PROJECT REPORT ON

BHILAI STEEL PLANT

Name of the Trainer : Yashwant Kashyap Sir

Submitted By : Sujoy S. Suraj Jain

A BRIEF INTRODUCTION TO BSP

MERCHANT MILL
The merchant mill is a semi continuous high capacity mill designed to roll 500,000 tones per yr. as per present market demand. Main products are: Round Bars : 28, 32, 36, 40, 50, 53, 56, 60, 63 & 67 mm dia. TMT Bars : 28, 32, 36, 40 & 45 mm are also being rolled. Angles : 5050, 6565, 7575, 8080, 9090, mm length & 5 to 10mm of thickness. 50 65 75 80 90 Channels : 10050, 7540 mm. 100 75 100 105105,150 RAW MATERIALS: Raw materials used are billets of size 100100, 105105,150150 & length ranging from 5M to 6M. THE MERCHANT MILL CONSIST OF 3 MAIN SECTIONS: 1.Re1.Re-heating furnaces. 2.The mill stands and cooling beds. 3. Finishing zone & shipping. ReRe-heating furnaces installed into the mill is used to heat the billets to the required temperature necessary for hot rolling. The capacity of each furnace is 60 ton per hr.

MERCHANT MILL
IMPORTANT TECHNICAL PARAMETERS OF THE FURNACE ARE: Breadth of furnaces : 6.5m Effective width : 6.1m Length : 20m No. of burners : 16 THE WORKING OF THE MILL: Billets are supplied from billet yards by magnetic cranes on to the charging device. Furnace approach table is designed to receive billets and deliver them to the furnaces. The furnace pushes the billets after leveling and the furnace pushing the heated billets on to the delivery roll table. The turn-over devices installed on the turnrolling lines are used for turning over billets by 90deg. There are 12 working stands in the mill: 9 stands are horizontal & 3 are vertical. The 1st line of rolling consists of 8 stands. After the 8th & 10th stands there is a chain transfer to deliver the bar. All stands are of non reversing type & driven individually by dc motors. In the case of vertical stands, the roll stand can be moved up & down bye the housing lifting mechanism. The rolls are placed in the housing and are clamped. There are 2two repeaters between 8th & 9th stand & in between 10th & 11th stand. Repeaters r used for rounds upto 67mm dia. & TMT bars upto 45mm. The finished bar from stand 12 travels on the delivery roll table through the switch point bifurcator to the cooling bed. The bifurcator distributes the flow of bars to both side of cooling bed.

MERCHANT MILL

PLATE MILL
Introduction: Introduction: With the commissioning of 3600mm plate mill under 4MT expansion programme. 3600mm programme. Plate mill has covered area about 15680m. The production of mill is 0.95 million tonnes of 15680m finished plates in 5600 operating hrs. The thickness if the plates range from 5-120 mm. It is hrs. mm. called 3600 mm Plate Mill because the barrel length of the work roll is 3600 mm. Continuously mm. cast slabs in the length range of 5.6-10.2 M are delivered in hot condition to the slab yard. 10. yard. The sequence of operations are : Slab heating, descaling, rolling, leveling, cooling, inspection and shearing to required size. These furnaces have five Heating Zone, Soaking Zone, top and size. bottom preheating zone, top and bottom heating zone. The soaking zone has a flat roof with zone. sixteen small capacity vertical burners through the roof. The other four zones have six burners roof. each. each. Mixed gas of calorific value 2500 K cal/cum is used as a fuel. The solid hearth in the fuel. soaking zone is made of electro cast corundum blocks. blocks.

Product Mix :
A) Input sizes of slabs are: 200 x 1300 200 x 1500 length from 1800-3350 mm 1800250 x 1500 Depending on the order position sometimes 320 x 1500 mm size is also being used. B) Plates sizes produced are : Thickness 07 - 120 mm Width 1500 - 3200 mm Length 4500 12500 mm

Salient Features :
Cost of construction Capacity Length Width Mech Equipments Elect Equipments Date of commissioning : : : : : : : Rs. 800 crores (Approx.) 950,000 T/year 1056 meter 256 meter 76,452 T 35,200 T 29th March 1983

TRANSPORT & DIESEL ORGANISATION

Transport and Diesel Organisation is a vital department which takes care of all internal and external movement on Rails of various raw, semi-finished materials involved in running of a steel plant. This semiplant. movement is right from Railway exchange yards at material handling points of user shops. It takes shops. care of movement of hot metal, slabs and also muck, scrap, used refractories etc. which are etc. generated during various processes in the plant. Collection of empties from Railways and supply to plant. different loading points, like various mills and dispatch of loads to Railways, is also the job of this department. department. Transport & Diesel Organisation comprises two main sections : 1. Traffic Section (Rail Transport) 2. Maintenance wing
1.

TRAFFIC SECTION :
Rail Transport is linked up with the technological process of steel making from the beginning of the process and continues till the completion of the process. Receipt of raw materials, dispatch of semi process. finished and finished products, removal of industrial wastes, internal process movements etc., etc. should maintain a strict continuity with the technological process of a Steel Plant. Plant. There are two parts of Traffic Section, i.e. : a) External Traffic b) Internal Traffic

TRAFFIC HANDLING FACILITIES IN T & D ORGANISATION A. Control : There are six controls to co-ordinate, round the clock, the spread and number of activities coof Rail Transport Department from one end to other end of the works. These controls are as follows works. : a) Train Control b) Traffic Control c) Commercial Control d) Power Control e) Permanent Way Control f) Railway Signaling Control B. (i) Locomotives (ii) Rail Cranes C. Trams : TRAMS is an acronym for Traffic Management System. It is a computerised system of its System. kind in India. It has been developed indigenously, with very little imported hardware components. India. components.
2.

MAINTENANCE WING :
Maintenance of the plant locomotives and the rolling stock (for internal traffic handling) are carried out in the Loco and Wagon Depots of Transport & Diesel Organisation. Organisation. Loco Depot : The locomotive are subjected to periodical examination and repairs at prescribed time intervals which are adhered to, for reliable service. service. Planning & Procurement Group Wagon Depot

A.

B. C.

D. E.

Permanent Ways Railway Signaling and Communication

Some Highlights Of T & D Organisation

a)

Dispatches of 5 BOX N ES rakes on 7.8.2002 from 10:15 to 13:30 hrs in a shift. Transport of 3490 tons of Rail Blooms from SBS to Rail & Structural Mill in a day. Dispatch of 58109 Tons of Rails to Railways in the month of September, 2002. Highest hot metal movement from B.F.s to SMS-II on 26.8.2002 and SMS-I on 28.08.2002 to SMSSMSproduce 76 blows & 36 heats respectively. 41000 tons of finished material transported to Bhilai Stock Yard through plants internal wagons. Out of 668 heats pushed to Blooming & Billet Mill in August 2002, 598 heats were having more than 800 degrees centigrade surface temperature.

b)

c)

d)

e)

f)

THANK YOU