SUMMER VOCATIONAL

TRAINING REPORT

BHILAI STEEL PLANT, SAIL

REPORT
ON
“MILL ZONE”
BLOOMING & BILLET MILL
Blooming & Billet Mill popularly known as "Mother
Mill", is a primary mill designed to roll 2.5 MT/
Annum of ingots into semis in the form of blooms
& billets. A two high reversing blooming mill and
12 stands continuous billet mill are part of this
department. The 1150mm two high reversing
Blooming Mill is designed to roll steel ingots into
blooms for Continuous Billet Mill and Rail &
Structural Mill. Average weight of steel ingots
which are used for rolling is 8 to 9 Ton.
SOAKING PITS
• Heating of the ingots and soaking at a particular
temperature is done in the soaking pits.
• 14 groups of recuperative type soaking pits and
each group consist 2 pits.
• Each pits are heated by two burners situated
diagonally opposite of top of the lateral walls of
pits.
• The fuel burnt is mixture of coke oven gas and
blast furnace gas with a calorific value of 1600
KCal./Cu.M.
• Air is preheated in ceramic recuperators and the
gas in the metallic recuperators.
• The position of ingots are such that the full
circulation of flames around the ingot is ensure.
• 16 ingots are placed in one chamber at a time.
• After rolling, cleaning of the pit is done by
scrapper bar held by the tongs crane and bottom
is made with two buckets of Coke.e Breeze.
Operational data of Soaking Pits
Dimensions of the pit
• Length : 6.7m
• Width : 4.2m
• Depth : 4.5m
• Soaking temp. : 1300 °C
• Pit pressure : + 0.2/0.3mm w.c.
BLOOMING MILL
• The heated ingot are placed on the ingot buggy
(two ingots at a time) by means of tongs crane
which delivers it on to the receiving roller table
of Blooming Mill.
• The Blooming Mill is a 2-High horizontal stand,
equipped with individually driven rolls. Each roll
of the Blooming Mill is driven by 930 V, 8000
KW, 0-20-80 rpm motor.

Length of Roll - 2800 mm

Dia. of Roll - 1150 mm (Min.1100mm &
Max.1180mm)
• The Top Roll is balanced by counter weights by
moving up and down by screw down
mechanism.
• There are manipulator side guards on both sides
of the Roll stand for manipulating rolling stock.
• Tilters are fitted in the front manipulator for
tilting the rolling stock whenever required.
• The total rolls from ingot to bloom is done in 11 -
17 passes.
• After rolling, the bloom proceeds to the shear
where the front and back ends are cropped off to
eliminate defects and also to get required length.
• The shear is of the up-cut crank shaft type with
maximum cutting force of 1000 Ton and
operating speed of up to 10 cuts per minute.
• Crop ends are pushed down and conveyed to
crop pit for cooling. Further blooms are sent to
billet mill.
• Common Sizes of Blooms and Narrow Width
Slabs
i) 320 x 320 mm
ii) 265 x 340 mm
iii) 260 x 300 mm
iv) Shaped blooms for Beam-450mm & Beam-
600mm
v) Narrow Width Slab 200 x 320 mm
vi) Narrow Width Slab 200 x 420 mm
BLOOM STORAGE
• Blooms assigned for Rolling in the Rail &
Structural Mill and requiring inspection and
conditioning are transported hot, by 15 ton over-
head cranes and stacked in specified areas
depending on quality of steel.
BILLET MILL

• The Billet Mill has been designed to roll billets

from blooms of cross section 325x325 sq.mm in
6 to 12 passes depending on cross section of
billets to be produced in the Mill.
• The capacity of the Mill was designed to roll
15,01,000 Tons/Year.
• The Mill consists of 12 working stands arranged
in three groups.
a. The First group contains Two 2-High Horizontal
stands with a 90 deg. tilter in between. These
stands are equipped with rolls of diameter
1000mm and length 1200mm.
b. The Second group called the roughing group
contains 4 stand - 2 each of Horizontal and
Vertical stands arranged alternately. These stands
are equipped with rolls of diameter 700mm.
c. The Third group called the finishing group located
after the transfer table contains 6 stands - 3
horizontal and 3 vertical stands arranged
alternately. These stands are equipped with rolls of
diameter 500mm.
• Rolled billets after the roughing group of stands
which are not to be rolled further are stored and
there the cooling take place.
• If necessary, the front end of billet can be
cropped off by 250 T shears installed in front of
the group.
• End arising are controlled by a computer
installed in the Mill.
• After cutting, the billets are transported to
cooling beds by roll tables and transfer skids.
• SECTION OF BILLETS ROLLED ARE
1. 150 x 150 mm
2. 110 x 110 mm
3. 105 x 105 mm
4. 100 x 100 mm
5. 90 x 90 mm
PLATE MILL
• With the commissioning of 3600 mm Plate Mill
under 4 MT expansion programme, Bhilai has
entered into the area of flat products in a big way.
• This giant rolling mill complex which extends to
over a kilometer in length has an overall covered
area of about 15680 m².
• It consists of six main bays; 1-3 bays of span 36
meters each, 2 bays of span 30 meters each and
one bay of 18 meters span, also, two open gantries
for scrap removal.
• The mill is intended for an annual production of
0.95 million tonnes of finished plates in 5600
operating hours.
• The thickness of the plates range from 5-120 mm.
• It is called 3600 mm Plate Mill because the barrel
length of the work roll is 3600 mm.
• Continuously cast slabs in the length range of
5.6-10.2 M are delivered in hot condition to the
slab yard.
• These slabs are cut to smaller lengths in 3 non
flame cutting machines as per requirement.
• Inspection and conditioning is carried out after
cutting of the slabs to the required sizes.
• Inspected slabs with proper identification are
supplied to Plate Mill.
• The sequence of operations are :
▫ Slab heating
▫ Descaling
▫ Rolling
▫ Levelling
▫ Cooling
▫ inspection and
▫ shearing to required size.
RAIL AND STRUCTURAL MILL
• Rail and Structural Mill of Bhilai Steel Plant,
SAIL is the world's largest producer of rails with
an installed capacity to produce 500,000 tons of
rails and 250 000 tons of structurals.
• Bhilai is also the sole supplier of the country's
longest rail tracks of 260 metres. The length of
rails produced so far since inception is sufficient
to encircle the globe more than 8 times.
• The major profiles produced in the mill are:

▫ 1. RAILS
 a. IRS 52 Kg/m
 b. UIC 60
 c. Thick Web Asymmetric Rail Zu1-60

▫ 2. HEAVY BEAMS
 a. 600 * 210 * 12mm
 b. 500 * 180 * 10.2 mm
 c. 450 * 150 * 9.4 mm
 d. 400 * 140 * 8.9 mm
 e. 350 * 140 * 7.5 mm
 f. 250 * 125 * 6.9 mm
▫ 3. CHANNELS
 a. 400 * 100 * 8.8 mm
 b. 300 * 90 * 7.6 mm
 c. 250 * 82 * 7.6 mm

▫ 4. ANGLES
 a. 200 * 200 * 20/16 mm
 b. 150 * 150 * 20/16 mm

▫ 5. CRANE RAILS
 a. CR 120
 b. CR 100
 c. CR 80

▫ 6. CROSSING SLEEPERS
1. STEEL INPUTS OF RSM:

• The Rail Steel making process at Bhilai Steel Plant is

one of the most advanced.
• Rail steel is made in BOF converters at SMS 2 and
processed through RH degasser and ladle furnace etc.
• The steel thus obtained is very clean and has
hydrogen in liquid steel less than 1.6 ppm a world
benchmark.
• It is continuously cast into blooms which are flame
cut to specified length & weight, and sent to Rail and
Structural Mill for rolling. Steel for structurals is
made at SMS 1 in twin hearth furnaces and is cast
into ingots, which are rolled into blooms at the
blooming mill.
2. PROCESS FLOW AT RAIL AND STRUCTURAL MILL:
3. ROLLING MILL AREA

• It constitutes of the following areas:

▫ Reheating furnaces

▫ Roughing Stand

▫ Intermediate Stands

▫ Finishing Stands

▫ Hot saws, Stamping Machine & Cooling

beds
THANK YOU…

KAUSHIK DAS
METALLURGY 5TH SEM.
ROLL-3203810048