Free Air Compression
▪ Air Pre-Cooling Unit
▪ Air Purification Unit
▪ Air Cryo-Cooling Unit
▪ Main Distillation Unit
▪ Argon Unit
FREE AIR COMPRESSION UNIT::
A compressor sucks the atmospheric air through air filters. The filtersare of self-cleaning type,
which removes the dust particles in the air. A fourstage centrifugal compressor then sucks the dust free air.
The compressor is run by a motor and driven by a gearbox. It is provided with a main oil pumpand auxiliary
oil pump, which supplies the lube oil for the compressor.
Air is pressurized in four stages up to 6.4 kg/cm2 . During the compression, the
temperature of the air increases up to 50°c and this is cooled in an inter cooler. Inter coolers are shell and
tube type heat exchangers in which the shell side fluid is air and tube side is water. Each stage is provided
with an inter cooler and fourth stage is provided with an aftercooler. The air temperature at the discharge of
the after cooler is 45°c. Air with 6.4 kg/cm2 pressure is fed to the air-pre-cooling unit.
In the suction line of the compressor an inlet guide vane is provided which controls the airflow rate to the
compressor. Anti-surge valve is also provided to the compressor in view of safely.

Compressor Stages Pressure after each stage

First stage 0.7 kg/cm2
Second stage 2.0 kg/cm2
Third stage 3.8 kg/cm2
Fourth stage 6.4 kg/cm2
AIR WATER TOWER:

. Chilled water at a temperature of 5°c is pumped to the air water towerat a pressure of 8 kg/cm2 .
The tower is provided with bubble cap trays, which increases the contact area of water with air. The pressure
inside the tower is maintained at 6 kg/cm2 . The temperature of compressed air decreased upto 8-10°c. Due
to decrease in temperature, moisture present in the air gets condensed and the chilled water collected at the
bottom is again recycled
NITROGEN WATER TOWER:
In this water, the service water is initially cooled with waste nitrogen to19-20°c. water is fed from
the top and waste nitrogen is fed at the bottom so that more contact can be provided. Water is sprayed by
using diffusers. The water collected at the bottom of the tower is pumped to the refrigeration unit.
Water inlet temperature→ 32-35°c
Water outlet temperature →19-20°c
Waste nitrogen inlet temperature→ 13°c
Waste nitrogen outlet temperature→ 25°c
The cooled water from the bottom of the nitrogen water tower is pumped to the refrigeration unit.
Refrigeration is done by vaporcompression Freon vapors are compressed in a compressor and fed to the
condenser where it is condensed. The condensed vapors are again evaporated in the evaporator. In the
evaporator, the water is passed throughthe tube side and the water is cooled to 5-7°c. This chilled water is
fed to theair water tower.

AIR PURIFICATION UNIT:

This unit consists of dryers and post filters. Two electric heaters are also provided. The cool air at a
temperature of 10°c is purified from CO2, moisture and hydrocarbons.
DRIES
The air at a temperature of 10°c is fed from the bottom of the drier. Drier is a horizontal
cylindrical vessel in which two beds of activated alumina and molecular sieves are arranged. Purification is
done adsorption process. The moisture in air is adsorbed by activated alumina and molecularsieves adsorb
carbon dioxide and hydrocarbons. The activation time is 5 hrs.Then the drier is deactivated which is
subjected to regeneration.
REGENERATION:
Regeneration of driers is done by wasting nitrogen. Waste nitrogen is initially heated in electric heaters to 220-240°C.
The hot waste nitrogen gasis blown from top of the regenerator for one and a half hour. Then the bedsare heated, and
the moisture gets evaporated. After one and a half hours, thebeds are cooled by passing cold waste nitrogen for three
hours. During thisperiod, CO2 and hydrocarbons are removed and the drier is ready for use.
POST FILTERS:
The dried air in the driers is fed to the post filters. These driers are meant for separating any dust particles
generated due to air fraction in the driers. The post filters consist of line mesh through which the air passes
and dust is removed. The air is then fed to the heat exchangers.

AIR CRYO COOLING UNIT:

This unit consists of main heat exchangers and expansion turbines.
HEAT EXCHANGER:
The dry and purified air from the air-purified unit is fed to the exchanger, which supplies the
necessary cold for the process. The exchanger is plate type with counter current flow of fluids. The
exchanger consists of several plates of fin type in brazed aluminium. The air passes through one side and the
end products like pure oxygen gas, pure nitrogen gas and waste nitrogen gas are fed through another side.
These products enter at cryogenic temperatures and leave at about 10-13оC. The air entersat 8-10оC and
leaves the exchanger at -150 to -160oC. A part of the air is taken at an intermediate point of the exchangers
and fed to the expansion turbine. The other part is fed to the bottom of the medium pressure column.
EXPANSION TURBINES (DO1/DO2):
The air from the exchangers is fed to the centrifugal expansion turbine equipped with a break
generator. This provides the necessary refrigeration to make up the thermal losses of the cold box. Air is
cooled from -135о C to -178оC. This temperature is attained due to the sudden expansion of the air. Then
the pressure is dropped from 6 kg/cm2 to 0.6kg/cm2g
MAIN DISTILLATION UNIT:
The column is a double column rectification unit provided with three sections. Medium pressure
section (KO1), Low-pressure section (ko2) and the pure nitrogen section (ko3). The rectification units are
provided with a suitable number of trays to achieve the required purity of the products. The main feed to the
column is liquid air, gaseous air and the refluxes. The liquid air is from air liquefier, fed to the NP column
and the gaseous air is from exchanger, fed to the NP column. The gaseous air from the bottom of the
exchanger is fed to the medium pressure column.
Part of this air is fed to the air liquefier (EO6) which is a plate type exchanger. The cooling medium is liquid
oxygen. The oxygen vaporizes and the gaseous oxygen is fed to the main heat exchanger. The air liquefies in
the air liquefier and the liquid air is fed at the bottom of the medium pressure column.
MEDIUM PRESSURE COLUMN:
This is the lower part of the column. It is provided with 46 trays of ripple sieve type. A pressure of 6.5
kg/cm2 absolute is maintained in this column. At the top of the MP column a condenser-cum –evaporator is
provided. This acts as a condenser for MP column and as an evaporator for the LP column.
The gaseous air from the exchanger is fed at the first tray of the column at a temperature of -177о C and the
liquid air from the air liquefier is fed at the 10th tray of the column. The up flowing gas becomes enriched
with nitrogen gas by contact with the down coming liquid. This results from the nitrogen condensing in
EO3. The products from the column are.
Poor liquid at a temperature of -174о C from the 24th tray with low oxygen content is used and reflux on the
top of the LP column after passing through nitrogen sub-cooler and an expansion valve. Rich liquid having
35-38% oxygen from bottom of the column is fed to the LP column through rich liquid sub-cooler and an
expansion valve. The temperature of the RL at the outlet is -172оC. The rich liquid sub-cooler (EO4) is
provided to cool the RL from - 172о C to -183о C. The liquid oxygen is fed through Eo4 which cools the
RL. The liquid oxygen is fed to the oxygen filters before the sub- cooler.

LOW PRESSURE COLUMN:

Low-pressure column is at the top of the column. It consists of 72traysof ripple sieve type. The pressure in
the column is maintained at 1.5 kg/cm2 absolute. Temperature in the column is in the range of -185 to -188о
C.
The air cooled in the expansion turbines is fed at the 60th tray of the LP column. Rich liquid from the MP
column is fed at the 61st tray of the LPcolumn at a temperature of -190оC. Lean liquid from the MP column
passesthrough the EO5 and fed at the top plate of the LP column. The oxygen condensed from the liquid air
is collected at the bottom of the LP column at a purity of 99.5%. Pure oxygen liquid is withdrawn from the
bottom of the LP column. Liquid oxygen is fed to the LOX filters. These filters permit the abnormal removal
of hydrocarbons particularly acetylene products in oxygen path. Part of the liquid oxygen is again fed tothe
LP column as reflux. Another part of the liquid oxygen before the LOXfilters is fed to the air liquefier where
it is vaporized and fed to the main exchanger. Liquid O2 from the bottom of the 1 st tray is pumped to the
liquid Oxygen storage tanks through EO5 sub-cooler.
PURE NITROGEN COLUMN:
Liquid nitrogen is passed through EO5 exchanger and fed to the pure nitrogen column, which consists of 15
trays. Part of the NL from the exchanger is fed to the phase separator and the liquid N2 from three bottomsis
fed to the storage tank. The N2 vapors from the top of the phase separatorare fed top the pure nitrogen
column. The gaseous N2 from the top of the KO3 is passed through EO5 and recovered its cold and it’s
passed through main exchanger and is sent to customers.
No. of trays of MP column→ 46
Working pressure of MP column→ 6 kg/cm2
No. of trays of LP column→ 72
Working pressure of LP column →1.42kg/cm2
No. of trays of pure nitrogen column →15
Type of trays design→ Ripple sieve of lined
Material of construction of trays→ Aluminium alloy

ARGON UNIT:
Argon unit is designed to process crude argon and crude liquid argon as 99% purity. Each argon unit
is having a capacity of 120 NM3
CRUDE ARGON COLUMN:
For crude argon column a gaseous flow is taken from the LP column at 38th tray where argon content is 9-
11% maximum. This column contains70 trays and the pressure is 1.5 kg/cm2 This fraction is fed to the
bottom of the crude argon column (K1O) for partial condensation by vaporization of rich liquid in the crude
oxygen condenser E40. Then the oxygen present in the gas is condensed and flows back to LP column. The
non-condensable gaseous fraction, which is called as crude argon. This gas contains 95- 98%of crude argon.
WARM ARGON UNIT:
The crude argon is fed to the warm argon unit through E41 heat exchanger where the vapors are warmed up
to the ambient temperature by exchanger with purified argon mixture. The crude argon from E41 is
compressed to 3-4 kg/cm2 in a compressor of water ring type. A stream of hydrogen gas is fed into the argon
vapoUrs before the compressor. The vaporsfrom the compressor are fed to the water separator B 10where
water if any entrained from the compressor is removed. Crude argon and hydrogen gas mixture is passed
through reactor R10 where hydrogen reacts with oxygen present in the gas in the presence of palladium
catalyst. At the outlet of the reactor, argon gas contains less than10 PPM of O2. As it is exothermic reaction,
the temperature of the gas increases to 300-400оC. So de-oxo argon is cooled in E42 atmospheric cooler,
then in E43 water cooler up to 40оC. This de-oxo argon is further cooled in X10 refrigeration unit up to
10оC and send to B11 separator. Dueto cooling the moisture in the gas is condensed and this condensed
moistureis removed in the B11 separator. The moisture free de-oxo argon is sent to R11/R12 drier where
moisture and CO2 are adsorbed. Argon gas from the drier is passed through F10 dry type filter and further
passes through the E41 heat exchanger in which it is cooled to -164о c. This argon is fed to thebottom of the
pure argon column.
PURE ARGON UNIT:
Pure argon unit consists of pure argon column. The column isprovided with 60 trays and two
reboilers one at the top (E 46) and the otherat the bottom (E 45). The de-oxo argon passed through the E45
condenser of the K11 column where the gas becomes liquid. This liquid is expanded and sent to H2
separator where unreacted H2 is sent to the compressor. Thisexpanded de-oxo argon is again fed to the
middle of the K11column. The vapors rise to the top of the column and enter to the E46 exchanger where,
the argon vapors are condensed collected at the bottom. In the E46 exchanger, pure nitrogen liquid is used to
condense the argon vapors. From the bottom of the E45 pure argon is fed to the liquid argon storage tanks.
The noncondensable from the top of the column are vented into the atmosphere. The noncondensable mainly
contain nitrogen and hydrogen gases.
LIQUID STORAGE AND DISTRIBUTION:
GASEOUS OXYGEN:
The requirement of oxygen in converters is cyclical, the pattern being characterized by high flow rates
followed by periods of no consumption. These short time peak demands are met by providing buffer vessels
at the SMS. The supply oxygen at this minimum pressure the buffer storage vessels should operate between
40-20 kg/cm2 to release the required quantityof O2 during flowing.

GASEOUS NITROGEN:
Gaseous nitrogen is required for blast furnaces continuously at a pressure of about 8-10 kg/cm2 . Gaseous
nitrogen buffer vessels are providedat the blast furnace plant to meet the fluctuation demand of BF. For
supplyof nitrogen to various consumers, six compressors are provided.
STORAGE TANKS FOR OXYGEN AND NITROGEN
Storage tanks are long cylindrical vessels. The tank is provided with a cylinder inside the outer shell. The
annular space is filled with perlite powder for reducing heat losses. Small amount nitrogen gas is purged to
maintain positive pressure in the annulus. This is done to prevent any leakages of the liquid.
Two liquid oxygen storage tanks each of capacity 1000m3 water volume have been provided. Three liquid
oxygen pumps of centrifugal typeeach of capacity 10 tons per hour at a discharge pressure of 41 kg/cm2 ,
threevaporizes of the steam bath type each with capacity 10 T/hr are alsoprovided.
Three liquid nitrogen storage tanks each of capacity 1000m3 of water volume are provided. For meeting the
requirements, the liquid nitrogen will be pumped at 40 kg/cm2 and vaporized in a steam bath vaporizer. Four
liquid nitrogen pumps each of capacity 20 T/hr at a discharge pressure of 41 kg/cm2 and three vaporizes
each of capacity 20 T/hr are provided. Liquid argon is stored in a tank of 50001 capacities. For meeting the
requirement, liquid argon is pumped at a pressure of 7 g/cm2 and vaporized in atmospheric vaporizers.
CYLINDRICAL FILLING STATION:
Cylinder filling facilities are provided to ensure supply of O2, N2 and argon to consumers to who piped
supply is not provided. For the oxygen cylinder filling facility, a liquid storage tank of 5000 liters capacities
is provided together with 3 pumps of 200. 1 hr capacity each. Four filling facility, a liquid storage tank of
5000 liters capacity is provided together withtwo pumps of 100 1 hr capacities each. Two filling manifolds
each with 20 points are provided. The argon cylinder filling facility is identical to that ofnitrogen facility.
The cylinder filling pumps operate at a pressure of 165 kg/cm2 . Atmospheric vaporizers are provided for
vaporizing the liquidoxygen nitrogen and argon after pumping. It is proposed to provide a total of 2000
cylinder for oxygen, nitrogen and argon in the filling plant. The cylinder filling plant is provided with
cylinder testing and painting facilities.As argon gas at high purity is needed, argon cylinder manifolds are to
be vacuum bed before filling argon cylinders. Vacuum pump is provided in thecylinder filling station for this
purpose.

PRODUCTS OF A.S.P:-
S.NO PRODUCTS DEPARTMENTS WHERE THEY ARE USED

OF ASP USED
1. GASEOUES SMS CONVERTOR BLOWING
O2 (STEEL MELT
SHOP)
BF (BAST COLD BLAST ENRICHMENT
FURNACE)
2. GASEOUS N2 SMS SLAG SPLASHING
CCCD COKE DRY QUENCHING

BF BF TOP GEAR BOX COOLING
3. GASEOUS Ar SMS ARGON RINSING AND COMBINED
BLOWING
4. LIQUID O₂, SALES AND FOR EMERGENCY

N₂, Ar
5. O₂, N₂, Ar WELDING/PURGING

CYLINDERS

CHILLED WATER PLANT:-
Chilled water is required for use in Air Conditioning systems of various plant control rooms and electrical
control rooms in addition to this, it is also required for process uses such as in the primary gas coolers in
coke oven and by-product plant and in the pre-coolers of the turbo-flowers of power plant and
blower house. The total chilled water requirements for various process consumers as well as for the air
conditioning requirements are 6223 m3 /hr in 3.0 m stage.
PROCEDURE:
The chilled water pumps pump warm water from warm water storage tank through evaporators of
centrifugal chillers. This water gets cooled from 16⁰C. In chillers water is supplied computer center. Chilled
water pump the warm water from warm water storage tank to the warm water common header. Individual
chillers out lets are connected to a chilled water common header.

The warm water from the consumer is returned back to warm water storage tank.
The warm water storage tank is an RCC tank. This tank and all chilled water lines all fully insulated with
thermo-coal insulation to avoid cold losses. By-pass arrangement is provided in the discharge header of the
chilled water pump to by-pass a part of chilled water to warm water. Storage tank in case of reduction in
consumer requirement of chilled water. This results in a drop in a temperature of warm water. There by
reducing the heat load of the chillers and the temp. Of the chilled water at the chiller out let begins to drop.
This is sensed by temp. Sensors at the chilled water outlet lines from each chiller which in turn closes the
IGV unit, thus reducing the capacity and bringing the system in to equilibrium. The refrigerant cycle at the
evaporator. The warm water flowing through evaporator tubes is warmer than the refrigerant in the shell
around the tubes consequently heat is transferred from warm water to the refrigerant; thus chilling the warm
water. This heat evaporates the refrigerants at a temp.
Corresponding to the lower pressure in the evaporator. Evaporated refrigerant vapour flows through the pre-
whirl vanes IGV unit in to the centrifugal compression where it is partially compressed by the first stage
impeller. It then mixes with the steam of gas, which comes from the economizer. The mixer of suction and
economizer gas enters the second impeller where it is compressed and discharged in to condenser. If
economizer was not used, this would all be generated at the evaporator and would all have to be pumped
from the evaporator pressure to the condenser pressure. The pumping of a portion of the gas back to the
condenser from the intermediate economizer pressure increases the cycle efficiency and saves power
consumption.
2. COMPRESSOR HOUSE:-
Compressed air is required in the various production methods of steel. Plant air is required for the operation
of pneumatic devices, pneumatic tools and for general purpose. Whereas dry air is required forthe operation
of instruments and controls. To meet the above requirements 4 no. of centrifugal compressors and 4 no. of
dry air units are installed.
PROCESS DESCRIPTION:
The content of hard particles and mechanical mixture in air must not exceed 0.5 mg/Nm3 of air. Hence air is
filtered and cleaned of dust particles so as to avoid mechanical wear of the rotor and prevent it from
unbalancing.
The air is cleaned in self-cleaning dry type air filters (pulse clean). This pulse cleans intake air filters
provide a constant flow of filtered intake air. And eliminates the necessary of charging filters due to high
atmospheric dust conditions. Thus intake air filters reduces dust concentration in the exit air to 0.1 mg/Nm3
this filtered air is fed to the fourth stage centrifugal compressor through a suction silencer. The flow and the
pressure of the discharge air will be controlled by the setting of the inlet guide vane unit provided in the up
streamside of the 1st stage impeller.
Air after getting compressed to 0.9 kg/cm2 the temperature is raised to 110оc in the first stage and fed to the
second stage through the first stage inter cooler where air gets cooled to 45 оc to so thermal compression. Air
from second stage at 2.6 kg/cm2 and 110оc is fed to third stage through second stage inter cooler after
getting cooled to 45оc. The compressed air from third stage at 5.0 kg/cm2 and 110оc is cooled in third stage
inter cooler to 45оc. This air is fed to the fourth stage from which air comes out at 8.5 and 100 оc and
discharged through the discharge header, through a discharge silencer. All the inter coolers and the after
coolers are provided with moisture separation where the condensed moisture of compressed air gets cooled
and collected. The compressor shall always be operated with airflow above the surge flow rate.
AIR DRYING STATION:

Compressed air passes through a pre filter to remove water droplets and dust particles. Water thus collected
shall be drained through automatic drain trap. This air is directed to the distributor. From this distributor a
part of the air will go to the Regeneration bottle and the rest to the Adsorption bottle. There are two
numbers of absorbers filled with silica gel as desiccant, in which one will be under adsorption and the other
will be under regeneration.
Regeneration is carried out by heating the part of air, which comes out from the distributor, is an
electric heater and passed through the bed under regeneration. Moisture will be picked up from the hot air
from the desiccants bed and passed into shell and tube regeneration cooler. Moisture will be condensed on
the shell side by circulating cool water in the tube side. Condensed water will be knocked off in the
moisture mixes with the rest of air in the distributor. Now the total air goes to the bottle under adsorption
where moisture will be absorbed by silica gel desiccant. The dry air then passes through the after filter to
remove dust particles. This moisture dust air will discharge to a common header, which is connected to the
instrument air consumer network.

LPG
LPG stands for liquified petroleum gas.
➢ LPG is a mixture of propane (c3h8) and butane (c4h10). Generally 20:80 ratio is maintained .generally it
changes according to weather conditions.
➢ The boiling point of propane is -420c and butane is -0.50.
➢ The LPG is a mixture of both propane and butane as butane does not vapourise ( i.e turn liquid to gas) at
colder temperature. so propane is added to known percentage accordingly to vapourise butane at colder
climates.
➢ As the boiling point of propane is less than butane.
NOTE: LPG is stored as a liquid under pressure and if is consumed in liquid form it can lead to rapid
vapourisation and expansion when exposed to normal temperature conditioned. This sudden expansion can
cause explosions or fires.
PROPERTIES OF LPG:
➢ LPG at atmospheric pressure and temperature is gas which is 1.5-2 times heavier than air.
➢ LPG is a colourless gas.
➢ LPG is generally a odour less gas. But the addition of ethyl mercapton additive to LPG gives the smell
of alert users of a leak.
➢ LPG boiling point: -420c.
➢ LPG freezing point: -1880c.
➢ LPG flame point : 19670c
CHEMICAL PROPERTIES OF LPG

➢ LPG on reaction with o2 produces carbon dioxide and water on complete combustion.
➢ At 200c the soloubility in water is less than 200ppm. LPG dissolves in organic solvents such as alcohol.
CHARACTERISTICS OF LPG:
➢ Flammable and heavier than air.
➢ High energy level fuel.
➢ Stored water pressure as liquid.
➢ Large vapour to liquid to liquid ratio.
➢ It is very light in weight.
➢ Non corrosive in nature.
USES OF LPG:
➢ In household sector as cooking fuel, heating and lightning source.
➢ In automatic sector as fuel for toxic, vans, etc.
➢ In industrial sector as gas cutting and heating fuel
➢ GOVERNMENT INSTITUTE OF CHEMICAL ENGINEERING
➢ In agriculture sector as crop drying

➢ In manufacture of petrochemicals in production of electricity generation.
PROCESS:
➢ In the LPG storage plant some specific colours are used for indicating the transporting material.
➢ Yellow pipeline for LPG liquid.
➢ Orange pipeline for LPG vapour.
➢ Purple pipeline for LPG gas supply lines to consumers.
➢ Green pipeline for water.
➢ Blue pipeline for nitrogen gas for purging purpose only.
➢ The main consumers of LPG is sms-1 and sms-2 and Es&F for gas cutting purpose only.
➢ The main purpose of LPG storage installation is to store the LPG which came or supplied from HPCL
and send it to the consumers i.e sms-1 and sms-2 according to their requirement.
➢ There are two LPG storage installations are placed in the plant i.e LPG plant 1 and LPG plant 2.
1. BULLETS: Bullets contains both liquid and gas state of LPG according to weather conditions its
ratio is adjusted.
2. VAPOURISER: The liquid LPG from bullets pass into the coils of the vapouriser through pipeline
system. in vapouriser the coils are immersed in hot water at 20=250c temperature. Due to heat exchange
between hot water and liquid LPG, liquid LPG attains its boiling point and vapouriser.
3. ENTRAINMENT SEPERATOR: The vapours of LPG formed in vapouriser are sent to the
entrainment seperator to remove if any dirt or dust is present based on density difference and purify LPG
vapour.
4. PRESSURE REDUCTION SECTION: The purified LPG vapours are sent to PRS to
reduce or adjust the pressure of the LPG vapours according to consumers requirement and was
sent to sms-1 and sms-2.
LPG LEAKS
➢ LPG leaks as a gas or a liquid. If the liquid it will quickly evaporate and form a relatively large cloud of gas
which will drop to ground as it is heavier than air.
➢ LPG can cause cold burns to the skin and it can act as a asphyxiation at high temperature.
➢ (ASPHYXIATION: A vapour or gas which can cause unconsiousness or death of suffocation).
➢
K. SAMBABU N.R.RAVI
GM,UTILITIES DEPARTMENT GM,UTILITIES DEPARTMENT

QA & TD Department
Mr.S.MuraliKrishna
Sr.Manager (QATD)
(Quality Assurance & Technology Development)

INTRODUCTION:
The QA & TD dept. has been set up to take care of activities pertaining to Quality Control of
Raw Materials, semi-finished products, and finished products. The QA & TD labs are provided at major
departments like CO&CCP, SP, BF, SMS, Rolling Mills etc., in addition to Central Laboratory. The
Department monitors the process parameters for production of quality products. QA & TD carries out
analysis, testing and final inspection including spark testing of finished products and assigns grades to them.
QA & TD is categorized into:
• ANLAYTICAL Lab
-Central Laboratory
• CO & CCP Lab
-Coke oven
• TPP & CPP Lab
-Thermal & Captive power plant

Analytical Laboratory
This department performs Qualitative and quantitative analysis of water, air, and oil in Steel plant and this
department ensures that the water released by the plant should be in its norms.
These are the following sections:
➢ Environmental Lab
➢ Oil Testing lab
➢ Microbiology Lab
➢ Wet Lab
ENVIRONMENTAL LAB:
This is a sub lab of analytical section, QATD. This is a quality assurance lab. This lab
performs various tests on drinking water, recirculatory water, effluent water, and respirable air in various
areas of Steel plant and surrounding areas or affected areas by Steel plant.
➢Drinking water:
As we all know, drinking water plays an important role in the life cycle of living organisms. As we are
running a metallurgical industry which involves in usage of different types of chemicals which are carried
by moving wind and water which mixes with nearby drinking water sources which makes them unfit for
drinking.
Norms of Drinking Water:

• PH – 6.5 to 7.5
• Ammonical nitrogen-50ppm
• Chemical oxygen demand-250ppm
• Volatile phenol- 1ppm
• Oil & greases- 10ppm
• Conductivity- 0.5 to 3 μs/cm
Tests done for drinking water:
• pH
• TDS (Total Dissolved Solids)
• Chloride content
• Sulphide content
• Total Hardness

• Calcium Hardness
• Magnesium Hardness
• Fluorides
• Turbidity
➢Effluent water:
Effluent water or industrial wastewater is the aqueous discard that results from substances having been
dissolved or suspended in water, typically during the use of water in an industrial manufacturing process are
the cleaning activities that takes place along with that process.
Norms of Effluent water:

• PH- 6 to 8
• Ammoniacal Nitrogen - <0.2ppm
• Phenols- <0.2pp
• TSS (Total Suspended Solids)- <250ppm
• COD (Chemical Oxygen Demand)- <250ppm
• Oil&grease- <50ppm
• Cyanides - <0.2ppm
Tests done for Effluent water:

• pH
• Ammoniacal Nitrogen
• Volatile Phenols
• TSS (Total Suspended Solids)
• COD (Chemical Oxygen Demand)
• BOD (Biological Oxygen Demand)
• DO (Dissolved Oxygen)
➢Recirculatory water:
Our earth consists of ¾th of water which is nearly 75%. But ocean holds about 96.5% of water
which can’t be used for our needs. So, usable water is very less which is precious. So, we need to conserve
water. Industries uses a plenty of water daily, which can use again by treating it. Mainly the water usage in
boiler is more. So, the water is demineralized and then evaporated by the boiler to generate steam. Steam is
used to rotate the turbine which helps to generate electricity. The used steam will condense but having
temperature more 40°c. So, we need to cool to reuse it dispose it. In cooling process at cooling tower, they
add acids which prevents to form algae. The water is neutralized by adding some base in it and again the
water is reused in the process.

Tests done for Recirculatory water:

• Nitrites
• Zinc
• Phosphates
➢Air Analysis:
Breathing is part of a process called respiration. All living things takes in oxygen from air and
leaves out carbon dioxide. This process helps to get energy to eat, grow and live. As we are running a ferro
metallurgy cell industry which deals with the raw materials and capable to produce the aerosols, CO2, NO2,
CO …. etc, in air. They should be analysed.
Tests done on Air:

• Total suspended particulate matter
• NOX
• SOX
• CO analysis
• Benzo pyrene
Tests that are being done in common for both effluent and drinking water is:
❖ DETERMINATION OF pH:
PREPARATION OF pH BUFFER:
pH buffer tablets of 4.02, 7.0 & 9.2 are taken, and each tablet is dissolved in 100ml of demineralized (DM)
water in separate beakers.
Procedure:
▪ Samples are taken in 100ml beaker and PH electrode of ion selective meter is dipped in the sample.
▪ PH electrode is washed with demineralized (DM) water and with the sample to be analyzed.
▪ The electrode is dipped in the sample and the PH value is noted directly.
TESTS FOR DRINKING WATER:

DETERMINATION OF CHLORIDE CONTENT:
Chemicals Used:
• Potassium di chromate (K2Cr2O7)
• Silver Nitrate (AgNO3)
Procedure:
▪ Take 50 ml of sample in conical flask.
▪ Add 2-3 drops of Potassium di chromate K2Cr2O7
▪ Then titrate with Silver Nitrate until yellow colour of solution turns brick red and then note the
corresponding values of titration that gives the chloride content of water.
▪ Take 50 ml of sample in conical flask. ▪ Add 2-3 drops of Potassium di chromate K2Cr2O7 ▪ Then titrate
with Silver Nitrate until yellow colour of solution turns brick red and then note the corresponding values of
titration that gives the chloride content of water.
DETERMINATION OF TOTAL HARDNESS:

Chemicals Used:
• Ammonia Buffer
• Ethylene diamene tetra acetic acid (EDTA)
Procedure:
▪ Take 50 ml of sample in conical flask.
▪ Add 2-3 drops of Ammonia Buffer and Edichrome Black T indicator
. ▪ Now titrate the mixture with 0.01 N EDTA (Ethylene diamine tetra acetic acid) until it turns blue, then
note the corresponding values of titration that gives the total hardness present in the sample.
DETERMINATION OF CALCIUM HARDNESS:

Chemicals Used:
• Patton and Reeder (P&R) Indicator

• Sodium Hydroxide
• EDTA
Procedure:
▪ Take 50 ml of sample in conical flask
. ▪ Add 2-3 drops of P&R Indicator and sodium hydroxide solution.
▪ Now titrate with 0.01 N EDTA solution until it turns blue which indicates the end point and note the
corresponding values of titration that gives you the calcium hardness percent present in sample.
❖CALCIUM HARDNESS = TITRATION VALUE × 20
❖TOTAL HARDNESS = TITRATION VALUE × 20
❖MAGNESIUM HARDNESS = TOTAL HARDNESS–CALCIUM HARDNESS
TESTS FOR EFFLUENT WATER:

DETERMINATION OF AMMOUNICAL NITROGEN:
Chemicals Used:
• Boric acid
• Mixed Indicator• Borate Buffer • KOH
PREPARATION OF REAGENTS FOR EFFLUENT WATER SAMPLES:

PREPARATION OF BORIC ACID:
20gm of boric acid is dissolved in 1000ml of DM water.

PREPARATION OF MIXED INDICATOR:
Solution A: 0.1gm. of methyl red powder is dissolved in 50ml of ethanol. Solution B: 0.15gms.
of bromo cresol green indicator is dissolved in 150ml of ethanol. Solution A and solution B are mixed to get
mixed indicator.
PREPARATION OF BORATE BUFFER:
9.5 gm of sodium tetra borate is dissolved in 1000ml DM water & 0.5gms of sodium hydroxide
pellets is added
. PREPARATION OF 6N POTASSIUM HYDROXIDE:
33.6gms of potassium hydroxide is dissolved in 100 ml of DM water and is cooled simultaneously

PREPARATION OF 0.1N SULPHURIC ACID:
200ml of DM water is taken in one-liter volumetric flask and 27.8ml of 36N Concentrated sulphuric
acid is added slowly and is cooled under tap water simultaneously. The contents are made up to the mark of
volumetric flask with DM water. 100ml of the above prepared solutions are taken in one-liter volumetric
Flask and is made up to the mark with DM water standardize with 0.1N sodium hydroxide.
Procedure:
▪ 50 ml volume of sample is taken in 500ml kjeldal flask and 25 ml of borate Buffer solution is added.
▪ 2ml of 6N potassium hydroxide solution and half amount of water is added and is connected to distillation
unit.
▪ The distillate is collected in a conical flask containing 50ml of boric acid + 2 Drops of mixed indicator is
added.
▪ The distillate is titrated with 0.1N sulphuric acid and the colour changes form Light green to pink.
Calculation:
𝐴𝑚𝑚𝑜𝑛𝑖𝑐𝑎𝑙 𝑁𝑖𝑡𝑟𝑜𝑔𝑒𝑛(𝑝𝑝𝑚) = 𝐓𝐕 𝐱 𝐍 𝐱 𝟏𝟒 𝐱 𝟏𝟎𝟎𝟎/V
Where,
TV- Titration Value (ml)
N- Normality of Sulphuric acid Solution (0.1N)
V- Volume of sample(ml)
Ammoniacal Nitrogen value can also be determined on instrument through which we get the Direct value
displaced on screen, only by the addition of Sodium Hydroxide and the value can be considered directly.

DETERMINATION OF TOTAL SUSPENDED SOLIDS:

Procedure:
▪ Glass microfiber filter paper of 47 mm is taken and dried in a oven at 100-1050 c for 1 hour.
▪ The dried filter paper is cooled in a desiccators and initial weight (W1) is taken.
▪ The weighed filter paper is placed in a crucible and suction pump is connected
. ▪ Suitable volume of sample is passed by the suction pump.
▪ The filter paper is removed and dried in a oven at 100-1050 c for 1 hour.
▪ Dried filter paper is cooled in desiccators and final weight(W2) is taken.
Calculation: 𝑇𝑆𝑆(𝑝𝑝𝑚) = (W2 − W1) X 106/ V
Where,
W2- Final weight of filter paper (gms)
W1 - initial weight of filter paper (gms)
V- volume of sample(ml)
✓ TOTAL DISSOLVED SOLIDS = TOTAL SOLIDS – TOTAL SUSPENDED

SOLIDS DETERMINATION OF BIOLOGICAL OXYGEN DEMAND:
Procedure:
▪ Two sets of BOD bottles, each set containing two bottles labelled as blank and sample are taken
. ▪ 20 ml of sample is pipetted into BOD bottles labelled as sample.
▪ 10ml of seed prepared as per work procedure.
▪ The BOD bottles are filled up to the mark with dilution with DM water.
▪ 10ml sample is taken in a blank BOD bottle.
▪ Dissolved oxygen content is measured immediately for one set of BOD Bottles by Membrane Electrode
Method. (Blank & sample)
▪ The other set of BOD bottles are incubated at 200 c for 5 days in BOD Incubator. And the temperature of
incubator is monitored frequently.
▪ The BOD bottles are taken out from incubation after 5 days and dissolved Oxygen content is measured
immediately by Membrane Electrode Method for Blank (B2) & sample(S2)
Calculation:
BOD = (S1-S2) – (B1-B2) × 15
Where, S1= Initial dissolved oxygen in the sample.
S2= Dissolved oxygen left out in the sample after 5 days incubation.

B1= Initial dissolved oxygen in the blank.

B2= Dissolved oxygen left out in the sample after 5 days incubation.
DETERMINATION OF CHEMICAL OXYGEN DEMAND:

PREPARATION OF REAGENTS FOR EFFLUENT WATER SAMPLES:
POTTASIUM DICHROMATE SOLUTION:0.1N To 500 ml of distilled water add 4.903 gr of
K2CR2O3 and 167ml of conc. Sulphuric acid and 33.3gr of mercuric sulphate cool the solution and make
the Solution to 1000ml.
FERROUS AMMONIUM SULPHATE :0.1 N Dissolve 39.2gr of FAS in little amount of DM water add
20ml of conc. Sulphuric acid, cool the solution to make the volume up to 1000ml.
SULPHURIC ACID REAGENTS: 5.5 gr of silver sulphate per 1kg of conc. Acid
FERRION INDICATOR
Procedure:
▪ Wash the digestion tubes with 20 % H2SO4 before analysis to prevent contamination
▪ Fill the digestion tube with 1.5 ml standard potassium di chromate (K2Cr2O7) digestion solution and 3 ml
of Sulphuric acid reagent
▪ Add suitable volume of sample or diluted sample to digestion tube. Cap the tube tightly, invert the tube
several times to mix the contents completely.
▪ Repeat the same procedure for blank with DM water.
▪ Place the tube in Block digester which is pre heated to 150° C & reflux for 2 hours & cool the digested
tube to room temperature
▪ Transfer the contents of the tube to a larger vessel & add small TFE covered magnetic stirring bar for
suitable swirling for the purpose of titration.
▪ The contents are titrated with 0.1 N Ferrous Ammonium Sulphate using Ferroin indicator. The end point is
a sharp colour change from blue green to reddish brown.
Calculation: 𝑪𝑶𝑫(𝑝𝑝𝑚) = (𝐀 − 𝐁) 𝐱 𝟖𝟎𝟎𝟎 𝐱 𝐍 𝐕
Where, A=volume of ferric ammonium sulphate consumed for blank.
B= volume of FAS consumed for sample
N= normality of FAS
V= volume of sample taken 8000= Milli equivalent of Oxygen in 1000 ml per litre

Norms of Drinking Water:

PH → 6.5 to 7.5
Ammonical nitrogen → 50ppm
Chemical oxygen demand → 250ppm
Volatile phenol → 1ppm
Oil & greases → 10ppm
Conductivity → 0.5 to 3 μs/cm
Norms of Effluent water:

P H → 6 to 8
Ammonical Nitrogen → <0.2ppm
Phenols → <1ppm
TSS (Total Suspended Solids) → <10ppm
COD (Chemical Oxygen Demand) → <250ppm
Oil & grease → <50ppm
Cyanides → <0.2ppm
TEST FOR RECIRCULATE WATER:

DETERMINATION OF NITRATES:
Principle: This method is based on the ability of primary aromatized amines in presence of Nitrous acid to
produce diazo compounds intensively red violet colour.
Procedure:
▪ Take 1 ml or 2ml of filtered sample into 100 ml volumetric flask containing 50 ml of DM water.
▪ Add 2 ml of sulphonilic acid and 2 ml of 1-Naphtyl amine.
▪ Make up the volume with DM water to 100 ml. Keep it 40 min.
▪ Observe the absorbance at 520 nm. Run the blank simultaneously.
Calculation:
Conc. = 100/vol of sample × k × Absorbance
❖ Along with nitrates, zinc and phosphate content is also determined for recirculating water.
OIL LAB:
Industries involves in the large machinery which is mostly works in centrifugal action. Large machinery
needs lubrication property because machine should operate according to our expectations. Performing
regular oil analysis on your lubrication system provides valuable insight into the operating levels of machine
and the lubricant analysis you are leaving the efficiency of your equipment to change. The oils used and test
in this lab are Transformer oil, Reclaimed oil, Tanker oil (Hydraulic oil).
Transformer Oil: In Industries we need high voltage of current as well as low voltage. To alter the voltage of
electricity which keeping the electrical power unchanged we need a transformer. Transformer oil plays an
important role in transformer. So, we need to test the oil periodically.
Reclaimed oil: Reclaimed oil or waste oil is defined as any petroleum based or synthetic oil that, through
contamination has become unsuitable for its original purpose due to the presence of impurities or loss of
original properties. This oil can be re-refined into lubricants, processed into fuel oils, and used as raw
materials for the refining and petrochemical industries. These oils needed to check their physical properties
to confirm the life of the lubricant pinpoint problem in the machinery.
Tanker oil (Hydraulic oil): It is a non-compressible fluid that is used to transfer power with in hydraulic
machinery and equipment. This oil plays an important role in industries so they need to be test periodically.
TESTS DONE IN OIL LAB

DETERMINATION OF SEDIMENT CONTENT:
Chemical Used: Toluene.
Procedure:
▪ 50ml of well mixed sample is taken in 100ml centrifuge tube.
▪ 50ml of toluene is added and mixed thoroughly.
▪ Centrifuge tube is placed in centrifuge machine and the machine is rotated for a minimum of ½ hour at
2000rpm.
▪ The volume of sediment settled at the bottom of centrifuge tube is noted and calculated as % volume
DETERMINATION OF MOISTURE CONTENT:

Chemicals Used: Toluene.
Procedure:
▪ 100ml of well mixed sample is taken in 500ml round bottomed flask.
▪ 100ml of toluene is added and mixed thoroughly.

▪ Round bottomed flask is fixed to the clean and stark apparatus along with water condenser.
▪ The whole contents are heated in a heating metal apparatus of 1100 c, all content volumes of water
collected in the receiver.
▪ The volume of water collected in the receiver is noted and calculated as % Volume

DETERMINATION OF SPECIFIC GRAVITY OF OIL SAMPLE:

Procedure:
▪ The specific gravity of oil is measured using HYDROMETER.
▪ Pour 200 ml of sample oil into the hydrometer jar. Place the hydrometer in the jar and give it a quick twirl
to dislodge any air bubbles. Once the hydrometer has settled, take the reading from the appropriate scale at
the lowest level of the liquid’s surface.
DETERMINATION OF TAN (TOTAL ACID NUMBER):

TOTAL ACID NUMBER: It is a measure of concentration of acidic constituents in oil
. Procedure:
▪ POTENTIOMETRIC TITRATOR is the equipment used to determine the TAN of different grades of oil.
▪ By titration method, take the sample & mark them in serial order.
▪ Weigh the sample of 5 g.
▪ Add 35 ml of titration solvent (Toluene+ DM water)
▪ Switch on the titrator equipment.
▪ Mark the weight of oil in it.
▪ Wait for some time the value of TAN will be shown on screen, which can be noted and this TAN value is
used to enhance the quality control of lubricating oil.
DETERMINATION OF VISCOSITY OF OIL SAMPLE

Procedure
: ▪ CAPILLARY TUBE VISCOMETER is used to determine the viscosity of oil.
▪ Viscosity Analysis would be done with accurate tubes depending upon the oil degree of the oil (HLP,
SERVO)
▪ Then take the sample in tube with the help of vacuum pump.
▪ After the sucking of oil sample to a certain mark calibrated with some constant value, here constant refers
to the tube calibrated value or constant, which varies with tubes
. ▪ Insert the tubes in available spots of viscosity bath for over 30mins
▪ Then with the help of blower, oil is sucked to the starting mark.
▪ In the equipment, constant value is noted.
▪ Then the time is calculated from the starting mark to ending mark.
▪ Viscosity is calculated through time and constant value of that tubes.
▪ Then viscosity is analysed.
Calculation:
VISCOSITY = TIME × CONSTANT VALUE
MICROBIOLOGY LAB:
Microorganisms or microbes is an organism of microscopic size, which may exist in its single celled form or
as a colony of cells. Some microorganisms that are seen to be beneficial to health, but some are causative
agents in many infectious diseases.
As steel plant is a large area there is possible of stockage of water which may cause development of
unwanted microbes. In some cases, we deal with high temperatures and pressures which may kill useful
microorganisms. So, we need to test drinking & processes water.
TESTS DONE IN MICROBIOLOGY LAB

SPT TEST (STANDARD PLATE COUNT)
One of the most fundamental microbiological techniques is plate counting which is used to determine the
number of viable (i.e. living) cells in a s
Procedure:
▪ Diluting the sample
▪ Plating the sample
▪ Incubating the plates
▪ Counting the colonies
▪ Determining how many viable organisms were in the original sample.
SBR (SULPHUR REDUCING BACTERIA) TEST

Sulphur reducing bacteria (SRB) is a bacterium that can obtain energy by oxidizing organic compounds /
molecular hydrogen and reducing sulphate (sulphate) to hydrogen sulphide. In essence, bacteria ‘breathes’
sulphate. The SRB test is a small vial containing a culture gel that turns black if sulphides are present in the
test sample.
Sulphides are produced when sulphates are reduced by bacteria. The amount of colour change can be
compared with the included chart to help determine the level of contamination.
Sulphur reducing bacteria are anaerobic organisms that cause corrosion and spoilage in multiple industries.
The bacteria can cause particular damage to oil pipelines and metal parts.
Sulphur-reducing bacteria (SRB) are strict anaerobes, with an optimal temperature range of between 25 and
44°C and a pH between 5.5 and 9.0. There are currently over 20 well known genera such as Desulfovibrio,
Desulfmonas, Desulfotomaculum, Desulfolobus, Desulfobacter, Desulfococus, Desulfosarcina. These
fastidious microorganisms can be found in environments such as freshwater and salt marshes or in the
human body, mainly in the intestinal microbiota, where the species Desulfovibrio desulfuricans is frequently
detected.
Procedure:
▪ The SRB test kit comes in a pack size of 10 slides / tests per box.
▪ Add 2ml of the test sample to the tube

. ▪ Incubate the SRB test / dip slide at 30 degrees Celsius for up to 5 days. Check the test daily for the first
three days.
▪ If there is no colour change after 5 days, this indicates a negative result.
E-COLI TEST (FOR DRINKING WATER):

The detection of E. coli in drinking water indicates fecal contamination and therefore that fecal pathogens
may be present which can pose a health risk to consumers. Thus Ecoli test is done and if we find some
contamination then necessary successive steps are done.
Procedure:
▪ Take MacConkey broth (Nutrient)
▪ Take 5 vails for double strength (DS)solution for each sample.
▪ Take 10 vails for single strength (SS) solution for each sample.
▪ 1 control for D/S (minimum)
▪ 1 control for S/S (minimum)
▪ For DS vail take 10 ml of sample (drinking water).
▪ For SS vail take 1 ml,0.1 (drinking water) sample.
▪ After proper addition of sample in sterilized condition, keep the vails in incubator at 37°C and for 48
hours, study the release of gas for present, if not report as absent
If any gas form that indicates:
✓ The presence of E-coli (Durham tubes) will come up to the surface.
✓ Maintain proper asceptic condition that is to be cooled in laminar flow with UV lamp.
WET LAB:
ESTIMTION OF MOISTURE CONTENT IN LCC (LADLE COVERING
COMPOUND) BY DRYING OVEN METHOD.
Aim: To estimate the moisture in (LCC, TCC) samples using DRYING OVEN METHOD.
Apparatus: Oven, simple balance, crucible
Process description:
▪ Label the crucibles
▪ Record crucible weight
▪ Add sample of 20g and record sample weight (wet bases) (W1)
▪ Place the crucibles in drying oven for 1 hour at 100-200°C

▪ After defined time remove the crucibles and place in desiccators to cool (up to 30-60min)
▪ Note down the final weight (W2) when the sample attains constant weight.
Calculation:
% of moisture content = 𝑊1 − 𝑊2/ W ∗ 100
W1 – Initial weight of sample
W2 – Final weight of sample
DETERMINATION OF ALUMINIUM IN POLY ALUMINIUM

CHLORIDE SAMPLES:
Aim : Determination of aluminium as Al2O3 for Poly Aluminium Chloride samples.
Apparatus : Weighing balance, burettes, Volumetric flask
Chemicals Used :
1. Nitric Acid ( 1:12)
2. M/20 EDTA
3. Sodium Acetate Buffer Solution.
4. Xylenol Orange Indicator
5. Hydrochloric acid 6. M/50 Zinc solution
Procedure :
▪ Weigh accurately to the nearest 1 mg of Non -ferric sample ( for powder about 2.5 g & for liquid about 7
g) in a weighing bottle. Transfer it quantitatively to a 500 ml volumetric flask with aid of about 150 ml
water, dissolve by shaking & make up to mark.
▪ Pipette out accurately 20 ml of this solution to a 250 ml conical flask, add 2 ml of nitric acid (1:12) the pH
value shall be between 1-2 .Boil for 1 min, allow to cool & add 20 ml of M/20 EDTA solution exactly.
▪ Adjust pH to 3 with nitric acid or 10 percent sodium hydroxide solution using pH meter or thymol blue pH
test paper .Boil for about 2 min.
▪ Cool & add approx.10 ml sodium acetate buffer solution (pH of mixture should be 5.4-5.6 ,add 2-5 drops
of xylenol orange solution or add 30 -50 mg 1 percent (w/w) xylenol Orange mixture in potassium nitrate.
▪ Titrate the solution with M/50 Zinc solution until the colour of the solution changes from pale yellow to
pale red indicating reaching of end point . Note down the volume of zinc solution consumed during titration.
▪ In parallel, pipette out 20 ml M/20 EDTA ,add 2 ml of nitric acid (1:12) solution to a 250 ml conical flask,
add about 20 ml distilled water & proceed the test as described above for blank.

Calculation :
𝑨 = 127.45 × 𝑀1 (d − a)/ S
Where,
A - percent aluminum as Aluminium oxide

M1 - Molarity of standard zinc Solution
d - Litre of standard zinc solution used in blank determination
a - Litre of standard zinc solution used for sample solution in ml
S - Sample taken for test in grams
DETERMINATION OF PHOSPHATE CONTENT IN TRISODIUM PHOSPHATE

SAMPLE:
Aim : To determine phosphate Content in TRISODIUM PHOSPHATE SAMPLE.
Reagents :
• Standard hydrochloric acid – 0.1N
• Methyl orange indicator solution – 0.01gm in 100 ml of water

• Silver nitrate solution about 5%
• Benzyl alcohol
• Methyl red indicator solution – 0.15 g in 500 ml of water
• Standard sodium hydroxide solution – 0.1 N
Procedure :
▪ Weigh accurately about 2.5 gm of the material in case of anhydrous grade. And dissolve it in water . filter
off insolubles, if any, and make up the filtrate and the washings to 250 ml in a volumetric flask.
▪ Transfer 25 ml liquor of the solution to 250 ml beaker, add 1 drop of methyl Orange indicator titrate with
standard hydrochloric acid to light pink end Point
. ▪ Add sufficient sliver nitrate solution to precipitate all the phosphate. 2ml 0f Benzyl alcohol to coagulate
all the precipitate and 0.5 ml of methyl red Indicator. Titrate the liberated nitric acid with standard sodium
hydroxide Solution
▪ The end point shall be from red to yellow
Calculation :
𝑷𝒉𝒐𝒔𝒑𝒉𝒂𝒕𝒆 % 𝒃𝒚 𝒎𝒂𝒔𝒔 = Titre volume in ml ∗ 3.55 /M
M - Mass in grams of sample, weighed Initially

CO&CCP laboratory:
This department of Coke oven ensures that the raw material (coal) which is imported from Australia is fit for
processing.
Products, bi-products, waste products are analysed and certified.
This department is sub divided as follows:
• CO&CCP lab (Coke Oven& Coal Chemical lab)
• MBC lab (Mechanical Biological Chemical lab)
CO & CCP Lab:

As Indian coal is non coking coal and unfit for iron making. So, we import coal from Australia. Imported
coal can’t be processed directly. We need to test and certify the coal as per the required norms, this
certification is done in the lab. There are some by - products which we can recover in the processes of coal
to coke (destructive distillation). This lab performs the test on the by-products which are recovered and
certifies them.
We have a heat recovering system in the coke oven by which waste heat is recovered from coke while
cooling. This heat is used to lift the water to steam and runs the turbine to produce electricity. The water
evaporated should not contain any minerals & pH should be in control, the water is being tested in this lab.
Test done for coal & coal chemicals:

➢ Ultimate analysis of coal
➢ Calorific value of coal
➢ Volatile matter.
➢ Moisture content
➢ Ash content
➢ Fixed carbon percentage
➢ Composition analysis of CO gas
➢ Benzol recovery
➢ Solar oil analysis
Test done of water:

➢ Silicon test
➢ Phosphate test
➢ pH
➢ conductivity
DETERMINATION OF SILICON CONTENT :

Aim : To determine the silica content in Drum samples.
Chemicals Used :
1. 5% Ammonium Molybdate 2. 5% Oxalic acid 3. 2:21 Metol

Procedure :
▪ Take 25 ml volume of sample in test tube
▪ Now add 5% Ammonium Molybdate of 1 ml then green colour develops, wait for 5 minutes
▪ Add 2 ml of 5% Oxalic acid & 1 ml of metol, allow it to settle for 15 minutes & then check the
concentration of samples in spectrophotometer.
Calculation :
Silica content = Factor × absorbance
✓ Factor to determine silica content is 2. 79
DETERMINATION OF PHOSPHATE CONTENT:

Aim : To determine phosphateContent
Chemicals Used :
1. 2% Citric acid
2. 5 % Ammonium Molybdate
3. 2:12 Metol
Procedure :
▪ Take 5 ml of sample in test tube
▪ Now add 1 ml of 2% Citric acid

▪ Now add 1 ml of metol and 1 ml of 5 % Ammonium Molybdate
▪ Then add 17 ml of DM water and shake it properly, we get sea blue colour Then, get the corresponding
values of absorbance from spectrophotometer at 728 nm wavelength and calculate the phosphate content .
Calculation :
Phosphate Content = Factor × absorbance
MBC laboratory:
Coking of coal involves high temperature (nearly 1200°C) at this temperature the volatile matter
present in the coal is evaporated as coke Oven gas. This gas temperature is up to 600°C, so we need to cool
it. We provide a direct contact of CO gas to ammonia water. Ammonia is taken by CO gas and tar and water
is get settled down. The water is treated before disposal into the sea in MBC treatment plant. This treatment
involves in reduction of tar, phenols, rhodanides, ammonical nitrogen etc. The water is certified in this lab
before disposal into the sea.

Test done for water:
➢ pH
➢ Ammonical Nitrogen
➢ Phenols
➢ Rhodanides
➢ Ammonia test Phosphorus test
➢ COD (Chemical Oxygen Demand)
➢ BOD (Biological Oxygen Demand)
➢ DO (Dissolved Oxygen)
DETERMINATION OF PHENOLS:
Aim : To determine phenol content in samples of water in coke oven department .
Chemicals Used :
1. Ammonia buffer
2. Amino Anti – pyrine
3. Potassium Ferric Cyanide
Procedure :
▪ Take 5 ml of sample in volumetric flask and for some samples like P1,P2 are taken 2ml due to higher
phenol concentration in those samples.
▪ Then add 2 ml of Ammonia buffer, 2 ml of 2% Amino Anti – Pyrine ,2 ml of 8% Potassium Ferric
Cyanide.
▪ Make up with DM water and shake them well.
▪ The absorbance of sample is determined by spectrophotometer, against blank.
Calculation :
For 2 ml sample, Phenol (ppm) = 50 × absorbance × k-factor.
For 5 ml sample, Phenol (ppm) = 1000 × absorbance × k- factor
DETERMINATION OF RHODANIDES:
Aim : To determine Rhodanides [ SCN ] Content
Chemicals Used :
1. Zinc sulphate
2. Zinc chloride
3. 1 % Sodium Hydroxide

4. Nitric Acid ( 4 N )
5. Ferric Nitrate
Procedure :
▪ 50 ml of sample is taken in 250 ml volumetric flask.
▪ 1 ml of ZnSO4 & 1 ml of 1% NaOH solution are added.
▪ The solution is thoroughly shaked & made up to 250 ml with. Again shaked and kept for 5 minutes stand
by.
▪ The samples are filtered using filter paper & 50 ml of filtered sample is taken in 100 ml conical flask.
▪ 1 ml of 4N Nitric Acid & 2 ml of ferric nitrate solutions are added & absorbance of the sample is taken at
wavelength for Rhodanides using blank as reference.
Calculation :
𝑨𝒎𝒐𝒖𝒏𝒕 𝒐𝒇 𝑹𝒉𝒐𝒅𝒐𝒏𝒊𝒅𝒆𝒔 = 250 S × Absorbance × k – factor
S - Volume of sample
✓ K-factor to determine Rhodanides is 9.98
DETERMINATION OF PHOSPHORUS:
Aim : To determine phosphorus Content in samples.
Chemicals Used :
Stannous Chloride : 2.5 g of SnCl2 is taken in 25 ml concentrated HCl & boiled in water bath until SnCl2
dissolves completely (Clear solution). The remaining solution is made to 50 ml in volumetric flask. ( OR )
0.1 g of Tin metal is added to 2 ml HCl & 1 drop of 5% CuSO4 is added . The mixture is heated in water
bath till complete dissolution . The solution is cooled & diluted to 10 ml with DM water.
Ammonium Molybdate : 10 % Ammonium Molybdate – Solution – 1
50 % Sulphuric Acid – Solution – 2
Both solutions mixed in 1:3 ratio.

50 % Sulphuric Acid – Solution – 2 Both solutions mixed in 1:3 ratio.
Procedure :
▪ 2 ml of sample is taken in 100 ml volumetric flask
▪ 2 ml of Ammonium Molybdate & 6 to 8 drops of Stannous Chloride are used.

▪ The solution was made to mark with DM water & absorbance was taken against blank ( DM water )

Calculation :
𝑷𝒉𝒐𝒔𝒑𝒉𝒐𝒓𝒐𝒖𝒔 𝑪𝒐𝒏𝒕𝒆𝒏𝒕 = 100 S × absorbance × k – factor
TPP&CPP LAB :
TPP laboratory (Thermal power plant):
This is the major source of electricity in steel plant, which can produce more than 315 MWe of electricity.
This power plant has 6 boiler, each boiler takes 125m3 /hr of demineralized water. The water is imported
from KBR (Kaniti Balancing Reservoir). The water taken from KBR is rich in salts and silicates which is
unwanted thing. So, we need to demineralize the water. DM water is tested and certified by this lab. This
power plant use boiler coal as a fuel, so they test the coal before burning it.
Test done for boiler coal:

➢ Ash content
➢ Calorific value
➢ Moisture content
➢ Fixed carbon percentage
➢ Gas chromatography of flue gas
CPP laboratory (Captive power plant):

This is an alternative power plant which was introduced recently, have a capacity of 180 MWe. This power
uses blast furnace and coke oven gas as the fuel in the boiler. This power plant uses total wastewater which
is generated in the steel plant. This power plant has a special water demineralization plant in which the water
first goes through ultrafiltration-RO filtration-then to demineralization.
Tests done for DM water are same in both the labs .

They are :
➢ P-alkalinity
➢ M-alkalinity
➢ Total hardness
➢ Calcium hardness
➢ Magnesium hardness
➢ Chloride estimation
➢ Silicon test
➢ Phosphate’s test
➢ SO4 test
DETERMINATION OF P & M ALKALINITY:

Aim : To determine P & M Alkalinity.
Reagents Used :
1. Standard H2SO4 0.02 N
2. Phenolphthalein Indicator
3. Methyl Orange Indicator
Procedure :
▪ Take 25 (or) 50 ml sample in conical flask & add 2- 3 drops of phenolphthalein Indicator.
▪ If pink colour develops titrate with 0.02 N H2SO4 till the pink colour disappears .If pH is 8.3 ,then note
the volume of H2SO4 required (A)
▪ Add 2-3 drops of Methyl Orange indicator to the same flask & continue titration, note the value of
Sulphuric acid used(B) till pH falls to 4.5 (or) Orange yellow colour change to Orange Red.
▪ In case , pink colour does not appear addition of phenolphthalein continue to do test for M- Alkalinity
▪ Calculate total ‘M’ &' P ' Alkalinity as follows & express in mg & CaCO3 / litre
Calculation :
𝑷 − 𝑨𝒍𝒌𝒂𝒍𝒊𝒏𝒊𝒕𝒚 = A × 1000/ ml of sample
𝑴 − 𝑨𝒍𝒌𝒂𝒍𝒊𝒏𝒊𝒕𝒚 = B × 1000/ ml of sample
𝑻𝒐𝒕𝒂𝒍 𝑨𝒍𝒌𝒂𝒍𝒊𝒏𝒊𝒕𝒚 = (A + B) × 1000 /ml of sample
DETERMINATION OF SILICON CONTENT:

Aim : To determine the silica content in MCR samples, DM WATER Sample
Chemicals Used :
1. 5% Ammonium Molybdate
2. 5% Oxalic acid 3. 2:21 Metol
Procedure :
▪ Take 100 ml volume of sample in test tube .
▪ Now add 5% Ammonium Molybdate of 4 ml then green colour develops ,wait for 5 minutes.
▪ Add 4 ml of 5% Oxalic acid only in drum samples in order to neutralize phosphate content & 1 ml of metol
,allow it to settle for 15 minutes & then check the concentration of samples in spectrophotometer at
wavelength of 90 nm.
Calculation : Silica content = Factor × absorbance

✓ Factor to determine silica content is 2. 79
DETERMINATION OF SULPHATE CONTENT :

Aim : To determine sulphate content of UT Inlet, RCPH sample, Make Up water, Clarified & SBA Sample
in TPP Lab.
Chemicals Used : 1. Conditioning agent 2. Barium Chloride powder

Procedure :
▪ Take 25 ml of sample & dilute it to 4 times i.e., make up to 100 ml
▪ Then take this sample into test tube up to marked level on rest tube
▪ Now add 1 ml of Conditioning agent & pinch of Barium Chloride powder such white colour develops.
▪ Now, Check the concentration of sulphate in samples & note down the corresponding values at 83-85 nm
of wavelength using HACH meter on which the values are displayed on screen.
DETERMINATION OF AMMONIA CONTENT :

Aim : To determine Ammonia Content in CEP sample
Chemicals Used : 1. Sodium Potassium Tatrate
2. Nesler’s Reagent
Procedure :
▪ Take 50 ml of CEP sample in conical flask.
▪ Then add 3 ml of Sodium Potassium Tatrate and 1 ml of Nesler’s reagent to sample.

▪ Then, note the NH3 concentration using HACH meter at 31 nm wavelength & note the corresponding
values.
DETERMINATION OF HYDRAZINE CONTENT :

Aim : To determine Hydrazine Content in feed samples.
Chemicals Used :
1. 1:9 HCl
2. Dimab
Procedure :
▪ Take 50 ml of feed sample in conical flask
▪ Then add 2 ml of 1:9 HCl & 2 ml of DIMAB ( Di Methyl – Amino Benzaldehyde ) reagent to sample.
▪ Note the Hydrazine ( N2H4 ) Concentration using HACH meter at 31 nm wavelength and note the
corresponding values.
✓ The phosphate content procedure is same as we do in CO & CPP lab and the test for hardness is
same as in water lab.

S OF
RAW WATER
Parameter Make Up water Clarifier pH-4
pH 7.5 – 9. 0 8.0 – 8.5 9.0
Conductivity (μS/cm ) 200-350 200-350 600- 1200
Turbidity (NTU) 10-25 <10 < 100
P-Alkalini Nil Nil nil
M- Alkalinity 90-140 100-150 200-300
Ca Hardness 40-60 40-60 200-240
Mg Hardness 50-60 50-60 200-300
Total Hardness 90-120 90-120
Chlorides 16-20 16-20 60-80
Sulphate 15-30 30-60 60-120
✓ The Norms for every parameter should be maintained such that when they are disposed out there are environmental
friendly and doesn’t harm any aquatic life
✓ In the same way the norms for Drinking water are to be maintained such that as we consume it be would healthy &
doesn’t harm health of man kind.
✓ This is the importance of QA & TD department in handling the materials or substances in eco- friendly way..
Mr.S.MuraliKrishna
Sr.Manager (QATD)

THERMAL POWER PLANT

Mr. SABYASACHI PANI
GM (TPP) I/C
DM PLANT
Vizag steel plant power station is a 315 megawatt captive coal plant. In Andhrapradesh the power plant has
120 megawatts of gas fired capacity. It fuels the vizag steel plant.
Demineralized water plant:
Demineralisation is the process of removing mineral salts from water by using the ion exchange process.
Demineralization water is water completely free or almost of dissolved minerals as a result of thr following
process:
1 .distillation
2 .deionization (ion exchange process)
3. Membrane filtration (reverse osmosis)
Demineralised water also known as deionisation water, water that has mineral ions are removed. Mineral
ions such as cations of sodium, calcium, iron, copper,and anions such as chlorides, sulphides, nitrates, are
common ions present in water. Deionisation is a physical process which was specially manufacturing ion
exchange site for the replacement of the mineral salts in water, with water forming h+ and oh- ions because
the majority of water impurities and dissolved salts, deionization process and high purity water is generally
similar to distilled water and this process is quick and without scales build-up. Demineralisation technology
is the proren process for treatment of water. Dm water produces mineral free water by operating on the
principle of ion exchange degasification and polishing demineraliser water system.
In thermal power plant boilers produces steam used to produce electricity.
Chemicals used in dm plant:
Hydrochloric acid, sodium hydroxide, alum, coagulant, polyelectrolyte, chlorine.

WATER DEMINERALIZATION PLANT

• ALUM <120 m3/hr,
• POLYELECTROLITE
• CHLORINE <1.5kg/cm2
KANITHI BALANCEING Activated

Clarifloc Horizontal
RESERVIOR < 140 m3/ hr,
Pressure carbon
ullator < 2 kg/cm2
filter
Filter
PH-1
< 125 m3/hr,

< 125 m3/hr,
< 1.5kg/cm2
< 1.5kg/cm2
< 125 m3/hr,
< 1.5kg/cm2
deaerator
Cation
Exchanger Anion
D.M Tank
Exchanger
Mixed Bed
Exchanger
< 300 m3/h

Degasser
< 1.5kg/cm2
➢OLD DM PLANT
➢ NEW DM PLANT (EXPANSION)
➢CAPTIVE POWER PLANT (CPP)
1. OLD DM PLANT:-
PROCESS DESCRIPTION:
Raw water from Godavari river is stored in Kanithi Balancing Reservoir (KBR) for 40-50 days.
From KBR the Raw water is sent to the pump house-1
From pump house-1 the water is sent to flash mixer. In flash mixer we add chemicals.
The chemicals used in flash mixer are:

(A) Alum: It is used to remove turbidity.
(B) Chlorine: It is added to remove bacteria present in water. (c)
Poly electrolyte: It is used as coagulant and to remove unwanted and
dissolved particles.

• From flash mixer the water is sent to clariflocculator. In clariflocculator the sludge and
clarified water is separated.
• Then the sludge is removed by draining. Clarified water is stored in clarified water storage
tank.
• Then
tank.
the sludge is removed by draining. Clarified water is stored in clarified water storage
• By using clarified pumps the water is sent to the pressure sand filters.
• In pressure sand filters, turbidity and dirt particles will be removed.
• Then the water is sent to the activated carbon filter. In ACF, free chlorine and traces of oil
&greeze will be removed.
• Then the water is sent to the cation exchanger. In cation exchanger remove all the captions
present in the water.
• Then the water is sent to the De-Gassers. In DG CO2 will be removed.

• Then the water is sent to DG storage tank.

FLOWSHEET OF DM PLANT
KBR (RAW WATER)
↓
PUMP HOUSE -01
↓
FLASH MIXER (ALUM, CHLORINE, POLYELECTROLYTE)
↓
CLARIFLOCCULATORS
↓
BY USING CLARIFIED PUMPS WATER IS TRANSFERRED INTO PRESSURE SAND
FILLTERS
↓
PRESSURE SAND FILTERS (TO REMOVE TURBIDITY)
↓
ACTIVATED CARBON FILTER (TO REMOVE CHLORINE)
↓
CATION EXCHANGER (TO REMOVE CARBONATES)
↓
DEGASSER (TO REMOVE CO2)
↓
ANION EXCHANGER (TO REMOVE BICARBONATES)
↓
MIXED BED (TO REMOVE SPILLAGES OF CATIONS AND ANIONS)
↓
DM WATER STORAGE TANK
↓
DEAERATORS (TO REMOVE OXYGEN)
↓
DEAREATOR STORAGE TANK
↓
BOILERS (NH3 TO BOOST UO PH)
FLASH MIXER
A rapid (or flash) mixer is used to uniformly disperse and blend chemicals, such as coagulant aids, chlorine,
and sulphur dioxide, into the process stream. These chemicals, either in solution or slurry form, are added
for the purpose of neutralization, odor&color control, and/or to aid in the removal of solids. Flash Mixers or
Rapid Mixers Mechanism are widely used in all Industrial, water & Waste Water Application for rapidly and
uniformly dispersing Coagulant all over the tank liquid. Usually slow to medium speed impellors are
designed for optimum power consumption for maintaining turbulent stage of liquid. Baffled tanks are
preferred and give better results for large size of flash mixers.
CLARIFLOCCULATOR
Clariflocculator is a combined flocculator and clarifier in which floc formation and its subsequent removal
by sedimentation occur. It has two concentric tanks where the inner tank serves as a flocculation basin and
the outer tank serves as a clarifier. In the Clariflocculator, the water enters the flocculator, where the

flocculating paddles enhance flocculation of the feed solids. As heavy particles settle to the bottom, the
liquid flows radially upward in the clarifier zone,. The clarified liquid is discharged over a peripheral weir
into the peripheral launder.
PRESSURE SAND FILTER
These filters are the most popular method for removal of turbidity from water. The Pressure Sand Filter
consists of a multiple layer of sand with a variety in size and specific gravity. These Filters are designed to
remove turbidity and suspended particles present in the feed water with minimum pressure drop. These
Filters are custom designed to suit the process requirement.
ACTIVATED CARBON FILTER
Activated carbon filters are generally employed in the process of removing organic compounds and/or
extracting free chlorine from water, thereby making the water suitable for discharge or use in manufacturing
processes.

DEGASSER
Degasser is an essential part of any Demineralization Plant (DM), where it removes dissolved carbon
dioxide (CO2) in order to reduce the load on anion exchanger that further maximizes regeneration
frequency. Degasser towers used in this process are made of FRP or Mild Steel or rubber lined coatings.
ION EXCHANGE PROCESS
Ion exchange systems are used for efficient removal of dissolved ions from water. Ion
exchangers exchange one ion for another, hold it temporarily, and then release it to a regenerate
solution. In an ion exchange system, undesirable ions in the water supply are replaced with more
acceptable ions .Ion exchange is the process through which ions in a solution are transformed into a solid
which releases ions of a different type but of the same polarity. This means that the ions in solutions are
replaced by different ions originally present in the solid. Ion exchange is a chemical reaction in which free
mobile ions of a solid, the ion exchanger, are exchanged for different ions of similar charge in solution. The
exchanger must have an open network structure, either organic or inorganic, which carries the ions and which
allows ions to pass through it.

IN SOME DM PLANTS ULTRAFILTRATION AND REVERSE OSMOSIS ARE ALSO USED.
ULTRAFILTRATION
Ultrafiltration (UF) is a water purification process in which water is forced through a semi
permeable membrane. Suspended solids and high-molecular-weight solutes remain on one side of the
membrane, the retentate side, while water and low-molecular-weight solutes filter through the membrane to
the permeate side.
REVERSE OSMOSIS
Reverse osmosis (RO) is a water purification process that removes ions, unwanted molecules and larger
particles from drinking water using a partially permeable membrane. As a result, the solute is kept on the
membrane's pressurised side and the pure solvent is allowed to pass to the other side. Reverse Osmosis (RO)
works by reversing the principle of osmosis, the natural tendency of water with dissolved salts to flow through a
membrane from lower to higher salt concentration. This process is found throughout nature. Plants use it to absorb
water and nutrients from the soil.
V.MADHUSUDHAN
DGM, TPP

WATER MANAGEMENT DEPARTMENT

KBR (KANITHI BALANCING RESERVIOUR)
Raw water to Visakhapatnam Steel plant by Visakhapatnam Industrial Water Supply Company Limited
(VIWSCO) on chargeable basis and is supplied from Yelaswaram Reservior (located in East Godavari
District at about 153km from Steel plant) and/or River Godavari (located in East Godavari near Rajamundry
at about 200km from steel plant). The water from Yeleswaram reserviour is supplied through an open
Yeluru canal and water from Pump house on River Godavari travels in a pipeline of 55km in length and
joins into Yeluru Canal at about 2km from Yeleswaram reserviour. The raw water from the canal flows to
Visakhapatnam Steel plant reserviour I.E. Kanithi Balancing reserviour (KBR). Before entering into KBR,
raw water flows through a parshall flume structure where rate of water flow is measured in million gallons
per day (MGD). Last Year One More Reserviour i.e. a new reserviour came into existence for additional
storage of raw for steel plant and named as LBR-2. ,first one being as KBR=01. The main supply canal is
extended to supply raw water to KBR-2 with a new parshall flume to measure the rate of flow of water
entering into KBR-2. Both reservoirs are independent rate of flow measurement at its parshall flume.
KBR-1(spread over 300 hectares) is divided into two compartments (Eastern compartment
& Western compartment) and raw water from the canal is taken to single is taken to single compartment and
/or both the compartments. Raw water enters into KBR-1 from its north side and its intake pump house(ph-
1) and first group (installed 5no pumps) supplies raw water to plant (to RWTP located inside the plant about
5.5 km from ph1. Through 3 no of pumps 1200 dia PSC underground pipes and second group at pump house
sends raw water to 18MLD treatment plant. Raw water from KBR-1 can be drawn from individual
compartment. Raw water from KBR-1 enters into pump house through travelling water screens and the first
water chamber is called Pumping pit which sends water into next pit called Gravity pit. From Gravity pit raw
water flows by gravity to RAW WATER TREATMENT PLANT(RWTP). First group pumps are operated
when reserviour level is less than around 19 meters else water flows by gravity. There is no flow
measurement arrangement at IPH to measure the flows to RWTP. The second group of pumps 3no at IPH
pumps raw water to 18MLD plant through one underground CI pipe and MS over ground pipe. There are
small pumps to recover seepage water from reserviour flowing in the toe drain and this water is pumped
back to eastern compartment.

18 MLD WATER TREATMENT PLANT

It receives raw water through the two (CI & MS) pipes from IPH of kbr-1 and treats it to make drinking
water. Raw water is received into cascade areator. From the aerator water flows to clariflocculator where
coagulant (ferric alum) solution dosed. The clarified water (overflow) flow to 4no of gravity sand filters
(having different grades of gravel & sand as filter media). The filtered is water is storage in two storage
reservoirs namely on ground reservoirs (OGR) i.e. OGR 1 &2. The capacity of OGR- 1 is 800m3 & ogr-2 is
2750 m3. For disinfection of water, sodium hypo chloride generated from electro-chlorinator or commercial
grade hypo or bleaching powder solution is used. Ogr-1 supplies drinking water to stage-1 pump house and
Ogr-2 supplies drinking water to stage-2 pump house. Stage-1 pump house pumps water through
underground pipe network to service reservoirs-1 (sr-1) located near UKKU club from where drinking water
is distributed to residences of sectors -1,4,5,6,7 & CISF colony. Stage-2 pump house pumps water to service
reservoir-2 (sr-2) from where drinking water is distributed to residences in sector-8,9,10,11. Drinking water
from stage-2 pump house is distributed to residences in sector-12. Stage-2 pumps drinking water to service
reservoir-3(sr-3) which distributes drinking water to residences at sector -2&3. These service reservoirs are
overhead tanks (OHTs) the drain (sludge water) of clariflocculator ,filters back washed waste water and any
gland leak water in the stage -1&2 pump house are sent to a sludge pit and after separation, the water is
pumped back to clariflocculator.
YELESWARAM RESERVOIR
↓
KBR
↓
AERATOR
↓
CLARIFLOCCULATOR
↓
GRAVITY SAND FILTERS
↓
ON GROUND RESERVOIR
↓
STAGE 1&2 PUMPS
↓
SERVICE RESERVOIRS
↓
STEEL PLANT SECTORS
18 MLD DRINKING WATER TREATMENT PLANT DIAGRAM
9MLD WATER TREATMENT PLANT

. SEWAGE WATER
(FROM SECTORS, GENERAL HOSPITAL, CLUBS, SHOPPING COMPLEXES, TRAINING CENTRE,
HRD OFFICE,CISF BARRACKS, GUEST HOUSES, RESIDENCES,ETC)
↓
9MLD WATER TREATMENT PLANT

↓
AERATORS
↓
CLARIFIER
↓
ULTRAFILTRATION PLANT

It receives sewage water from (i.e from kitchen, toilet , bathroom) generated in the township areas
(i.e residences, shopping complexes, general hospital, clubs, schools, restaurants, main administration
building, technical training institute, HRD centre, CISF barracks, guest houses, town administration
department, agro forestry department etc). Sewage is pumped from its raw sewage sump to 4no of aerators.
From the aerators the water flows to clarifier. The clean water from the clarifier and after disinfection by
commercial grade sodium hypo chloride flows to balancing tank for onward pumping of this secondary
treated sewage water to ultra filtration plant. UF is located inside the plant at RWTP zone and about 4kms
from 0mld. At UF the secondary treatment sewage water is further treated to be used in recirculating water
systems
9 MLD SEWAGE WATER TREATMENT PLANT FLOWSHEET
PUMP HOUSE-1
RAW WATER TREATMENT PLANT
Raw water from kanithi balancing reservoir is taken via raw water treatment plant to makeup water
sump after treatment in RWTP. This water is called makeup water. Makeup water is supplied to various
pump houses to makeup for the various losses in recirculating system or consumption of consumer end like
water for cleaning, flushing, spraying. The total holding capacity of makeup water sump is 1900m3. Water
from main sump enters the individual sumps through bar screen to screen out the grass, weeds, etc. There are
two main lines of dia 120mm going one on each side of the plant plaza road. There are four butterfly valves
in the main header in the pump house. These can be used to isolate two sumps at a time during shut down.
8 nosof makeup water pumps and ventilation system are the units that are available in pump house 1.
INTRODUCTION
The drinking water and fire fighting water for pump house no-24(for administration building, training
centre, project office, CISF) and for plant (except TPP, COCCCP, RMHP, sinter plant zones where F&D
water is being supplied from Pump house-28) is supplied from Pump house no-2. The water for drinking and
fire fighting purposes is distributed throughout the plant by underground pipeline networks. Same water is
used for both drinking and fire fighting purposes.
RWTP FLOWSHEET
In Pump house no-2 following equipments are available :

1.six no of treated (fire and drinking)water pumps(two pumps no.6&1 for supply to pump house-24 and four
pumps no:2,3,4,5 for F&D water purposes with interconnection between their headers).
2. One of electrical fire fighting pump and two numbers of diesel fire fighting pumps.
3. Eight no of pressure filters.
4. Two no of air blowers for air scoring of filters.
5. Bleaching powder solution dosing system.
6. Diesel generator set.
7. Diesel dewatering pump
8. Backwash water pump.

9. Gas chlorination system.
PROCESS
Makeup water from pump house 1 is enters the raw water of mains ph-2 along the pressure filters. This raw
water passes through the filter beds of the pressure filters. The filtered water then goes on ground reservoir
through filtered water main. Bleaching powder solution is injected into this filtered water main for
chlorination of drinking water. Water from OGRs are pumped by PH-2 pumps to overhead tank for
distribution.
These are six treated water pumps in PH-2 which pump OGR water to the overhead tank at 30m level. below
this OHT at ground level chlorine solution is added into the two uptakes pipeline for the purpose of
chlorination of drinking water before it is let into overhead tank out of six maximum four treated water
pumps run at a time. This is due to limitations of electrical panel and cable load carrying capacity.
The bleaching solution pump house there is an MSRL tank over which an agitator is installed. This is for
preparation and storage of bleaching powder solution.
HAZARDS AND PRECAUTIONS
1 .Bleaching powder reacts and evolves chlorine gas which is highly toxic.
2. Use PPEs live PVC, apron, gum boots, eye protector, safety helmet, gloves, and nose mask.
3. Use proper ventilation while preparing solution. Door and windows of the room must be kept opened.
RUNNING EQUIPMENTS
Ensure coupling guards before starting the equipment.
PUMP HOUSE 18
Uses of Water in a Coke Oven:
Water plays a crucial role in several keyprocesses within a coke
oven, including:
Quenching: This is the most significant use of water in a coke oven. After
the coking process is complete, the hot coke needs to be rapidly cooled to prevent
combustion and ensure its quality. This is achieved by quenchingthe coke with large
quantities of water.
Gas cooling and condensation: The hot gases produced during the coking
process contain valuable byproducts, such as tar and ammonia. Water is used to cool and
condensethese gases, allowing for the recovery and separation of the byproducts.
Steam generation: Steam is crucial for various processes in a coke plant, including
driving turbines, heating equipment, and stripping ammonia from coke oven gas. Water is
used to generate steam in boilers.
Equipment cooling: The high temperaturesinvolved in the coking process necessitate

continuous cooling of various equipment likepumps, compressors, and tuyères. Water is
circulated around these components to maintaintheir temperature and prevent overheating.
Dust suppression: The coking process generates a significant amount of dust, which can
be harmful to the environment and workers'health. Water sprays are used to suppress dust
emissions and improve air quality.
Cleaning: Water is used for various cleaning purposes within the coke plant, such as
washingcoke ovens, gas pipelines, and equipment.
Hydraulic systems: Some coke plants utilizehydraulic systems for operating specific equipment. Water is
used as the hydraulic fluid in these systems.
RO PLANT
CHEMICALS USED IN RO PLANT
1. PAC→POLY ALUMINIUM CHLORIDE
USES: To treat slurry particles forms small particles to large particles. Depend on the quantity of TSS, PAC
is supplied.
2. PE→POLYELECTROLYTE
USES: to create gravity to large particles formed by PAC and settle down
3. SMBS→SODIUM META BISULPHATE
USES: Antiscalant, Remove Chlorine, To Control TSS &TDS Below 100, Inhibit Fungal Growth And
Aerobic Bacteria On Ro Membranes When Used As A Preservative Solution.
4. HCL→HYDROCHLORIC ACID
USES :To Maintain PH And Conductivity
5.NAOH→SODIUM HYDROXIDE
USES: To Raise The PH Level Of The Water
6.EDTA→ETHYLENE DIAMENE TETRA ACETIC ACID

USES: To maintain ph and used as a cleaning powder for membrane filters.
7. CL→CHLORINE
USES:To kill bacteria.
8.AKALI
USES: To provide alkalinity and to maintain PH.
9.CITRIC ACID
USES: Used as a cleaning solution for membrane filters, descaling heat transfer surfaces in heat exchanger
and to maintain/ control PH
10. SLS→SODIUM LAURYL SULPHATE
USES: It is alkali substance

PROCESS DESCRIPTION
From the effluent treatment plant (ETP), the effluent water is send into ESTPS estimating sewage transfer
pumping station. Then the water is send into flash mixer. In the flash mixer, add poly aluminium chloride , it
works as a coagulant to extract and clump together contaminants, collodial and suspended matter. And then
the water is sent into the clarifier. In the clarifier, add polyelectrolyte for blending suspended solids in
wastewater and allowing them to settle. And then the water is sent into chlorine contact tank which we add
chlorine to kill bacteria and some other impurities. And then the water is sent into pressurized sand filters to
remove turbidity and suspended particles present in the feed water with minimum pressure drop. Then the
water is sent into activated carbon filter to remove chlorine which we add in the chlorine contact tank and
removing organic compounds and extracting free chlorine from water. Then it is sent into ultra filter feed
tanks for storage and then it is sent into ultra filtration skids to remove essentially all collodial particles from
water and some of the largest dissolved contaminants. And then it is sent into ro membranes to remove a
large majority of contaminants from water by pushing the water under pressure through a semi-permeable
membrane and last it is sent into permeate tank.
FLOWSHEET OF RO PLANT
ETP (EFFLUENT TREATMENT PLANT)
ESTPS (ESTIMATING SEWAGE TRANSFER PUMPING STATION)
FLASH MIXER TANK
CLARIFIER
CHLORINE CONTACT TANK
PRESSURIZED SAND FILTER
ACTIVATED CARBON FILTER
ULTRA FILTER FEED TANK
UF MEMBRANES/SKIDS
RO FEED TANK
RO MEMBRANES
PERMEATE TANK

EFFLUENT TREATMENT PLANT
Effluent Treatment Plant Procedure:
An effluent treatment plant (ETP) utilizes various processes to remove contaminants and
pollutants from wastewater, transforming it into cleaner water suitable for discharge or
reuse. Here's a generalprocedure followed in most ETPs

1. Pretreatment:
• Screening: This stage removes large objects like rags,sticks, and debris using
bar screens and grinders.
• Equalization: The wastewater flow is balanced to
ensure consistent treatment throughout the plant.
• Oil and grease removal: Oil and grease are separatedfrom the wastewater using
gravity separators or skimmers.
2. Primary Treatment:
• Sedimentation: The wastewater is allowed to settle inlarge tanks, allowing
heavier solids to sink to the bottom as sludge.
• Clarification: The remaining liquid is clarified using specialized equipment
like lamella settlers or dissolvedair flotation (DAF) units to remove additional
suspended solids.
3. Secondary Treatment:
• Biological treatment: Microorganisms like bacteria areused to decompose
organic matter in the wastewater. This can be done in various ways, including
activated sludge processes, trickling filters, and rotating biological contactors.
• Aeration: Air is pumped into the wastewater to provideoxygen for the
microorganisms.
• Secondary sedimentation: After biological treatment,the wastewater settles
again to remove the formed biological sludge.
4. Tertiary Treatment (Optional):
• Disinfection: This step eliminates harmful bacteria andviruses using methods
like chlorine disinfection, ultraviolet (UV) radiation, or ozonation.
• Filtration: Filtration through sand filters or membrane filters further removes
any remaining suspended solids.
• Advanced treatment: Depending on the desired water
quality, additional treatment processes like reverse osmosis or ion exchange
can be employed to removespecific contaminants.
5. Sludge Treatment:
• Thickening: The sludge removed from the variousstages is thickened
using gravity thickeners or centrifuges to reduce its volume.
• Digestion: Anaerobic digestion decomposes organic matter in the sludge,
reducing its volume and producingbiogas.

SMS (STEEL MELT SHOP)

COOLING TOWERS
COOLING TOWERS: cooling tower is a specialized heat exchanger to which air and water are brought
into direct contact with each other to reduce the water temperature. It is an arrangement of technologies that
remove damaging impurities from your cooling tower feed water, circulation and blow down. Cooling tower
treatment involves using select filtration technologies and chemical products in order to remove toxic or
otherwise damaging impurities from your cooling tower system. Proper water treatment in cooling system to
minimise the risk of corrosion, scaling, and microbiological build up. A water cooling tower is used to cool
water, expelling building heat into the atmosphere and returning colder water to the chiller. A water cooling
tower receives warm water from a chiller. This warm water is known as condenser water because it gets heat
in the condenser of the chiller. Heat is transferred from hot water into the cooling water through an
fan/agitator. The evaporation of a small percentage of this cooling water in a cooling tower, then reduces the
temperature of the cooling water, allowing it to be used for cooling again.
TYPES OF COOLING TOWERS
1. NATURAL DRAFT
2. MECHANICAL DRAFT
 INDUCED DRAFT
 FORCED DRAFT
1. NATURAL DRAFT COOLING TOWER: It is an open, direct contact system. It works using a
heat exchanger, allowing hot water from the system to be cooled through direct contact with fresh
air. No fans are used since it works on natural convection process.
2. INDUCED DRAFT COOLING TOWER: Induced draft implies on inlet fan placed on the top of
the cooling tower and creation of low pressure. Axial flow are always used in this type of draft. In
induced draft cooling tower, air is given both sides of cooling tower as the dried air enters the
cooling tower gets contact with water.
3. FORCED DRAFT COOLING TOWER: Forced draft means an exhaust fan forced at the base of
the cooling tower which then causes over pressure. The hot water from the particular department are
collected through long pipe are enters into the cooling tower, fans are located at the top of the tower.
NATURAL DRAFT COOLING TOWER

INDUCED DRAFT COOLING TOWER
FORCED DRAFT COOLING TOWER
STEEL MELT SHOP – LAB
Water plays a crucial role in the continuous castingprocess of steelmaking, serving

several essential functions:
1. Cooling:
• Mold cooling: Water jackets are used to circulatewater around the mold,
absorbing heat and preventing the molten steel from solidifying prematurely.
This ensures the formation of a strong and uniform shell around the strand.
• Spray cooling: As the strand exits the mold, it is immediately sprayed with
water to further cool the surface and control the solidification process.This
process significantly affects the final properties of the steel product.
• Secondary cooling: After the initial solidification,the strand continues to be
cooled with water sprays as it travels down the run out table. This process
ensures complete solidification and prevents internal defects.

2. Lubrication:
• Mold lubrication: Water is mixed with a lubricantto create a thin film on the
mold surface, reducing friction and preventing the molten steelfrom sticking.
This allows for smooth strand movement and prevents surface imperfections.
• Runout table lubrication: Water is used to lubricate the runout table, facilitating
the movement of the strand and minimizing wear andtear on equipment.
3. Descaling:
• High-pressure water jets: Water jets are used toremove scale (oxide layer)
from the surface of the strand before it enters the finishing mill. Thisprocess
ensures the quality of the final product and improves mill efficiency.
4. Hydraulics:
• Water is used to operate various hydraulic systems within the
continuous casting plant,including mold clamps, strand withdrawal
mechanisms, and tilting tables.
5. Dust suppression:
• Water sprays are used to suppress dust emissions generated during the
continuous casting process. This improves air quality in theplant and protects
workers' health.
6. Equipment cooling:
• Water is used to cool various equipment used in the continuous casting process,
such as pumps, compressors, and motors. This prevents overheating and ensures
the smooth operation ofthe plant.

PUMP HOUSE-6(BLAST FURNACE)

Water is used in the blast furnace to cool and fragment the slag, which is a byproductof the
process. To keep the refractory materials from burning out, plates, staves, or sprays for circulating
cool water are built into them 1. The slag can be cooled and fragmented using a granulation
process, in which molten slag is subjected to jet streams of water or air under pressure 12.
Alternatively, in the pelletization process, the liquid slag is partially cooled with water and
subsequently projected into the air bya rotating drum 2.
The process of liquid iron production in the blast furnace the flue gas is produced. The flue gas
contains iron particles. We use water tocapture the particles in flue gas. The pump house 6 water
is sprinkle on the B.F gas, the water is captured the particles in the gas.
Another use of the water in the blast furnace is cooling purpose. Water is pumped continuously.In
case the power is not coming the pumps are not worked, at that time over head emergency
tanks are used.
Uses of Water in a Blast FurnaceCooling:

• Furnace walls: Water jackets circulate water toabsorb heat and prevent
melting.
• Tuyeres: Water cools the air inlet pipes to
prevent warping.
• Hot blast: Water spray reduces the temperatureof the hot air entering the
furnace.
Granulation:
• Slag: High-pressure water jets solidify moltenslag, reducing dust and
improving handling.
• Dust suppression: Water sprays control dust
emissions and improve air quality.
Gas cleaning:
• Water scrubbers: Remove pollutants from fluegas to reduce air pollution.
Additional uses:
• Boiler feedwater: Generates steam for variousplant purposes.
• Equipment cooling: Cools pumps,
compressors, motors, and other machinery.
• Hydraulic systems: Operates variousmachinery within the
steel plant.

Importance:
• - Water is a crucial resource for efficient and safeblast furnace operation,

contributing to cooling, granulation, gas cleaning, and other essential
functions.
• The amount of water used varies based on furnace size, type, and
operating conditions.

Water jackets used in blast furnace
WATER JACKET

LAB ANALYSIS
Procedure for Measuring Total Hardness andCalcium
Hardness
Both total hardness and calcium hardness are commonly measured in water quality
assessments.Here are the procedures for each:
Total Hardness:
Materials:
• Water sample
• EDTA titrant (0.01 M)
• Eriochrome Black T indicator solution
• Burette
• Erlenmeyer flask (250 ml)
• Magnetic stirrer
• Stir bar
Procedure:
1. Prepare the sample:
o Pipette 50 ml of the water sample into theErlenmeyer flask.
o Add 2 ml of the indicator solution.
o Add a small amount of buffer solution (pH 10).
2. Titration:
o Fill the burette with EDTA titrant.
o Place the flask on the magnetic stirrer and startstirring.
o Slowly add the EDTA titrant dropwise whilecontinuously
stirring.
o The color of the solution will change from red toviolet to blueish-
grey as the endpoint is approached.
o Stop titrating when the color just turns blueish-grey.
3. Calculations:
o Record the volume of EDTA titrant used (V).
Calculate the total hardness as follows:Total
hardness (mg/L) = V * EDTA titrant concentration
(M) * 1000 / ml of sample
Calcium Hardness:
Materials:
• Water sample
• Calmagite indicator solution
• Calcium standard solution Ammonia-cyanide buffer solution
• Burette
• Erlenmeyer flask (250 ml)
• Magnetic stirrer
• Stir bar
Procedure:
1. Prepare the sample:
o Pipette 50 ml of the water sample into theErlenmeyer flask.
o Add 2 ml of the Calmagite indicator solution.
o Add 1 ml of the ammonia-cyanide buffer solution.
2. Titration:
o Fill the burette with calcium standard solution.
o Place the flask on the magnetic stirrer and startstirring.
o Slowly add the calcium standard solution dropwisewhile continuously
stirring.
o The color of the solution will change from red toblue as the endpoint
is approached.
o Stop titrating when the color just turns blue.
3. Calculations:
o Record the volume of calcium standard solutionused (V).
o Calculate the calcium hardness as follows:
oCalcium hardness (mg/L) = V * Calcium standard
solution concentration (mg/L) / ml of sample
Note:
• Use distilled or deionized water for preparing solutionsand rinsing glassware.
• Make sure all glassware is clean and free ofcontaminants.
• Standardize the EDTA titrant and calcium standardsolution regularly.
• The procedures described here are general guidelines.Consult the specific
instructions provided by the manufacturer of the test kits used.
Safety Precautions:
• Wear safety glasses and gloves when handlingchemicals.
• Dispose of waste chemicals properly.
• Follow all safety protocols for your laboratory
DETERMINATION OF TOTAL SUSPENDED SOLIDS:

Procedure:
▪ Glass microfiber filter paper of 47 mm is taken and dried in aoven at 100-

1050c for 1 hour.
▪ The dried filter paper is cooled in a desiccators and initial weight(W1) is taken.
▪ The weighed filter paper is placed in a crucible and suctionpump is connected.

▪ Suitable volume of sample is passed by the suction pump.
▪ The filter paper is removed and dried in a oven at 100-1050c for1 hour.
▪ Dried filter paper is cooled in desiccators and final weight(W2)is taken.
Calculation:
Where,
W2- Final weight of filter paper (gms)
W1 - initial weight of filter paper (gms)
V- volume of sample(ml)
✓ TOTAL DISSOLVED SOLIDS = TOTAL SOLIDS – TOTAL SUSPENDED

SOLIDS
DETERMINATION OF P & M ALKALINITY:
Aim : To determine P & M Alkalinity.
Reagents Used :
1. Standard H2SO4 0.02 N
2. Phenolphthalein Indicator
3. Methyl Orange Indicator
Procedure :
▪ Take 25 (or) 50 ml sample in conical flask & add 2- 3 drops of phenolphthalein Indicator.
▪ If pink colour develops titrate with 0.02 N H2SO4 till the pink colour disappears .If pH is 8.3 ,then note
the volume of H2SO4 required (A)
▪ Add 2-3 drops of Methyl Orange indicator to the same flask & continue titration, note the value of
Sulphuric acid used(B) till pH falls to 4.5 (or) Orange yellow colour change to Orange Red.
▪ In case , pink colour does not appear addition of phenolphthalein continue to do test for M- Alkalinity
▪ Calculate total ‘M’ &' P ' Alkalinity as follows & express in mg & CaCO3 / litre
Calculation :
𝑷 − 𝑨𝒍𝒌𝒂𝒍𝒊𝒏𝒊𝒕𝒚 = A × 1000/ ml of sample
𝑴 − 𝑨𝒍𝒌𝒂𝒍𝒊𝒏𝒊𝒕𝒚 = B × 1000/ ml of sample 𝑻𝒐𝒕𝒂𝒍 𝑨𝒍𝒌𝒂𝒍𝒊𝒏𝒊𝒕𝒚 = (A + B) × 1000 /ml of sample

Flow diagrams of BF-1 pump houses
Process Description:
There are two working and two standby pumps to supply water to hearth & under
hearth. Return water from BF-1 comes to heat exchanger HE-01 (1W+1S).The cooled water from
HE enters to pump suction then again supplied to BF-1.Make up water to circuit is added from P-
11 & P-12 pumps. In case of total power failure diesel pump is started and EOHT emergency
valve is opened.

There are two working and two standby pumps to supply water to hearth & under hearth. Water
returns from BF-1 to heat exchanger HE-01 (1W+1S).The cooled water from HE enter to pump suction then
again supplied to BF-1.Make up water to circuit is added from GR-11 &12 pumps. In case of total power
failure diesel pump is started and EOHT emergency valve is opened

There are two working and two standby pumps to supply water to tuyers. Return water from
BF-1 comes to GR-V hot water sump .GR-V pumps (2W+2S+1DP) supply water to CT-3 &3A.The cooled
water from cooling tower comes to GR-3 sump & then again supplied to BF-1.Make up water to circuit is
added from pump house-1 make up water line. In case of total power failure diesel pump is started and
EOHT emergency valve is opened.

Process Descriptio
There are two working and two standby pumps to supply water to GCP. Return water from GCP comes to
THK-1 & then to GR-VII hot water sump .GR-VII pumps (2W+2S) supply water to CT4&4A.The cooled
water from cooling tower comes to GR-VI sump & then again supplied to GCP. Make up water to circuit is
added from pump house-1 make up water line.
Mr. P.RAVI KUMAR

Sr.MANAGER,WMD

Harish Reddy

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An Industrial Report

RASHTRIYA ISPAT NIGAM LIMITED

An Industrial training report submitted to GICE, Visakhapatnam.

DEPARTMENT OF CHEMICAL ENGINEERING (Oil Technology)

GOVERNMENT INSTITUE OF CHEMICAL ENGINEERING

RASHTRIYA ISPAT NIGAM LIMITED

During the period of training his conduct is found to be .

GOVERNMENT INSTITUE OF CHEMICAL ENGINEERING

We take pleasure in thanking Mr.S.MURALI KRISHNA , Sr.Manager

MUDUNDI PARDHIV VARMA

GOVERNMENT INSTITUE OF CHEMICAL ENGINEERING

3. Quality Assurance & Technology Development:

GOVERNMENT INSTITUE OF CHEMICAL ENGINEERING

4. Thermal Power Plant:

5. Water Management Department:

GOVERNMENT INSTITUE OF CHEMICAL ENGINEERING

VISAKHAPATNAM STEEL PLANT:

VSP’S FRUITFUL ACHIVEMENTS:

GOVERNMENT INSTITUE OF CHEMICAL ENGINEERING

MODERN TECHNOLOGY & MAJOR PLANT FACILITIES:-

THE MAJOR PLANT FACILITIES:

GOVERNMENT INSTITUTE OF CHEMICAL ENGINEERING

The Importance of Industrial Safety:

Industrial Safety Objectives:

Industrial Safety Planning

• Adequate lighting in work areas and corridors

GOVERNMENT INSTITUTE OF CHEMICAL ENGINEERING

PERSONAL PROTECTIVE EQUIPMENT

Personal Protective Equipment:

GOVERNMENT INSTITUTE OF CHEMICAL ENGINEERING

Face and Eye Protection:

• Ensure that there are no cracks or deformities on the lenses.

• Clean and disinfect after use.

Skin and Body Protection:

GOVERNMENT INSTITUTE OF CHEMICAL ENGINEERING

GOVERNMENT INSTITUTE OF CHEMICAL ENGINEERING

GOVERNMENT INSTITUTE OF CHEMICAL ENGINEERING

MAJOR SOURCES OF RAW MATERIALS:

Iron ore lumps & fines Bailadilla, MP

SMS lime stone UAE

SMS dolomite Madharam, AP

Manganese ore Chirupalli, AP

Boiler Coal Talcher, Orissa

Coking coal Australia

Medium coking coal Gidi/Swang/Rajarappa/Kargali

GOVERNMENT INSTITUTE OF CHEMICAL ENGINEERING

MAIN PRODUCTS OF VISAKHAPATNAM STEEL PLANT:

Angles Nut Coke Granulated slag

Billets Coke dust Lime fines

Channels Coal tar Ammonium sulphate

Wire Rods Wash oil

UTILITIES & SERVICES:

Visakhapatnam steel plant is the most sophisticated and modern integrated

Further refinements in the process, such as basic oxygen steelmaking (BOS),

VARIOUS DEPARTMENTS IN STEEL PLANT:

1. RAW MATERIAL HANDLING PLANT (RMHP):

GOVERNMENT INSTITUTE OF CHEMICAL ENGINEERING

2. COKEOVEN AND COALCHEMICALPLANT(CO & CCP):