1. AN INDUSTRIAL TRAINING OVERVIEW
Done by
ASHWINI KUMAR SINHA
2012UMT1408
At
DEPARTMENT OF METALLURGY AND MATERIALS
ENGINEERING
2. CONTENT
• INTORDUCTION
• HISTORY
• COMPANY PROFILE
• PROCESS FLOW
• FACILITIES
• BLAST FURNACE
• HOT STRIP MILL (HSM)
• COLD ROLLING MILLS (CRM)
• BY PRODUCTS
• CONCLUSIONS
• REFERENCES
3. INTRODUCTION
• STEELAUTHORITY OF INDIA LIMITED (SAIL) IS THE LEADING STEEL-MAKING COMPANY IN INDIA.
• SAIL IS INDIA'S LARGEST STEEL PRODUCING COMPANY WITH A TURNOVER OF RS. 47,042 CRORE.
• SAIL IS AMONG THE FIVE MAHARATNAS OF THE COUNTRY'S CENTRAL PUBLIC SECTOR ENTERPRISES.
• IT IS A FULLY INTEGRATED IRON AND STEEL MAKER.
• APPLICATIONS OF STEEL PRODUCTS:
DOMESTIC CONSTRUCTION
ENGINEERING
POWER
RAILWAY
AUTOMOTIVE
DEFENCE INDUSTRIES
4. HISTORY
• AFTER INDEPENDENCE, FOR RAPID INDUSTRIALIZATION OF THE COUNTRY,
HINDUSTAN STEEL PRIVATE LIMITED WAS SET UP ON JANUARY 19, 1954 AT
ROURKELA(ODISHA).
• THE PRESIDENT OF INDIA HELD THE SHARES OF THE COMPANY ON BEHALF OF
THE PEOPLE OF INDIA.
SAIL TODAY:
• IT IS ONE OF THE LARGEST INDUSTRIAL ENTITIES IN INDIA.
• IT HAS FIVE INTEGRATED PLANTS ,THREE SPECIAL STEEL PLANTS AND ONE
SUBSIDIARY PLANTS.
• THESE ARE PRINCIPALLY LOCATED IN THE EASTERN AND CENTRAL REGIONS OF
INDIA.
6. SPECIAL STEEL PLANTS
Visvesvaraya Iron and Steel
Plant
(VISL) in Karnataka
Salem Steel Plant (SSP) in
Tamil Nadu
Alloy Steels Plants (ASP) in West
Bengal
8. BOKARO STEEL
PLANT
• FOURTH INTEGRATED STEEL PLANT IN PUBLIC SECTOR, WELL KNOWN AS SWADESHI PLANT
• COLLABORATION AGREEMENT WITH SOVIET UNION (USSR) ON 25TH JAN, 1965 ( SAIL FOUNDATION DAY)
• TOTAL AREA 33,045.35 ACRES
• CAPACITY
• FIRST PHASE : 1.7 MT OF INGOT STEEL
• SECOND PHASE : 4.0 MT OF INGOT STEEL
• AFTER MODERNIZATION : 4.5 MT OF LIQUID STEEL
• ENOUGH SCOPE FOR FURTHER EXPANSION (PLAN FOR 7 MT)
• TYPES OF PRODUCTS
FLAT PRODUCT
ROLLED PRODUCT
9. PRODUCTS
Hot rolled sheets(HRS)Hot rolled coils(HRC) Galvanised plain and
corrugated (GP/GC) sheets
Cold rolled sheets (CRS) Cold rolled sheets(CRS) Tin mill black plates (TMBP)
10. FACILITIES
• RAW MATERIALS & MATERIAL HANDLING PLANT
• COKE OVENS & BY-PRODUCT PLANT
• BLAST FURNACES
• CONTINUOUS CASTING SHOP
• SLABBING MILL
• HOT STRIP MILL(HSM)
• COLD ROLLING MILL(CRM)
• AUXILIARY SHOPS
11. RAW MATERIAL HANDLING PLANT( RMHP )
• Raw Material Handling Plant is meant for transporting material from raw material yard to various
process units of plant.
• Iron ore lump, Iron fines, coals are received by railway rake are unlocked in wagon tippler.
• Raw materials stored in open storage yard with help of various tock yard machine but coals are
stored in coal storage silo.
• A wagon can rotate from 0-172° during tippling process.
• Unlocking time provided for one railway rake = 4 hours
• Rate of unlocking = 59 wagon*65 tones/4hours = 950 tones/hour
12. COKE OVEN & BY-PRODUCT PLANT
• In Coke Oven Plant ,coal is converted into coke by heating the prepared coal blend charge in the
in the coke ovens in the absence of air at temperature of 1000 -1100°c for period of 16 – 19
hours.
• The volatile matter of coal liberated during carbonization is collected in gas collecting mains.
• Gas cooled from 800 to 80°c is draw to coal chemical plant by exhauster .
• Residue coke is pushed out of the oven by pusher car through a guide into coke bucket.
• The Primary by-product from crude coke oven gas are Ammonium sulphate ,crude tar, crude
Benzol and cleaned coke oven gas.
• The size of Blast furnace coke is +25 -80, Nut coke +15 -25, Coke breeze +0 -15.
13. PRODUCTION FLOW DIAGRAM
COAL COAL TIPPLER
COAL SILOS
81 NOS
HAMMER CRUSHER
9 NOS
COKE OVEN BATTERY
8 NOS
69 OVENS EACH
BF COKE
+25-
80mm
NUT COKE
+15-25
COKE
BREEZE
0-15
CRUDE
TAR
AMMONIUM
SULPHTE
CRUDE
BENZOL
HP
NAPTHALEN
E
EXTRA
HARD
PITCH
PITCH
CREOSOTE
MIXTURE
ANTHRACENE
OIL
BY PRODUCT
14. SIL
O
BATTER
Y
WAGON PUSHER
CAR
CONVEYER
BELTCAPACITY :- 2500 TONES
HEIGHT :- 38 METER
DIAMETER :- 12 METER
TOTAL NO. OF BATTERY:-8
NO OF OVEN IN A BATTERY:-
69
HEIGHT:- 5 METER
LENGTH:- 15METER
CAPACITY :- 5000 TONES
WAGON TIPPLER
15. SINTERING PLANT
• 3 SINTER MACHINES: CAPACITY 6.25 MILLION TONNES PER ANNUM
• SINTERING IS THE PROCESS WHERE INCIPIENT FUSION TAKES PLACE BY COMBUSTION OF COKE
WITHIN MOVING BED OF LOOSELY PACKED FINES OF MAINLY IRON ORE, COKE & FLUX SO AS TO
AGGLOMERATE INTO A COMPACT POROUS MASS CALLED SINTER.
• 75-80% SINTER IS BEING USED IN THE BURDEN OF BF
• AREA OF EACH SINTER BELT IS 252 SQ.M.
• PRODUCTIVITY OF SINTERING BAND : 1.2 T/M2/HR.
• THREE SECTIONS
a) RAW MATERIAL SECTION
b) STOCK BIN & PROPORTIONING SECTION
c) SINTER MACHINE SECTION
A view of Sinter belt
16. BLAST FURNACE
• 5 blast furnaces in BSL.
• Each of 2000 cubic meter useful volume and 2640 T/day
Hot metal capacity
• Hot metal temperature 1460-14800C
• BF productivity: 1.4 T/m3/day
• Capacity of B F 4.585 MT of hot metal per annum
• A top pressure of 1.60(maximum=1.80) bar
is maintained at upper zone of the blast furnace to utilize co,
which is comes out from blast furnace.
18. Sintering Plant
BF1 BF2 BF3 BF4 BF5
Blast Furnace
300 T
Con-1
300 T
Con-2
Steel Melting Shop - 2
Steel Melting Shop - 1
130T
Con-1
130 T
Con-2
130 T
Con-3
130 T
Con-4
130 T
Con-5
Tandem Mill-1
Tandem Mill-2
Soaking Pit
ll
SPM 1 & 2
Hot Dip Galvanizing Line
Galvanized Sheet Shearing Line
Galvanized Sheet Corrugation Line
HR Coil
HR PLATE /
SHEET
CR Coil
CR Sheet GP Coil
Galvanized Corrugated
& Plain Sheet
Iron Ore
Fluxes
O H P
Continuous
Casting
Department
Reheating
Furnace
SAIL
Bokaro
Pig Casting Machine
H R C F
PROCESS FLOW
BF Coke
Coking Coal
Coke Breeze
PL-II
PL-I
A
N
N
E
A
L
I
N
G CRCF
COKE OVEN BATTERIES
DCR Mill
Slabbing Mill Hot Strip Mill
Iron Ore, Lime Stone
& Dolomite Fines
20. HOT STRIP MILL (HSM)
• Hot rolling involves plastic deformation of a metal under squeezing force (a pair of rolls) above
its re-crystallization temperature.
• Designed to roll thin & wide strips
• Capacity: 3.955 MT of HR coils
• Rolling speed: 20 m/sec max.
21. COIL DIMENSIONS
• STRIP THICKNESS 1.6 TO 16.0 MM
• STRIP WIDTH 910 TO 1,850 MM
• COIL INSIDE DIA 650 MM
• MAX COIL OUTSIDE DIA 2,300 MM
• MAX COIL WEIGHT 32 T
APPLICATION OF PRODUCT
• WAGON BUILDING
• TUBE & PIPE INDUSTRY
• DRUM & FURNITURE `MANUFACTURING
22. COLD ROLLING MILLS
• COLD ROLLING IS DONE TO PRODUCE THINNER GAUGE STRIP OF SMOOTH FINISH
WITH BETTER MECHANICAL PROPERTIES THAN THOSE OBTAINED BY HOT
ROLLING
• CAPACITY: 1.66 MT OF CR SALEABLE
• IT CONSISTS OF TWO SHOPS:-
CRM I (REDUCES THICKNESS 2-4.5MM THICK INTO 0.63-2MM THICK)
CRM II (REDUCES THICKNESS 1.4-2MM THICK INTO 0.63-1.6MM THICK)
23. CR
M
IT CONSISTS OF :-
H2SO4 PICKLING LINE
4-STAND TANDEM MILL
ANNEALING FURNACES
SKIN PASS MILL-I & SKIN PASS MILL-II
SHEARING LINE I & II
SLITTING LINE AND SHIPPING LINE
24. PROCESS FLOW OF CRM
H2So4 Pickling
Line T1 T2 T3 T4 T5 ANNEALING
TANDEM MILL STANDS
(THICKNESS IS REDUCED )
SPM I & IIShearing Line I & II
SLITTING LINE
(CUTTING THE
COIL IN PROPER
SIZE)
SHIPPING
LINE
25. APPLICATION OF PRODUCT FROM CRM
Automobile Bodies
Drum & Barrels
Bending & Shaping Applications
Steel Furniture
26. CONCLUSIONS
My 45 days industrial attachment with sail bokaro was one of the most interesting,
productive and instructive experience in my life. Through this training, I have
gained new insight and more comprehensive understanding about the real
industrial working condition and practice. All these valuable experiences and
knowledge’s that I have gained were not only acquired through the direct
involvement in task but also through other aspects of the training such as : work
observation, interaction with collogues, supervisor and other people related to the
field. All students are advised to be sincere, honest and punctual during the training
period
