AN PRESENTATION

ON
INDUSTRIAL VISIT
(Vocational Training)
TO
VISAKHAPATNAM STEEL PLANT
FROM 27-06-2016 TO 18-17-2016

PREPARED BY :-
AAYUSH PANDEY
5 th SEM(MECH), SSGI
 Few important facts...
The Visakhapatnam Steel Plant, popularly known as Vizag Steel, is situated in coastal
region of Andhra Pradesh.
It is the largest single site plant in India
It is the only Indian shore-based steel plant.
The plant is built with German and Soviet technology.
Project announcement-On 17 April 1970
Foundation stone- On 20 January 1971
Submission of DPR in October 1977 for 3.4 Mtpa of liquid steel.
.The DPR is revised in November 1980 for USSR collaboration.
Foundation fot blast furnace was laid in January 1982
Vizag Steel Plant recived Navratna status on 17 November 2010.
Capacity enhancement work to 6.3MT/Year is under progress
 BASIC INFRASTRUCTURE
Blast furnace
Steel melt shop
Continuous casting shop
Light and medium merchant mill
Wire rod mill
Steel melt shop
Integrated Township
Coke ovens and coal chemical plant
Sinter plant
Captive power plant
O&M and HRD divisions
QA and Testing Department
Administration
Construction
 QUALITATIVE ANALYSIS AND TESTING DEPARTMENT
QA&TD plays key role in achiving product conforing to the designated properties,
performance and quality standards.
The final product quality is dependent on the quality of the incoming raw material,
metallaurigical processs and implementation of correct quality control measured.
QA&TD team is responsible for correct quality control measures, approved quality
assurance plan, exainationa and testing of the production samples.
It is equiped with modern examination tools, equipments and trained manpower for
excecution of the tast.
It has inhouse labs for both destructive and non destructivr testing of the samples viz,
Bend test, Impect test, Hardness test, Tensile test, Fatigue test, Visual examination, Dye
penetrent examination, Magnetic partical examination, Radiographic testing,Uultrasonic
Testing,Leak testing, Eddy Currect Testing, Remote feild electromagnetic testing, LRUT,
ect.
BLAST FURNACE
 VSP has three Blast Furnace (BF) with respective volume of 3820, 3200,3813 cubic meter.
Iron is produced in Blast Furnaces by smelting of iron bearing ores (hemetide) and dolomite
with help of coke and air.
The solid charge materials like sinter, sized iron ore, coke etc. are charged in the vertical
shaft at top and hot air blast is blown through the tuyeres located at the bottom.
The oxygen from the hot air combines with the carbon of the coke and generates heat and
carbon monoxide. The gases, while ascending upwards react with the descending charge
materials.
Eventually, the charge melts. Hot metal is produced and tapped out from bottom into laddle.
Slag is floating at the top is collected separately.
The eshast gas is also used as fuel in the plant. The Paul-Wurth, bell less top system is
installed for furnace charging.
 BLAST FURNACE 1

 It has 2.5 MT per annum capacity (After modernization)

 New generation Paul-Wurth "Bell-Less" Top with conveyor charging.
 BF Cooling elements (Cast Iron Staves & Copper Staves).
 High heat zone copper staves.
 Double compensator tuyeres, with PCI injection facility and
 extended tuyere platform.
 Circular type with full castable runner system (flat cast house).
 Hydraulic Drilling Machine, Mud Gun, Manipulators.
 Silencer to bin relief.
 New scrubber with annular gap element for better gas cleaning.
 HMI based control room.
 Equipped with Upper burden temperature Probes.
 BLAST FURNACE 2
 It has a capacity of 1.7 MT per annum.
 Conveyorised charging of Blast Furnaces.
 Paul-Wurth "Bell-less" top charging system for Blast Furnace.
 On-line correction of coke moisture and batch weights.
 Circular cast house with four tap holes and no slag notch.
 Cast house slag granulation plant.
 Tuyere leakage detection system.
 Gas Expansion turbines for power generation by utilizing the blast
 furnace gas top pressure.
 Automation with Programmable Logic Controllers (PLC).
 BLAST FURNACE 3

 It has a production capacity of 2.5 MT per annum

 New Generation Parallel Hopper Bell Less Top.
 BF Cooling elements (Cast Iron Staves & Copper Staves).
 Flat Cast house Equipment (by TMT).
 INBA Slag Granulation System.
 Annular Gap Scrubber.
 Pulverized Coal Injection System.
 Hot Stoves (internal combustion chamber) Automation.
SHEET METAL SHOP AND CONTINUOUS
CASTING
Steel is made from cast iron in steel melting shop in a 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 the carbon of the hot metal and this
reaction releases large quantities of gas rich in carbon monoxide along with
huge amount of heat and dust. 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
continuous casting 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.
FACILITIES:-

SMS-1:

 Three LD converters (2 x 133 and 1 x 150 cum. with DOG House facility).
 6 nos. of 4 - Strand Continuous Bloom Casting machines.

SMS-2:

 Two LD Converters of 150 cum. volume each.

 1 no. of 6- Strand Continuous Billet- cum- Round caster.
 2 nos. of 6- Strand Continuous Billet casters.
 Hot Metal Desulphurization Plant (HMDP).
 DOG House.
 RH Degasser.
SAILENT FEATURES:-

 100% Continuous casting of steel.

 Converters gas cooling, cleaning and recovery systems.
 Computerization of the converter process.

PRODUCTION CAPACITY:-

SMS-1 : Original Installed Capacity is 3.0 MT of Liquid Steel per annum & 2.820 MT of CC
Blooms per annum. After Modernization of all the 3 converters, capacity will be enhanced to
3.5 MT of Liquid Steel & 3.29 MT of CC Blooms per annum. (Currently, one converter is
modernized).
SMS-2 : 2.8 MT of Liquid Steel per annum & 2.730 MT of CC Blooms/Rounds per annum.
STRUCTURAL MILL
The Mill is designed to produce 7,00,000 tones per year of structural section in straight
length in approximately 3733 rolling hours and 8,50,000 tones per year of structural
sections in straight length in approximately within 4533 rolling hours.an input of
Continuous cast cold bloom of 200 mm x 200 mm x 12 m and weighing approximately
3760 kgs.
FACILITIES:-

 Walking beam re-heating furnace, 200 tph capacity with cold storage charge, and relevant
charging and discharging services.
 Furnace exit area with pinch roll and high pressure water static descaler.
 Exit furnace table for the feeding of continuous rolling mill.
 Continuous rolling mill composed of 17 rolling stand "housing less type" namely
SAILENT FATURES:-
 Roughing mill composed of 7 stands arrange in H-V disposition.
 Intermediate mill composed of 5 stands arranged either in H or H/V/U or H/U
disposition.
 Finishing mill composed of 5 stands arranged either in H or H/V/U or H/U or H/V
disposition.
 A crop type start/stop crank shear arranged after stand no. 7.
 A crop type start/stop rotary shear arranged after stand no. 12.
 Dividing shear for multiple length cut after stand 17.
 Double sided 90 m long cooling bed.
 Straightening machine.
 84 m long batching area.
 Three saw for cutting to length in each line.
 Stacking, strapping, weighting and collection stations.
 Continuous Mill consisting of 17 stands of housing-less design.
 Mode Optimization for cut length of bars.
 On line automatic measuring gauge for better quality control.
 Automatic bar bundling & strapping machines for packaging of finished
products.
 Basalt Rock Liner in the scale Flume tunnel to prevent wear out of the base
of the tunnel.
 Minimum tension control and tension free (loop) control.
 Optimized roll pass design for all product.
 Mills: 0.70 MT per annum. The enhanced production capacity is 0.85 MT
per annum.
 top type flying shears along the mill for emergency chopping of rolled stock.
Continuous cast cold bloom : 200 x 200 x 12,000mm - weight 3,760 kg
1) Beams : ISMB 100,125,150 mm; ISJB 150, 175 mm; ISLB 100, 125, 150 mm.
2) Channels : ISMC 75, 100, 125, 150, 175 mm; ISJC 100, 125, 150, 175 mm.
3) Angles : 55, 60, 65, 75, 80, 90, 100 mm.
4) Flat : 70 to 180 mm (thickness: 8 to 30 mm).

Special sections like

 Round : 45 to 95 mm
 Squares : 45 to 80 mm
 HE (columns with parallel flanges) : 100 to 120 mm
 IPN (Beams with tapered Flanges) : 100 to 180 mm

IPE
 (Beams with parallel flanges) 100 to 180 mm

TEE 60 x 60 x 7 mm

Unequal angles 80 x 50, 90 x 60, 125 x 75 mm

SPECIAL BAR MILL
The Mill is designed to produce 7,50,000 tons per year of plain rounds in straight length and
in coil form by using an input of Continuous cast billets of 150 mm x 150 mm x 12 m and
weighing approximately 2050 kgs. The mill is designed to roll medium and high carbon
steel, case hardening steel, cold heading quality steel, electrode steel, spring steel, bearing
steel and free cutting steel.
FACILTIES:-
 6 Stand each of Roughing, Intermediate, Pre-Finishing Train.
 3 Nos. Stand Finishing Train (Sizing train).
 Pendulum shear, Flying shear 3 nos and dividing shear.
 Controlled cooling facilities.
 Straight Form: Chain transfers, Cold Shear, Bundling Facilities and
 Strapping machines.
 Coil Form: Garret coilers, Cooling conveyors, Hook conveyors,
 Compacting and Strapping Machines.
SALIENT FEATURES:-

 Continuous Mill consisting of 21 stands of housing-less design.

 20 - 45 mm size in straight & coil form (Reduced wastage for end user).
 Free size rolling (Customized sizes with closed tolerances).
 Low temperature rolling for finer grain structure.
 Online automatic measuring gauge for better quality control.
 Automatic bar Bundling & Strapping machines for packaging of finished
products.
 0.75 MT per annum. The enhanced production capacity is 0.90 MT per
annum.
ROUND FORM OUTPUT:
Rounds - 20 mm to 45 mm diameter (with a special provision to
roll 16 mm to 18 mm).
Coils - 2.0 tons (as per billet weight).
STRAIGHT FORM OUTPUT:

Straights - 12.0 m bundle with 6 straps.

LIGHT MEDIUM AND MERCHANT MILL
 LIGHT AND MEDIUM MERCHANT MILL ( LMMM)

The cast blooms from 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, some of which are sold
and rest are sent to Bar Mill/WRM. The continuous two-line Bar Mill comprises of 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 stands
for tension free rolling in order to obtain good surface quality and tolerances. Housings are
of closed top type. Roll necks are mounted in anti friction bearings.
FACILITIES:-

BREAK DOWN MILL

 7 STAND BREAK DOWN MILL

 8 STAND ROUGHING MILL ( 2 STAND ROLLING)
 2X4 STAND INTERMEDIATE MILL ( SINGLE STRAND ROLLING)
 2X4 STAND FINISHING MILL ( SINGLE STRAND ROLLING)

SAILENT FEATURES:-

 VAPORATING COOLING SYSTEM IN ROLLING MILL FURNACES

 COMPUTERISED ROLLING MILL
 TEMPCORE COOLING PROCESS FACILITING HIGFH STRENGHTH WITH GOOD
BENDABILITY AND WELDABILITY

CAPACITY:-

A MILL OF 0.710 MT PER ANNUM

WIRE ROD MILL
WRM-1
The Mill is high speed 4 strand No-Twist continuous mill designed to
produce 8,50,000 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 billets
of 150 mm X 150 mm square cross section, 12 m length and weighing 2100
kgs approximately, are used as input material
FACILITIES:-

WRM 1
 7 STAND ROUGHING MILL (4 STAND ROLLING)
 6 STAND INTERMEDIATE MILL ( 4 STRAND ROLLING)
 4X2 STAND PRE FINISHING MILL (SINGLE STRAND ROLLING)
 4X10 STAND FINISHING MILL ( MORGAN BLOCK-SINGLE STRAND
ROLLING)

WRM 2
 6 STAND SINGLE STRAND FAST ROUGHING MILL
 2 STRAND INSULATYED ROLLER TABLE
 6 STAND INTERMEDIATE MILL 1
 4 STAND INTERMEDIATR MILL 2
 2X2 PRE FINSHINGT TRAIN
 2X8 STAND NO TWIST BLOCK
 2X4 STAND REDUCING AND SIZING MILL (RSM)
SAILENT FEATURES:-
 HIGHLY AUTOMATED AND COMPUTERISED ROLLING MILL
 CONTROLLED COOLING OF WIRE ROD, BY ‘STELMOR’ PROCESSWITH OPTIMESH TECHNOLOGY
 GIVING HIGH STRENGTH AND GOOD DUCTILITY
 CLOSED LOOP CONTROL FOR LAYING TEMPERATURE WITH MORGAN PATENTED METCS
( MORGAN ENHANCED TEMPERATURE CONTROLL SYSTEM)
 IN WRM 2 TO ENHANCE METALLURGICAL PROPERTIES
CAPACITY:-
 WRM 1 0.85 MT PER ANNUM
 WRM 2 0.60 MT PER ANNUM
PRODUCT MIX
WRM 1
 PLAIN ROD- 5.5 TO 12.7 MM DIAMETER & 14 MM DIA
 REBAR-8MM,10MM,12MM DIAMETER IN COIL FORM
WRM 2
 PLAIN ROD- 5.5 TO 20 MM IN STEP OF 0.5
 PLAIN ROD DIA 20.64 MM
MEDIUM MERCHANT AND
STRUCTURAL MILL
The Medium Merchant and Structural Mill (MMSM) is one of the modern
rolling mills of Visakhapatnam Steel Plant. This is a single strand
continuous mill having production capacity of 8,50,000 tons per year. The
important 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 beams because,
for the same weight, the section is stronger and stiffer due to greater
moment of inertia and higher radius of gyration.
FACILITIES:-

 8 STAND ROUGHING MILL

 6 STAND INTERMEDIATE MILL
 6 STAND FINISHING MILL

SAILENT FEATURES:-

 EVAPORATING COOLING SYSTEM IN ROLLING MILL FURNACES

 SOPHISTICATED HIGH SPEED ROLL WITH COMPUTERIZED CONTROLLS

CAPACITY:-

A MILL OF 0.85 MT PER ANNUM

COKE OVEN AND CHEMICAL
PLANT
 Coal is converted into coke by heating the prepared coal blend charge in the coke ovens
in the absence of air at a temperature of 1000oC-1050oC for a period of 16/19 hours.
The volatile matter of coal liberated during carbonization is collected in gas collecting
mains in the form of raw coke oven gas passing through stand pipes and direct contact
cooling with ammonia liquor spray. The gas cooled from 800oC to 80oC is drawn to
Coal Chemical Plant by Exhauster. The residual coke is pushed out of the oven by
pusher car through a guide into coke bucket. The red-hot coke is taken to coke dry
cooling plant for cooling.
The main by-product in the process of coke making is crude coke oven gas and this has
a lot of valuable chemicals. Coal Chemical Plant recovers Ammonia (NH3), Tar and
Benzol from CO-Gas. The primary by-products from Crude CO Gas are Ammonium
Sulphate (NH4)2SO4, Crude Tar, Crude Benzol and cleaned coke oven gas. The cooled
coke from CDCP (Coke Dry Cooling Plant) is separated into 3 fractions, BF Coke i.e.
+25-70 mm, which is sent to Blast Furnaces, Coke Breeze i.e. +0-15 mm, which is sent
to Sinter making and nut coke i.e., +15-25 mm, which is also used in the Blast Furnaces.
FACILITIES

 There are 4 batteries, each having 67 ovens.

 The volumetric capacity of each oven is 41.6 m3.
 Dry Coal charge /Oven is 32 tons.

SAILENT FEATURES

 Largest and technologically unique Coke Oven Batteries in the country at the time of
commissioning.
 7 meter tall coke ovens batteries.
 Selective crushing of coal to improve the coke quality.
 100% Dry Quenching of coke using Nitrogen gas.
 Power generation, from the waste heat recovered, at BPTS (Back Pressure Turbine Station).

CAPACITY

Production capacity (for 3 Batteries) - 2.635 Mt of Gross coke per annum (2.261 Mt of BF Coke per
annum).
SINTER PLANT
 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.
The vertical speed of sintering depends on the suction that is created under the
grate. At VSP, two exhausters are provided for each machine to create a
suction of 1500 mm water column under the grate.
FACILITIES:-

 Two Sintering machines of Dwight Lloyd type each having 312 M2 total grate area.
 One Sintering machine of Dwight Lloyd type having 408 M2 total grate area.
 On ground blending of sintering base mix.
 Bed Height 500 mm.
 Straight Line Sinter Cooler.
 Bed Height 700 mm.
 Chamber type Ignition Furnace with roof mounted energy efficient burners.
 27 m long extended hood with hot air supply through 4 feed points.
 Circular Sinter cooler with waste heat recovery system.
 Lime addition at Mixing and Nebulizing Section of Sinter Machine building.

CAPACITY:-
Sinter Machine - 1 & 2 : 5.256 MT of Gross Sinter per annum.
Sinter Machine - 3 : 3.611 MT of Gross Sinter per annum.
THERMAL POWER CAPTIVE POWER PLANT

PLANT
CAPTIVE POWER PLANT
 INTRODUCTION
UTILITY POWER PLANT CAPTIVE POWER PLANT

Power is produced solely Power is produced for

for purpose of generation
and supplied to the various
kinds of customers through
grid
supplying quality power for
effective functioning of
actual plant.import and
export of power takes place
in accordance with the load
CAPTIVE CAPACITY OF TPP IN
VIZAG
3 units of 60 mw generation capacity
2 units of 67.5 mw generation capacity
2 units of 7.5 mw capacity at back pressure turbine station
(BPTS)
2 units of 12 mw capacity at gas expansion turbine station
(GETS)
 BOILERS
BOILERS : 5( 4 WORKING + 1 STAND BY)
TYPE : WATER TUBE BOILER
CAPACITY : 330 Tons/Hr
PRESSURE : 101 ATM
TEMPERATURE : 540 Celsius
FUEL : pulverized coal, BF gas, CO gas ,
Furnace oil
 FUEL MIX COMPOSITION
COMPOSITION

BFG - 23% 0%

23%

COAL - 46.8% 30%

BFG
COAL

COG - 30% COG

OIL

OIL - 0.07%
47%
TURBO GENERATORS

 5 TGs: (3 x 60 mw + 2 x 67.5mw)
 ELECTRO HYDRAULIC TURBINE GOVERNING SYSTEM
 CONTROLLE DEXTRACTION AT 13 ata & 4 ata
 CENTRAL ADMISSION OF STEAM
 AIR COOLED GENERATORS
 RATED VALUE 47.5 TO 51.5 Hz
TURBO BLOWERS
BLOWER - 3 (2 WORKING + 1 STAND BY)
CAPACITY - 6067 m3/min
CONSTANT SPEED WITH EHTC (electro hydraulic
turbine governing system)
INLET GUIDE VANE CONTROL
AXIAL TYPE LARGEST BLOWER IN INDIA
 TRANSFORMER
CONNECTED TO 60MW
MAKE – MAY & CHRIS W.G
TYPE – DRY TYPE AIR COOLED
POWER RATING – 650 KVA
PRIMARY VOLTAGE – 11 KV
SECONDARY VOLTAGE – 480
Volts
CONNECTED TO 67.5
MAKE – BHEL, JHANSI
TYPE – DRY TYPE AIR COOLED
POWER RATING – 500 KVA
PRIMARY VOLTAGE – 11 KV
SECONDARY VOLTAGE – 380 Volts
THANKING YOU
MADE BY
AAYUSH PANDEY
5 th SEM
MECHANICAL
ROLL 28