Bhushan Power and Steel Ltd operates a coke oven plant and DIR kiln plant. The coke oven plant converts coal into coke through a coking process in ovens. The plant has 8 batteries with 12 ovens each. The DIR kiln plant has 12 kilns that produce sponge iron. Mechanical maintenance at the plants includes preventative, proactive, and breakdown maintenance. Preventative maintenance involves regular inspections and servicing of equipment. Proactive maintenance allows scheduling repairs before failures occur. Breakdown maintenance is performed after indicators show equipment deterioration or failure.

1. INDUSTRIAL REPORT ON
BHUSHAN POWER AND STEEL LTD
(Vill. ThelkoloiTah.RengaliDist.Sambalpur, Odisha)
INSTITUTE OF ENGINEERING & SCIENCE - IPS ACADEMY
INDORE(M.P.)
GUIDED BY-: SUBMITTED BY-:

2. CONTENT
1.0 Acknowledgement….………………………………………………………………………………………3
2.0 Abstract…………………………………………………………………......................................4
3.0 Histry of the company…………………………………………………………............................5
4.0 Company profile………………………………………………………………….............................7
5.0 Vision of the company………..……………………………………………………………………………8
6.0 Policies of company………………………………………………………………………………………...9
7.0 Basic Working Process of this Plant…………………………………………………………………
8.0 Departments visited in training………………………..…………………………………10
8.1 Cock Oven Plant ………………………………………….………………………………..…11
8.1.1 Coal Handling Plant ……………………………..……………………………12
8.1.2 Coal Crushing Plant …….………………......................................14
8.1.3 Cock Oven Plant ……………………….………………………….….………17
8.1.4 Quenching and Distribution.………..………………………….…….…….20
8.1.5 By Product and there Utilation in Energy……………………………….
8.2 DIR Kiln Plant ……………..…………………………………………………………………….22
8.2.1 Process and Working………………………………………………………….…24
9.0 Mechanical Work Perform on these Plants………...……………………………………….…25
9.1 Maintenance Work…………………………………………………………………………..
9.2 Scheduling Work ……………………………………………………..............32
10.0 Conclusion…………………………………………………………………………………………………..
11.0 Reference…………………………………………………………………………………………………..…

3. ACKNOWLEDGEMENT
I would wish to express my gratitude to my H.O.D Mr. Snjay Jain for providing me the
opportunity to explore studies beyond academics. I am also thankful to BHUSHAN STEELS
Ltd for allowing me to undergo the TRAINING PROGRAMME in their organization. At last
but not the least I extend my thanks to all the staff members for providing valuable
information regarding the plant and processes that formed the core of the training.

4. ABSTRACT
In 20 days of my industrial training I have learned about various processes such as coke
makingDRI process etc. I had a good exposure to these processes which added more to my
knowledge. I worked on ‘coke oven plants’ in which carburizing of coal process takes place,
Also I worked on DIR plant .i worked on maintenance department.

5. COMPANY PROFILE
TYPE : PRIVATE
FOUNDED IN : 1987
HEADQAURTERS : INDIA
KEY PERSONS :BrijBhushanSinghal (Chairperson)
NeerajSinghal (Managing Director)
INDUSTRY : STEEL
Vision of the company:
The key to Vision is to use rigorous conceptual framework and to understand how that
framework connects to the underlying DNA of enduring great companies. A well-conceived
vision consists of two major components—“CORE IDEOLOGY” and an “ENVISIONED
FUTURE”. A good vision builds on the interplay between these two complementary Yin-and-
Yang forces; it defines “What we stand for and Why we exist” that does not change the Core
Ideology and sets forth “What we aspire to become, to achieve. It is true to say that most of
our visionstatements expressanelementof ambition BSL’s vision of total integration is a lot closer
to realization today. Through seamless backward integration, BSL is consolidating its position
on the entire steel value chain from iron ore to specialized is surging ahead.
POLICIES OF THE COMPANY:
BHUSHAN STEEL LTD:
Integrated Quality, Environment, Occupational Health & Safety Management System Policy
Bhushan Steel Ltd. commits to produce cold rolled and galvanized steel sheets of world class
quality in a safe, healthy and clean environment by involving employees with continual
improvements in system implementation, technological advancement, operational
integration, prevention of pollution & hazards maintaining
Legal compliance and satisfying needs & expectations of Customers:
 For environment management system we have ISO 14001:2004 certification
 For quality system we have ISO/TS 16949:2002 certification
 For safety management system we have OHSAS 18001:2007 certification for quality
system we have ISO/TS 16949:2002 certification.

6. 7.0 The process flowchart of the plant is as under:-

7. 8.0 Departments Visited in Training.
In the training period, I got opportunity to visit, understand the working of plant and
mechanical work preform onthe plant. I visited in two departments such as “Cock Oven
Plant, and DIR (Direct Reduction Iron) kiln Plant”.
8.1 Coke oven plant.
The main function of Coke Ovens is to convert coal into coke which is used as a fuel and
reducing agent in the Blast Furnace. Its secondary function is to recover Volatile Matter and
CO gas from coal and extract chemicals known as Coal Chemicals. CO gas produced is used
for heating purposes in the plant.
Various sub-sections of Coke Ovens and their functions are as follows:
1. Coal Handling Plant :
Generally coal comes from Australia in Bhushan power and steel through ship and trains. Train are
dispatch the coal in damping area by the wagon trippler. A big bucket crane are use to convey by
belt. By the mean of this of crane. Coal are distributed by crane to deferent conveyor belt for
different plant(Cock oven plant and DRI kilan plant)There are two Coal Handling Plants: Coal
Handling Plant -I (CHP -I ) and Coal
Preparation Plant-II (coal washer plant).
Indigenous Coal comes from Bhojudih, Sudamdih, Nandan, Rajarappa, Swangandimported
coking coal is received from Australia & New Zealand. Imported coking coal is prime coking
coal, having less than 10% ash. Blend is approximate PCC 10%,MCC 15% and imported 75%
for Batteries.
2. Coal Crushing Plant:
Generally the size of coal when it came from mines is about 10 to 25 cm, and it
should to come in the size of 3 -5 mm. So coalcrushers are needed. For this purpose
hammer crusher are use .
Specification of coal crusher plant
i) Diameter of crusher rotor 100 cm
ii) Size of hammer head 25 cm2
iii) Fluid coupling use between crusher and electric motor.
Iv) Electrical Motor Power = 37 KW
RPM = 1470
3. Cock Oven Plant :
Cock oven plant use for conversing of coal to cock in the absence of oxygen. This coal
are used in blast furnace and DRI Kiln Plant.
Description of plant:
i) Cock Oven:-

8. Cock oven plant have 8 battery and each battery have 12 oven,
mean it have 96 oven. The size of each cock oven is the 10* 4 feet and height is
about 6 feet. Once the coal is feeding on the oven then the process is started
automatically because the coal wall is already heated about 450 to 600 oC and the
for cock making process the required temperature is about 1100 oC. This
temperature gain automatically. The cocking process required 24 to 30 hours. If the
cocking process is completed between this time period then cock is withdraw from
the oven
ii) Hot Gas Tower:-
Each battery has one gas tower and this tower is connected to
12 ovens. So that 8 gas tower is used in the plant. These gas towers convey
vary hot gas so that is used for making electricity by gas power plant.
This plant is making as much electricity as sufficient for operating the all cock
oven plant. The coal tower situated in the middle of 96 ovens. The resultant
gas is used to recovery the chemicals.
Properties of coke oven gases-
 Coke oven gases are highly explosive due to the presence of
dangerous CO (carbon mono oxide).
 It is lighter than air that means if it is leaked in the atmosphere than it
will be collected at the bottom.
 Coke oven gas is usually colorless and has a smell of naphthalene.
 On burning it gives yellow color flame
 Its explosive limit is 6 to 30 %. That means if the gas is leaked in the
atmosphere and its percentage in the atmosphere lies in this range
than it cause explosion.
 Calorific value is 4332 Kcal/meter cube.
Presence of higher concentration of CO in coke oven gas is very harmful for us.
It reacts with the hemoglobin present in our blood and makes a complex compound called
carboxyl-hemoglobin. Due to this, the oxygen content of the blood is reduced which result
in unconsciousness and even death also.
So if coke oven gas is leaked than it will be very harmful for human health. For this,
a device called CO gas monitor is used which measures the amount of CO present in the
atmosphere. The presence of CO in the atmosphere should be less than 40 ppm. If the CO
content is equal to 40 ppm then the workers can work up to 8 hours in that atmosphere.
iii) Hydraulic press:
Hydraulic press are used for making coal brick. And this brick in the
size of 1 m long and 30 cm width and 30 cm breadth. Coal brick is vary compact
and pressurized so the it easy to convey one place to another place.
iv) Pushing Car and Quenching Car:-
The plant has 3 cars for the travelling of coal and hot cock. It have 3 car such
as:
1) Pushing car

9. 2) Moving Car
3) Quenching car
This three car travelled each side of cock oven. This car are travelled in the
rail. Its have train type arrangement for moving the car. It have 5.6 kV electric
line at the bottom side of cock oven and a electrical motor used to run the
car. This car is operated by control room.
Pushing car used to push the coal bricks on the moving car and also it is using for pushing
the coal into the oven. When cock making
process is done it is used to using to push the red hot cock in the quenching car. Moving car
is used for transportation the coal brick to cock oven. Quenching car using for the
transporting the red hot cock from cock to water spray zone. Once the coal is quench by
water then it gone in the blast furnace and DRI kiln plant by the conveyor belt
8.2DIR Kiln Plant:-
Bhusan power plant have the 12 DRI (Direct Reduction Iron) kiln. 8
Kiln on one group and reaming 4 on the other group. The overall production of the plant is
about 500 TPD (Ton per Day). The product of kiln plant is the sponge iron.
Each DIR Kiln has 3 bunker.
i) Iron ore bunker.
ii) Feed coal bunker.
iii) Dolomite bunker.
They are feed in kiln by the web feeder. Each bunker have
Different wed feeder for the different gear ratio for the different combination of
the iron ore, coal and dolomite.
Size of one kiln:- 80 m length.
4 roller and tires are used here. At the center of the kiln on gear is fastend which
is rotated by the pinion.
Teeth on gear 190
Teeth on the pinion 25
Module 55
Pressure angle 21.4
Each kiln have 2 Gear box 1st Master gear and 2nd Sleeve Gear.
The rotary kiln have 8 burner fan on the different location. Fan Discharge capacity is 7000
m3/h.
It have the 11 temperature zone. Where the different temperature achieved in the
different zone.Where temperature is to measure.
Working:-
DRI kiln have 2 circuits.

10. 1) Feed circuit.
2) Ignition circuit.
1) Feed circuit:-
It have3 basic material to feed are is,
I iron ore
II Coal (washed coal)
III Dolomite
2) Ignition Circuit:-
Ignition circuit have air blow with the fine coal in opposite side of the feed circuit.
Which is used to burning process in kiln.
Blower fan is used to accelerate the process according to needed the
time of burning. DRI kiln also have a cooling roller, when the red hot sponge iron is
coming from the kiln, then It is used to cool the sponge iron. This cooler situated on
lower side of rotary kiln.

11. 9.0 Mechanical work performed on these plant.
9.1Maintenance work
1. Preventive Maintenance
2. Proactive Maintenance
3. Breakdown Maintenance
Preventive Maintenance
Preventive maintenance (PM) has the following meanings:
1. The care and servicing by personnel for the purpose of maintaining equipment and
facilities in satisfactory operating condition by providing for systematic inspection,
detection, and correction of incipient failures either before they occur or before
they develop into major defects.
2. Maintenance, including tests, measurements, adjustments, and parts replacement,
performed specifically to prevent faults from occurring.
Proactive Maintenance
A proactive maintenance plan gives a company the ability to prolong the life of machinery
and prevent a complete and unexpected breakdown of production facility. A proactive
maintenance plan allows an organization to schedule production shutdowns for repairs,
inspection and maintenance.

12. Breakdown Maintenance
It is maintenance done when need arises. This maintenance is performed after one or more
indicators show that equipment is going to fail or that equipment performance is
deteriorating.
 The maintenance work is held on every day in between 2pm to 4pm during the coal
coking process (conversion of coal in coke.)
 In between these 2 hour wheels of car (pushing and quenching car), lubrication,
hydraulic system are inspected.
 In dir kiln the inspection work is held on in between every 2 hours .
 The area of inspection in DIR kiln is spur gear , lubrication and temperature of DIR
kiln etc.
 To measure the temperature, radiation pyrometer and bimetallic thermometer
(thermocouple up to 400ċ) are use.
Crane Maintenance: All picking and placing of ladles is done by the large Mixer cranes. also
all these processes are quite complicated and also the handling temperature is very high
ranging from 1200 to 1300 0C with the dust particle in the form of chips. All these cranes
require maintenance regularly keeping in mind the safety of workers and proper working of
the cranes for continuous operation of the steel production. In plant, all the transferring
process from one place to another is done by electric overhead travel cranes. As the name
implies, this type of crane is provided with movement above the floor level. Hence it occupies no
floor space and this can never interface with any movement of the work being carried out at the
floor of the building. These cranes are capable of lifting the load as large as 400-500 MT.
The three motions of such crane are the hoisting motion (lifting), long travel and the cross travel
motion. Each of the motions is provided by electric motors .The lifting of load takes place with
the help of a hoist mechanism. In hoist mechanism, an electric motor is used which
transmits the power to a drum which ultimately regulates the rope for the vertical
movement of hooks. The vertical movement is for lifting the load. Now for transferring the
load, there are two types of movement i.e. longitudinal travel and cross travel. For these the
guide ways are provided.

13. Usually the hooks are of two types - main hook and auxiliary hook.
The main hook is used for lifting of the ladle and auxiliary is used for tilting the ladle.
All these cranes require maintenance regularly keeping in mind the safety of workers and
proper working of the cranes for continuous operation of the steel production. Now, the
preventive maintenance of the cranes is done on weekly basis.
The mechanical maintenance includes-
 Ensure there are no loose, broken, or damaged parts on the hoist, trolley, bridge,
runway, or electric systems.
 Lubrication of gears and other mechanical components. . The lubrication should be
done timely to prevent the dry running of gears. Dry running causes rapid wear and
tear which ultimately reduces the life of gears and also the transmission efficiency.
Usually for lubrication of reducer same oil is used which we use in automobiles.
 Checking the brake clearance. The brakes used in EOT cranes are electromagnetic
drum brakes. So, during every maintenance we have to check coil and brake pads
and the gap between the drum and pads.
 Inspecting ropes and checking that the operating conditions of parts are good or
not and inspect if any breakdown that may happen in future.
 Check that the wire rope is revved and seated in the drum grooves properly. Verify
that the bottom block is not twisted (no two lengths of wire rope should touch).

14.  For lubrication purpose, earlier the mixture of oil and grease was used. But now a
days only oil is used for lubrication purpose. In lubricating the gears and brakes,
commonly used oils are Servo steel 460 and Servo mesh 460. In that also, servo
mesh 460 is mostly used. Servo steel 460 is used for higher temperature
applications. Here the prefix 460 shows the viscosity of the lubricant in centi- poise.