I had done my 2 weeks Vocational Training from Bhilai Steel Plant, Bhilai situated in Chhattisgarh. I am sharing my final internship report which I made for the submission in my University.

1. VOCATIONAL
TRAINING AT
BHILAI STEEL PLANT
Under the guidance of Academic Mentor
– Prof. Md. Izhar Hussain
PRESENTED BY- AMUL RAJ
4TH SEM, METALLURGICAL &
MATERIALS ENGINEERING
01UG18050013
OP JINDAL UNIVERSITY, RAIGARH
INTERNSHIP REPORT ON

2. Acknowledgement
The internship opportunity I had with Bhilai Steel Plant, Bhilai was a great
chance for learning and professional development. Therefore, I consider myself
as a very lucky individual as I was provided with an opportunity to be a part of
it. I am also grateful for having a chance to meet so many wonderful people and
professionals who led me though this internship period. I have taken efforts in
this training.
Bearing in mind previous I am using this opportunity to express my deepest
gratitude and special thanks to my Industry Mentor, Mr. Shobhraj Sinha who in
spite of being extraordinarily busy with his duties, took time out to hear, guide
and keep me on the correct path and allowing me to carry out my training at
their esteemed organization and extending during the training.
However, it would not have been possible without the kind support and help of
my Academic Guide, Prof. MD. Izhar Hussain. He was always InTouch with me
for any kind of help I needed. I would like to express my gratitude towards my
parents & member of SAIL-BSP, Bhilai for their kind co-operation and
encouragement which help me in completion of this training.
Thank You !

3. An Overview of Bhilai Steel Plant
Eleven times winner of Prime Minister's Trophy for Best Integrated Steel Plant in the country, Bhilai Steel Plant (BSP) is India's sole
producer & supplier of world class rails for Indian Railways including 260 metre long rails, and a major producer of large variety of
wide and heavy steel plates and structural steel. It is an organization under Steel Authority India Limited (SAIL), situated in the city of
Bhilai in the state of Chhattisgarh. It was established in the year 1955 with the help of USSR.
With an annual production capacity of 3.153 MT of saleable steel, the plant also specializes in other products such as wire rods and
merchant products. The entire range of TMT products (Bars & Rods) produced by the Plant is of earthquake-resistant grade and
superior quality. The plant also produces heavy structural including channels and beams.

4. Departments covered during the
training period
15/06/2020 – 27/06/2020
Coke
Oven
Coke Oven
Batteries
CCD SP -III
Sintering Plant
Blast
Furnace
SMS-
II
MARS
–I
Machine
Assembly & Re-
Engineering
Services
Coal Chemical
Department
Visit to Asia’s
largest Blast
furnace
Steel Melting Shop

5. PROCESS FLOW CHART OF BHILAI STEEL PLANT

6. 1. COKE OVEN
A Battery with RAM coke pusher
A coal tower providing coal
to batteries
Coke quenching using
phenolic water
• No. of Coke oven batteries in Bhilai Steel Plant - 11
• Height of the batteries - Varies from 4 mts to 7 mts.
• Input Materials – Coal
• Output Materials – Coke, ash, moisture, coke oven gas
• Process – Heating of coal at 900 degree Celsius upto 17-18 hrs.
(1500-1600 degree Celsius)
• Capacity of Coal tower- 3000 tons
• Capacity of batteries – 16 tons and 32 tons
• Major imports of coal – US, Russia, Australia
An information of capacities of each Coke Oven present in Bhilai Steel Plant

7. 2. COAL-CHEMICAL DEPARTMENT
DECANTER BENZOYL RECOVERY
PLANT
DISTILLATION SULPHUR
EXCESS AMMONIA
STORAGE TANK
TAR STORAGE TANK EXHAUSTER HOUSE
The coke oven gas is distilled at different temperatures to obtain the various by-products. After the extraction of all
the necessary by-products the final gas is then used for re-heating purposes in Blast Furnace, Coke Oven and Mills.
Above images are the display of various process during the distillation of the Coke Oven Gas.

8. 3. SINTERING PLANT
Sinter materials in a conveyer belt
Sinter Materials being seperated
There are 3 sintering plants in Bhilai Steel
Plant, namely SP -1,2, and 3.
Sinter plants agglomerate iron ore fines with
other fine materials at high temperature, to
create a product that can be used in a blast
furnace. The final product, a sinter, is a
small, irregular nodule of iron mixed with
small amounts of other minerals.
Input – Fe ore fines, flux, coke dust, mill
scale, scrap fines, limestone, BOF slag, Mn
ore.The encircled area shows the batch wise entry of sinter
materials into the blast furnace

9. 4. BLAST FURNACE
Blast Furnace-8, named ‘Mahamaya’ , One of Asia’s
largest Blast Furnaces
Series of Blast furnaces with stove and cast house in it’s
opposites sides.
Molten Metal coming out through
channels in a cast house
There are 8 blast furnaces in Bhilai Steel Plant. BF 1-3 are early established, BF 4-6 were during
the mid 70s and BF 7 & 8 are recently established. The coke, iron ore, and limestone along with
sinter materials are heated at 900°C - 1300°C with hot blast furnace gas being provided inside it
with the help of tuyeres. The hot gas comes from a stove being heated all the time where the coke
oven gas is reheated. Once the process is over the drill machine is used to open the tap hole and
let the molten metal flow into the channel. The channel gets separated into two parts and slag is
separated from the either side of the channel. Molten metal is then collected into a ladle/torpedo
and then is ready to be taken to Steel Melting Shops.

10. 5. STEEL MELTING SHOP
PRIMARY STEEL MAKING
A Basic Oxygen Furnace
SECONDARY STEEL MAKING
Vacuum Arc Degasser Ladle Furnace R-H Degasser
Continuous Casting Route
There are 3 Steel Melting Shops in Bhilai Steel Plant among which SMS-3 is the latest and newest one.
The molten metal is brought into the converter shop of a steel melting shop through the torpedo and here are
poured into a ladle and the ladle is dumped into a BOF. Oxygen is blown through a pipe into the furnace and scraps
are added to it ( mill scale/ iron scarps). The furnace is tilted to an axis of 360° and slag is removed from the top of
it. Now the molten steel is poured into a ladle and is taken to further processing's such as VAD, LF, RH DEGASSER
where various elements are stabilized into the steel as per the requirement of the customer. De - Sulpharization is
done to reduce the sulphur content which is done in a VAD. LF is used to reheat the molten steel. RH degasser
helps to reduce the dissolved hydrogen gases to maintain the quality of the steel. Finally the ladle is taken to a
Continuous casting shop where the molten steel is poured into the cast and Blooms of steel are obtained as per
required dimensions and are cooled down and sent to various other mills.

11. 6. MACHINE ASSEMBLY &
RE-ENGINEERING
SERVICES
A typical machine shop representation in a steel industry
Machine assembly & Re- Engineering Services is the
machine shop built under 4 MT expansion of BSP to
cater to the spares and assemblies requirements of
Converter Shop, Continuous Casting Shop, and Plate
Mill. The shop has got two machining bays (Light bays
and Heavy & Medium bays 78×24 M each). And one
Assembly bay (72×24 M) which forms a Tee with the
machining bays.
Main assemblies done are 5-roll set, 8-roll set, 10-roll
set, and Pinch rolls used in Slab Caster of Continuous
Casting Shop.

12. HIGHLIGHTS
◦ Bhilai Steel Plant (BSP) is eleven-time winner of the Prime Minister's Trophy for best integrated steel plant in the country. The
plant is the sole supplier of the country's longest rail tracks, which measure 260 metres (850 ft).
◦ SAIL has an annual turnover of INR 66967 Crores or 8.91 Billions US Dollars in which for the FY -2019, Bhilai Steel Plant has
contributed 25% of its revenue.
◦ An annual production of 4.70 MT of Hot Metal in BSP and overall a production of 16.3 million metric ton annually of SAIL has
been observed.
◦ 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.

13. CONCLUSIO
N
Within these two weeks of vocational training I’ve got the basic knowledge about the whole steel making
process. What I’d learnt in books were a little confusing and theory bind-up. Moreover the visit to each and
every essential department brought me a clear knowledge about steel making. I came to know about the steps
during the preparation of coke to reactions in a blast furnace. Steel Melting Shops are the heart of a steel
industry and I’ve observed step-by-step procedures during the preparation of steel to blooms and pellets. I’ve
also noted down some key points regarding the processes and reactions involved in a blast furnace as a
reference.
Thus, this vocational training of two weeks helped me a lot in building my blocks of steel industry strongly. I
admire more trainings from different organizations in future for better learning.

14. THANK YOU !