SAIL Bokaro Steel Plant Report

VACATIONAL TRAINING REPORT Page | 1
SUMMER VACATIONAL TRAINING REPORT
Industrial Training At :-
Steel Authority of India Ltd.
Bokaro Steel Plant
Bokaro Steel City, Jharkhand
Training Period :- 24/06/2019 To 20/07/2019
Prepared By :- AFTAB ALAM
Year :- 3rd
Year 6th
Semester
Session :- 2018-19
Department :- MECHANICAL ENGINEERING
University Roll No. :- 10300717021
College :- Haldia Institute Of Technology, Haldia

ACKNOWLEDGEMENT
I would to like to express my sincere gratefulness
and profound gratitude to STEEL AUTHORITY of
INDIA LTD. for providing an opportunity to undergo
Vacational Training at “Bokaro Steel Plant”, Bokaro
Steel City,Jharkhand.
I bear immense pleasure in expressing my gratitude
and thanks to all the Employees of respective
departments for their honest teaching, practical
demonstration, guidance and suggestions.
This training won’t be possible without the
permission of Asst. Training and Placement Officer
MD. JALAL KHAN and HOD of Mechanical
Engineering Department Dr.(Prof.)Goutam Kumar
Bose of HIT, HALDIA ,so thanks to them as well.

CONTENTS
1. Introduction
2. Process Flow of Steel Production
3.Areas Covered
3.1. Foundry Shop
3.2. Operational Garage
3.3. Traffic
3.4. Refractory Material Plant
3.5. Power Engineering Brigade
3.6. Raw Material Handling Plant
4.Products and Market of Bokaro Steel Plant
5.Conclusion

1.INTRODUCTION
Steel Authority of India Limited (SAIL) is an Indian state-owned steel making
company based in New Delhi, India. It is a public sector undertaking, owned and
operated by the Government of India with an annual turnover of INR 44,452 Crore
(US$6.83 Billion) for fiscal year 2016-17. Incorporated on 24 January 1973, SAIL
has 72,004 employees (as of 01-May-2019). With an annual production of 14.38
million metric tons, SAIL is the 20th largest steel producer in the world and the 3rd
largest in India .The Hot Metal production capacity of the company will further
increase and is expected to reach a level of 50 million tonnes per annum by 2025.
Sri Anil Kumar Chaudhary is the current Chairman of SAIL.
SAIL operates and owns 5 integrated steel plants
at Bhilai, Rourkela, Durgapur, Bokaro and Burnpur(Asansol) and 3 special steel plants
at Salem, Durgapur and Bhadravathi. It also owns a Ferro Alloy plant at Chandrapur. As
a part of its global ambition, the company is undergoing a massive expansion and
modernisation programme involving upgrading and building new facilities with emphasis
on state of the art green technology. According to a recent survey, SAIL is one of India's
fastest growing Public Sector Units. Besides, it has R&D centre for Iron & Steel (RDCIS),
centre for Engineering in Ranchi, Jharkand.
History
1959–1973
SAIL traces its origin to the Hindustan Steel Limited (HSL) which was set up on 19
January 1954. HSL was initially designed to manage only one plant that was coming up
at Rourkela.
For Bhilai and Durgapur Steel Plants, the preliminary work was done by the Iron and
Steel Ministry. From April 1957, the supervision and control of these two steel plants
were also transferred to Hindustan Steel. The registered office was originally in New
Delhi. It moved to Calcutta in July 1956, and ultimately to Ranchi in December 1959.
A new steel company, Bokaro Steel Limited (Bokaro Steel Plant), was incorporated on
29 January 1964 to construct and operate the steel plant at Bokaro. The 1 MT phases
of Bhilai and Rourkela Steel Plants were completed by the end of December 1961. The
1 MT phase of Durgapur Steel Plant was completed in January 1962 after
commissioning of the Wheel and Axle plant. The crude steel production of HSL went up
from 1.58 MT (1959–60) to 1.6 MT. The second phase of Bhilai Steel Plant was
completed in September 1967 after commissioning of the Wire Rod Mill. The last unit of
the 1.8 MT phase of Rourkela – the Tandem Mill – was commissioned in February 1968,
and the 1.6 MT stage of Durgapur Steel Plant was completed in August 1969 after
commissioning of the Furnace in SMS. Thus, with the completion of the 2.5 MT stage at
Bhilai, 1.8 MT at Rourkela and 1.6 MT at Durgapur, the total crude steel production
capacity of HSL was raised to 3.7 MT in 1968–69 and subsequently to 4 MT in 1972–73.
IISCO was taken over as a subsidiary in 1978 and later merged in 2006.

Holding Company
The Ministry of Steel and Mines drafted a policy statement to evolve a new model for managing
industry. The policy statement was presented to the Parliament on 2 December 1972. On this basis
the concept of creating a holding company to manage inputs and outputs under one roof was
mooted. This led to the formation of The Steel Authority of India Ltd. The company, incorporated on
24 January 1973 with an authorised capital of ₹2,000 crore (US$290 million), was made responsible
for managing five integrated steel plants at Bhilai, Bokaro, Durgapur, Rourkela and Burnpur, the
Alloy Steel Plant and the Salem Steel Plant. In 1978 SAIL was restructured as an operating
company.
Major Units
SAIL Integrated Steel Plants
Durgapur Steel plant
1. Rourkela Steel Plant (RSP) in Odisha set up with German collaboration (The first integrated
steel plant in the Public Sector in India, 1959)
2. Bhilai Steel Plant (BSP) in Chhattisgarh set up with Soviet collaboration (1959)
3. Durgapur Steel Plant (DSP) at Durgapur, West Bengalset up with British collaboration (1965)
4. Bokaro Steel Plant (BSL) in Jharkhand (1965) set up with Soviet collaboration (The Plant is
hailed as the country's first Swadeshi steel plant, built with maximum indigenous content in
terms of equipment, material and know-how).
5. IISCO Steel Plant (ISP) at Burnpur in Asansol, West Bengal (Plant equipped with Largest
Blast Furnace of country, Modernized in 2015 with investment of 16000 crore which will yield
total production of 2.9 Million Ton annually ).
Special Steel Plants
1. Alloy Steel Plant (ASP), Durgapur, West Bengal supplies to the Indian Ordnance Factories
2. Salem Steel Plant (SSP), Maramangalathupatti, at Salem, Tamil Nadu
3. Visvesvaraya Iron and Steel Limited (VISL), at Bhadravathi, Karnataka
Ferro Alloy Plant
1. Chandrapur Ferro Alloy Plant (CFP) in Maharashtra

Refractory Plants - SAIL Refractory Unit (SRU)
1. SAIL Refractory Unit, Bhandaridah in Jharkhand
2. SAIL Refractory Unit, Bhilai in Chhattisgarh
3. SAIL Refractory Unit, IFICO, Ramgarh in Jharkhand
4. SAIL Refractory Unit, Ranchi Road in Jharkhand
Central Units
1. Centre for Engineering and Technology
2. Research and Development Centre for Iron and Steel
3. SAIL Consultancy Organisation
4. Environment Management Division
5. Management Training Institute ,Ranchi
Joint ventures
NTPC SAIL Power Company Limited (NSPCL)
A 50:50 joint venture between Steel Authority of India Ltd. (SAIL) and National Thermal Power
Corporation Ltd. (NTPC Ltd.). It manages the captive power plants at Rourkela, Durgapur and Bhilai
with a combined capacity of 314 MW. It has installed additional capacity by implementation of 500
MW (2 x 250 MW Units) power plant at Bhilai. The commercial generation of Unit 1 commenced in
April 2009 and the Unit 2 in October 2009.
 NSPCL, Rourkela (2 x 60 MW)
 NSPCL, Durgapur (2 x 60 MW)
 NSPCL, Bhilai (2 x 30 MW + 1 x 14 MW)
During FY2013-14, NSPCL generated 6156.091 MU of electricity with a PLF of 86.33%
Bokaro Power Supply Company Pvt. Ltd. (BPSCL)
Established in 2001, A 50:50 joint venture between Steel Authority of India Ltd. (SAIL) and Damodar
Valley Corporation (DVC) and is engaged in power and steam generation and supplies power and
steam (at various pressures) to SAIL's Bokaro Steel Plant (BSL) located at Bokaro for meeting the
process requirement of BSL.
The plant has 9 boilers (5 boilers each of 220 TPH, 3 boilers each of 260 TPH capacity and 1 boiler
of 300 TPH) and 7 turbine generators (one 12 MW back Pressure Turbine Generator (TG), 2 TGs
each of 55MW capacity, 3 TGs each of 60 MW capacity and one 36 MW back Pressure Turbine
Generator. Gg

TPP
BOILER CAPACITY(T/Hr)
DATE OF
COMMISSIONING
MAKE TYPE
1 220 17.04.1972
Kransy
Kotelsic,
Russia
Tπ-156
2 220 14.07.1972
3 220 06.04.1974
4 220 15.07.1980
5 220 23.06.1980
TOTAL 1100
CPP
6 260 14.11.1985
Rafaco,
Poland
OPG-2607 260 30.07.1988
8 260 19.02.1989
TOTAL 780
UNIT
9
9 300 02.09.2014
Alstom
India
PCSM00
6071
TOTAL 2180

TPP
TURBINE CAPACITY(MW)
DATE OF
COMMISSIONING
MAKE TYPE
1 12 (BPTG) 31.12.1974 Kaluga Russia P-12-90-37
2 55 13.07.1972
LMZ Russia K-50-90-4
3 55 13.10.1973
TOTAL 122
CPP
6 60 25.01.1986
Zamech
Poland
9K-667 60 16.09.1988
8 60 31.03.1889
TOTAL 180
UNIT
9
9 36 (BPTG) 02.09.2014
Skoda, Czech
Rep.
PCSM006
071
TOTAL 338 With 660 TPH (Steam to BSL)
Mjunction services limited
mjunction services limited operating in Information Technology and the Internet, is a 50:50 venture
promoted by SAIL and TATA Steel. Founded in February 2001, it is today not only India's largest
eCommerce company (having eTransacted worth over Rs. 900 billion till date) but also runs the
world's largest eMarketplace for steel.
Bhilai JP Cement Ltd
SAIL has incorporated a joint venture company with M/s Jaiprakash Associates Ltd to set up a 2.2
MT slag based cement plant at Bhilai. The company shall commence cement production at Bhilai by
March'2010, whereas clinker production at Satna shall start within 2009.

Bokaro JP Cement Ltd
SAIL has incorporated another joint venture company with M/s JaiPrakash Associates Ltd to set up a
2.1 MT cement plant at Bokaro utilising slag from BSL. The project implementation is under progress
with commencement of cement production likely by July 2011. Bokaro Jaypee cement plant opening
ceremony was held by the chief minister of Jharkhand shri. Arjun Munda in 2012.
SAIL&MOIL Ferro Alloys (Pvt.) Limited
SAIL has incorporated a joint venture company with Manganese Ore (India) Ltd on 50:50 basis to
produce ferro-manganese and silico-manganese required for production of steel.
S&T Mining Company Pvt. Ltd
SAIL has incorporated a joint venture company with TATA Steel for joint acquisition and
development of coal blocks/mines. New indigenous opportunities for coking coal development are
being explored by the joint venture company for securing coking coal supplies.
International Coal Ventures Pvt. Limited
International Coal Ventures Private Limited is a special purpose vehicle set up to achieve the target
of making steel PSUs self-reliant in the area of coking coal, a joint venture company has been
incorporated composed of five central PSU companies i.e. SAIL, Rashtriya Ispat Nigam
Limited (RINL), Coal India Limited and other target countries.
Development of Hajigak iron ore mines in Afghanistan
A consortium comprising state-owned NMDC and RINL and private sector steel players—JSW, JSW
Ispat, Jindal Steel and Power, and Monnet Ispat and Energy and led by SAIL, plan to invest USD 75
million in first phase for the development of Hajigak iron ore mines in Afghanistan. The consortium,
in November 2011, had won the mining rights for three iron ore mines which are said to contain 1.28
billion tonnes of rich reserves.
Development of mines through outsourcing
SAIL has decided to outsource development of two virgin iron ore mines at Rowghat in Chhattisgarh
and Chiria in Jharkhand with an annual capacity of 14 and 15 million tonnes, respectively. The
development of each mine is likely to cost between ₹1,000 crore (US$140 million) – ₹1,200
crore(US$170 million).
SAIL SCL Limited
A 50:50 JV with Government of Kerala where SAIL has management control to revive the existing
facilities at Steel Complex Ltd, Calicut and also to set up, develop and manage a TMT rolling mill of
65,000 MT capacity along with balancing facilities and auxiliaries.
International Coal Ventures Private Limited
ICVL is a joint venture of five companies owned by the Indian government. Aside from Steel
Authority of India Limited, the other venturers are Coal India, Rashtriya Ispat Nigam, National
Minerals Development Corporation and National Thermal Power Corporation. ICVL acquired a 65
percent stake in the Benga coal mine from the Rio Tinto Group in July 2014.

SAIL RITES Bengal Alloy Casting Pvt. Limited
SAIL has signed a 50:50 joint venture with Burn Standard Company Limited for setting up a wagon
components manufacturing facility at Jellingham in West Bengal's Purba Medinipur district. The total
investment for this project would be ₹210 crore (US$30 million) in West Bengal, and commercial
production would begin from 2014. It will manufacture, sell, market, distribute and export railway
wagons, including high-end specialised wagons, wagon prototypes, fabricated components/parts of
railway vehicles, rehabilitation of industrial locomotives, etc., for the domestic market.
Ownership and management
The Government of India owns about 75% of SAIL's equity and retains voting control of the company.
However, SAIL, by virtue of its Maharatna status, enjoys significant operational and financial
autonomy.
Mr. Anil Kumar Chaudhary is the current chairman. He succeeded Shri Saraswati Prasad.
Operations
As of 31 March 2015, SAIL has 93,352 employees, as compared to 170,368 (as of 31 March 2002).
There has been a continuous reduction of headcount over the past few years due to enhanced
productivity and rationalised manpower.
The total requirement of its main raw material, iron ore, is met through its captive mines. To meet its
growing requirement, capacities of existing iron ore mines are being expanded and new iron ore
mines are being developed. In addition, new iron ore deposits in the states
of Rajasthan, Chhattisgarh, Madhya Pradesh, Maharashtra, Odisha and Karnataka are being
explored. Around 24% of its coking coal requirements are met from domestic sources, the remaining
through imports. For improving coking coal security, the company is also making efforts for
development of new coking coal blocks at Tasra and Sitanalla.
SAIL produced 13.9 million tonnes of crude steel by operating at 103% of its installed capacity,
which is an increase of 1% over the previous year. It also generated 710 MW of electricity during
FY2014-15.
Achievements
 "Best of all" Rajiv Gandhi National Quality Award in 1993, 2006, and 2007 for their Bhilai and
Bokaro plants
 Quality Summit New York Gold Trophy 2007 (International Award for Excellence & Business
Prestige) and Award of Excellence Maintenance for Sumitomo Heavy Industry & TSUBKIMOTO-
KOGIO, Japan won by Alloy Steel Plant, Durgapur.
 SAIL was featured in the 2008 list of Forbes Global 2000 companies at position 647.
 Golden Peacock Award for Combating Climate Change – 2008 for BSP, Occupational Health
and Safety- 2008 for BSL
 National Safety Award to Bhilai Steel Plant announced by the Ministry of Labour & Employment,
Government of India – 2008
 Durgapur Steel Plant won the 2nd Prize in the Association of Business Communicators of India
Awards – 2008.
 Ispat Bhasha Bharati. the Rajbhasha Journal of SAIL has been awarded with the first prize
under the All India House Journal Award Scheme – 2008–09
 Salem Steel Plant received the prestigious Greentech Gold Award in Metal and Mining Sector –
2008–09.

 Golden Peacock Award for Corporate Social Responsibility won by Bhilai Steel Plant (BSP) for
the third year in a row – 2009.
 Rourkela Steel Plant collectedthe prestigious Srishti Good Green Governance (G-Cube)
Award – 2009.
 Greentech HR Excellence Award secured by the Durgapur Steel Plant – 2009
 The steel township of Rourkela Steel Plant (RSP) has been ranked 14th in sanitation and
cleanliness by Union Urban Development Ministry – 2009–10
 Greentech Safety Gold Award was given to Bhilai Steel Plant – 2010
 The HR Excellence Award by the Greentech Foundation won by Bhilai Steel Plant – 2010
 SSP has won the prestigious Greentech Silver Award in Training Category of Greentech HR
Excellence Awards – 2010.
 Award for financial and operational strength by Indian Institute of Industrial Engineering (IIIE)-
2009–10
 Golden Peacock Environment Management Award – 2011
 Randstad Award for HR Practices and Employer Branding under 'Manufacturing Industries'
category – 2011
 Maiden Wockhardt Shining Star CSR Award in the Iron & Steel Sector category – 2011.
 Salem Steel Plant (SSP) has won the prestigious National Sustainability Award for the 6th time
in succession and 13th time since inception of the award from Indian Institute of Metals (IIM)-
2011
Of the 33 Prime Minister's Shram Awards announced for 2010 by the Ministry of Labour,
Government of India,17 of which went to PSUs, SAIL employees won 11 awards. Of the total
number of 76 awardees for the year, 45 belong to SAIL – a remarkable distinction for any
organisation. Maharatna SAIL has received the prestigious Golden Peacock Environment
Management Award for the year 2011. The award, in recognition of SAIL's initiatives and
achievements in the field of environment management, was presented by Union Minister for Home
Affairs Shri P. Chidambaram on 24 June 2011
74 of a total of 128 awardees who have won the prestigious Vishwakarma Rashtriya Puraskar (VRP)
are from SAIL. The 15 out of 28 awards won by SAIL went to our 74 employees for the performance
year 2008. Bhilai Steel Plant won 7 such awards involving 36 employees, Bokaro Steel Plant won 6
awards involving 29 employees. Durgapur Steel Plant and Salem Steel Plant both won 1 award each
involving five and four employees respectively. SAIL employees have won 4 out of 5 awards of
Class A, which is the highest number of A Class awards won by any PSU in India.
Future Plans
SAIL, is in the process of modernising and expanding its production units, raw material resources
and other facilities to maintain its dominant position in the Indian steel market. The aim is to increase
the production capacity from the base level production of 14.6 MT per annum (2006–07) to 26.2 MT
per annum of Hot Metal.
The following table shows the increased production of various items prior to and post expansion.
On 25 May 2012, Steel Authority of India Limited entered into a Memorandum of Understanding with
the Government of West Bengal and Burn Standard Company Ltd. for setting up of a Railway
Wagon factory of approximately ₹210 crore (US$30 million). This project will create an approximate
75,300 jobs.
The company also looking to establish one full capacity integrated plant in Andhra
Pradesh or Telangana and surveying the possibilities to set up the plant. The plant, which was
proposed to be the first steel plant of such scale in the state, was estimated to get an investment of
Rs. 4,400 crore.

BOKARO STEEL PLANT
Bokaro Steel Plant Main Gate
Bokaro Steel Plant (BSP) is located in the Bokaro district of Jharkhand. It is the fourth integrated
public sector steel plant in India built with Soviet help. It was incorporated as a limited company in
1964. It was later merged with the state-owned Steel Authority of India Limited (SAIL).Currently it
houses five blast furnaces with a total capacity to produce 5.2 MT of liquid steel. The plant is
undergoing a mass modernisation drive after which its output capacity is expected to cross 10 MT.
An up gradation of the plant was also done in 1990’s in its steel refining units and Continuous
Casting Machines. The plant has recently taken expansion plan along with Korean Steel Company,
Pohang Iron and Steel Company (POSCO). Initially, about 64 moujas (a mouja may have several
village units) had been acquired for the plant. Of the total land acquired, only 7,765 ha was used to
set up the steel plant. The rest has been given by SAIL to the private parties without government’s
approval.The plant's yearly profit stood at ₹11.2 billion(US$160 million) for the financial year 2003–
04 and has increased every year since then reaching to 84.26 billion INR in the financial year 2007–
08.
Major Landmarks in the History of Bokaro Steel Plant
YEAR & MONTH LANDMARKS
1966, JANUARY Beginning of Construction
1972, SEPTEMBER First Coke Oven Battery and Sinter Band Commisioned
1972, OCTOBER First Blast Furnace Commisioned
1973, DECEMBER Steel Melting Steel – 1 Started Ptroduction
1974, DECEMBER Trial Roll of Slabs in Slabbing Mill
1975, DECEMBER Hot Strip Mill Commissioned
1976, JANUARY Hot Rolled Coil Finishing Commissioned
1977, JUNE Cold Rolling Mill Complex -1 Commissioned
1983, JUNE Steel Melting Shop – 2 Started Production
1991, SEPTEMBER Cold Rolling Mill Complex – 2 Commissioned
1997, SEPTEMBER Continuous Casting Shop Started Production

Products
Bokaro Steel Plant is designed to produce a wide range of flat products:
 Hot rolled coils
 Hot rolled plates
 Hot rolled sheets
 Cold rolled coils(CRM)
 Cold rolled sheets
 Tin mill black plates (tmbp)
 Galvanised plain and corrugated (gp/gc) sheets
 Oxygen Gas Produced in Oxygen Plant.
 Hydrogen Gas
 Coke Oven byproducts
 Cowdung Mannure
The new features added in modernization of SMS-II include two twin-strand slab casters along
with a Steel Refining Unit. The Steel Refining Unit was inaugurated on 19th
September, 1997 and
the Continuous Casting Machine on 25thApril, 1998. The modernization of the Hot Strip Mill saw
addition of new features like high pressure de-scalars, work roll bending, hydraulic automatic
gauge control, quick work roll change, laminar cooling, etc. New walking beam reheating
furnaces are replacing the less effective pusher type furnace.
A new hydraulic coiler has been added and two of the existing ones revamped. With the
completion of Hot Strip Mill modernization, Bokaro Steel Plant is producing top quality hot rolled
products that are well accepted in the global market.
Bokaro Steel Plant is designed to produce flat products like Hot Rolled Coils, Hot Rolled Plates,
Hot Rolled Sheets, Cold Rolled Coils, Cold Rolled Sheets, Tin Mill Black Plates and Galvanized
Plain & Corrugated Sheets. Bokaro has provided a strong raw material base for a variety of
modern engineering industries including Automobile, Pipe&Tube, LPG Cylinder, Barrel and
Drum producing industries.
 Plant Area – 17,000 Acres
 Township Area – 19,000 Acres
 Carbon Content of Steel is 1.5% at Bokaro Steel Plant
Inside Bokaro Steel Plant
 300 km Railway Track
 100 Railway Crossing
 70 Locomotives
 10-12 Gates for Entry/Exit

2.PROCESS FLOW OF BOKARO STEEL PLANT

Raw materials required for the production of steel are iron ore, limestone, manganese, dolomite,
coke and sinter. These are supplied by RMHP, Coke Oven and Sinter Plant. Blast Furnace is
charged with iron ore lump along with limestone, coke and sinter. Intense heat in BF converts iron
ore and other raw materials into molten metal. This molten metal is fed to Steel Melting Shop, where
making of steel is done by blowing 99.95% pure oxygen through the molten metal to remove
impurities and suitable alloys are added to produce different grade of steel. The ingot produced in
SMS is sent to Slabbing Mill where it is converted to rectangular slabs of required dimension which
further goes to Hot Strip Mill which also gets slabs from SMS-2 which is based on Continuous
Casting method where slab is produced without requirement of ingots. These slabs are reheated and
made into sheets of different thickness in HSM. These steel sheets are rolled into coil in HRCF
where it is cut in appropriate dimension as specified by customers and packed for sale. Also the coil
from HSM is sent to CRM to produce high quality Tin Mill Black plate and galvanized product with
better strength and finishing. Cold rolling is done at temperature below re-crystallization temperature
to produce thin gauge plate of high density. Hot Dip Galvanization complex integrated with CRM
produces high quality zinc coated cold rolled steel.
Names of every departments inside plant are given below :-
1. Traffic Department
2. Raw Material Handling Plant(RMHP)
3. Coke Oven & By-Product Plant(CO&BPP)
4. Sintering Plant(SP)
5. Refractory Material Plant(RMP)
6. Blast Furnace(BF)
7. Steel Melting Shops(SMS-1&SMS-2)
8. Slabbing Mill(SM)
9. Continuous Casting Shop(CCS)
10. Hot Strip Mill(HSM)
11. Hot Rolled Coil Finishing(HRCF)
12. Capital Repair(Electrical)(CRE)
13. General Maintenance(GM)
14. Heavy Maintenance(HM)
15. Turbo Blower Station(TBS) and Outdoor Pipeline(ODPL)
16. Machine Shop(M/C SHOP)
17. Foundry Shops(FS)
18. Central Base Repair Shop(CBRS)
19. Operational Garage(OG)
20. Power Engineering Brigade(PEB)
21. Fire Station(FS)

3.AREAS COVERED
3.1 FOUNDRY SHOP
BOTTOM PLATES BEING MOULDED
 MOULDS OF 3000 PATTERNS OF SPARE PARTS
 TYPES OF MOULDING
o BOX MOULDING
o PIT MOULDING

 TYPES OF METAL USED IN MOULDING
o IRON
o COPPER
o STEEL
o ALUMINIUM
 PRODUCTS FROM INGOT MOULD FOUNDRY
o INGOT MOULD - 80 NOS./ANNUM
o BOTTOM PLATE - 150 NOS./ANNUM
o SLAG POT - 72 NOS./ANNUM]
 SIZE OF INGOT MOULD
o 17 TONS - REGULAR
o 20 TONS - REGULAR
o 25 TONS - REGULAR
o 28.2 TONS - ON DEMAND
 SIZE OF BOTTOM PLATE
o 11 TONS - REGULAR
o 14 TONS - ON DEMAND
 SIZE OF SLAG POT
o 27 TONS - REGULAR
3.2 OPERATIONAL GARAGE
 TOTAL EQUIPMENTS - 80 NOS.
 MAXIMUM CARRIAGE CAPACITY - 250 TONS
 DIESEL CONSUMPTION BY EQUIPMENTS -
1000LTRS./DAY

3.3 TRAFFIC
LOCO SHED BESIDE CENTRAL TRAFFIC STATION
 340 KMS. OF RAILWAY TRACK SPREAD INSIDE
PLANT PREMISES
 70 NOS. OF LOCOS OPERATING ACROSS
DIFFERENT DEPARTMENTS INSIDE PLANT
 APPROX. 100 RAIL CROSSINGS
 3 TYPES OF WDS CLASS ENGINES ARE BEING
USED
 TWO AREAS OF OPERATION
 INTERNAL - MOVEMENT INSIDE PLANT
 EXTERNAL - RECEIVING OF RAW MATERIALS
AND RETURNING OF EMPTY WAGONS,
DISPATCHING OF FINAL PRODUCTS

 COST OF A LOCO 15 CRS. APPROX.
 10-11 LOCOS ARE OPERATED IN BF
 10-11 LOCOS ARE OPERATED IN SMS
 DIESEL CONSUMPTION BY A LOCO 19-20
LTRS./HR.
 MAXIMUM OPERATIONAL SPEED INSIDE PLANT
60 KM
3.4 REFRACTORY MATERIAL PLANT
KILNS IN WORK
 CONVERTS LIME STONE INTO LIME AND
DOLOMITIC LIMESTONE INTO DOLOMITE
 FINAL PRODUCTS USED FOR BRICK LINING OF
CONVERTERS IN SMS - II AND METAL LADLES
 TOTAL NO. OF KILNS - 7
 CALCINATION IS DONE AT 700-900`C

 CHARGING OF RAW MATERIAL INTO KILN 24-25
TONS/HR
 DIMENSIONS OF ROTARY KILN
 LENGTH - 75 METERS
 DIAMETER - 3.6 METERS
 INCLINED AT 3.5% OF LENGTH
 DIMENSIONS OF COOLER KILN
 LENGTH - 36 METERS
 DIAMETER - 2.5 METERS
 INCLINED AT 3.5% OF LENGTH
3.5 POWER ENGINEERING BRIGADE
 PREVIOUSLY WORKING WITH BPSCL
 NOW WORKS ONLY WITH ROTORS AND VALVES

3.6 RAW MATERIAL HANDLING PLANT
TIPPLER UNLOADING MATERIALS
 OPERATION IS TO RECEIVE, STORE &
DISPATCH THE MATERIALS TO SP,BF&RMP
 CURRENTLY A TOTAL OF 5 TIPPLERS ARE
OPERATING
 TIPPLER USES SIDE ARC CHARGING
MECHANISM
 DIMENSION OF TIPPLER :-
 LENGTH - 280 MTRS.
 WIDTH - 48 MTRS.
 ANGLE OF ROTATION - 170’
 TOTAL 4 BEDS ARE AVAILABLE FOR STORAGE

 CAPACITY OF EACH BED :-
 UPTO A HEIGHT OF 7 MTRS. DURING RAINY
SEASON
 UPTO A HEIGHT OF 9 MTRS. DURING DRY
SEASON
 TWO TYPES OF MACHINE ARE USED FOR
MAINTAINING THE RAW MATERIALS :-
 RECLAIMER - TO EXCAVATE THE MATERIALS
FROM BED
 STACKER - TO ASSEMBLE THE MATERIALS
INTO BED
 FINE IRON ORES ARE SENT TO SP AND LUMPED
IRON ORES ARE SENT TO BF
 LIME AND DOLOMITE IS SENT TO RMP

4.PRODUCTS & MARKET OF BOKARO STEEL PLANT
BSL has made significant contribution in terms of meeting
domestic demand for Iron & Steel. Bokaro has been able
to produce special and new grades for Import Substitution.
Bokaro’s Pig Iron,Slabs,Hot Rolled Coils&Sheets,Cold
Rolled Coils&Sheets are exported to many countries.
The major products of Bokaro are Pig Iron,Hot Rolled
Coils/Sheets/Plates,Hot Rolled Slit Coils,Cold Rolled
Coils/Sheets,Cold Rolled Slit Coils,Galvanised
Sheets(Plain/Corrugated),Tin Gaue Black Plates.
It produces special steel products like SAILCOR,
SAILPROP, SAILMEDSi, SAILRIM, API Grade Steel,
HRNO, SAILMA, WTCR, BSL46 for auto sector, etc.
Many of these products have been introduced after
modernization. All the products of BSL are marketed in
India through SAIL’s Central Marketing
Organization(CMO).CMO keeps in touch with the
production unit as well as the transport and shipping
sector. It operates through a network of stockyards,
dockyards, branch sales offices, consignment agents,
extension counters and authorized dealers. SAIL’s
International Trade Division looks after export of steel
products, maintaining close liaison with buyers abroad. Its
products are exported to many countries.Notable among
them are Japan,Egypt,UK,Italy,Russia,Sri
Lanka,Bangladesh,Taiwan,Mayanmar & Nepal.

6. CONCLUSION
The training at BOKARO STEEL PLANT was very helpful.
Engineering students gain theoretical knowledge through
books which is volatile and less applicable without
knowing its practical implementation.Training is one of the
important aspects for an engineering student’s carrier to
strengthen the practical concepts.
It was an awesome experience in training as the things I
have learned in my previous year was seen implemented
practically.
I had a chance to see the Blast Furnace and Steel Melting
Shop where the main operation of steel plant is done and
also the working process of various other shops inside
plant which was quite interesting.
So, overall the training was more than hope to me and
helped me to acquire clear knowledge about the working
of an Integrated Steel Plant.

SAIL Bokaro Steel Plant Report

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SAIL Bokaro Steel Plant Report