Industrial Training Report on Plate Mill of Jindal Steel & Power Limited Raigarh Chhattisgarh

1. 1 | P a g e
One week Industrial Training Report File
On Plate Mill (02/05/2017-08/05/2017)
Submitted To Submitted By
Mr. R K Ajmeria Shani Kumar Singh
Executive Vice President(EVP) Roll No-1344948
Plate Mill Branch-Mechanical
Jindal Steel and Power Ltd, Raigarh Semester-8th
College-CGC-COE,Mohali
Signature-

2. 2 | P a g e
Acknowledgement
It is matter of great pleasure and privilege for me to present this report of One week
industrial training report on Plate Mill. Though this report, I would like to thank numerous
people whose consistent support and guidance is standing pillar in architecture of this
report.
To begin with, my sincere thanks to Ateet Namdeo, AGM-HR & ES of Jindal Steel and
Power Ltd for providing me an opportunity to get acquainted with various activities of
different Plant. I express thanks to Mr. R K Ajmeria, EVP of Plate Mill for extending co-
operation to enable me to get acquainted with the various activities of their department.
I would like to express my sincere gratitude to my guide Mr. RK thakur. I was privileged
to experience a sustained enthusiastic and involved interest from his side.
I would like to express my sincere thanks towards members of Maintenance &
Operation department for making me a deep knowledge about various activities of Plate
Mill.
Shani Kumar Singh

3. 3 | P a g e
INDEX
1. Introduction of Jindal Steel & Power Limited
2. Facilities at Raigarh Plant Include
3. Introduction of Plate Mill
4. Highlights of Plate Mill
5. Process Flow chart
6. Major Equipments and station
 Reheating Furnace
 Descaleing/Descaler
 Vertical Edger
 Roughing Mill
 Finishing Mill
 Entry and Exit Coiler Furnace
 Up Coiler
 Heavy Leveler

4. 4 | P a g e
Introduction of Jindal Steel & Power Limited
 JSPL is an industrial powerhouse with a dominant presence in steel, power, mining
and infrastructure sectors.
 Turnover of approx. US$ 3.3 billion, JSPL is a part of about US$18 billion diversified
Jindal Group conglomerate.
 In terms of tonnage, it is the third largest steel producer in India.
 The company manufactures and sells sponge iron, mild steel slabs, Ferro chrome,
iron ore, mild steel, structural, hot rolled plates and coils.
 JSPL operates the largest coal-based sponge iron plant in the world and has an
installed capacity of 3 MTPA (million tons per annum) of steel at Raigarh in
Chhattisgarh.
 JSPL has been rated as the second highest value creator in the world by the
Boston Consulting Group.
 The 11th fastest growing company in India by Business World and has figured in
the Forbes Asia list of Fab 50 Companies.
 In Oman (Middle East), the company has set up a US $ 500 million, 1.5 MTPA
gas-based hot briquetted Iron (HBI) plant. It has now added a 2MTPA integrated
Steel Plant.
 Alongside contributing to India’s growth story the company is driving an
ambitious global expansion plan in Africa, Australia and Indonesia.
 It deploys its resources to improve infrastructure, education, health, water,
sanitation, environment and so on in the areas it operates in. It has won several
awards for its innovative business and social practices.

5. 5 | P a g e
Facilities at Raigarh Plant Include
 DRI Plant-4nos. of 500TPD (0.72 Million TPA) and 6nos. of 300TPD rotary kilns (0.72
Million TPA)
 DRI Plant-4nos. of 500TPD (0.72 million TPA) and 6nos. of 300TPD rotary kilns (0.72
million TPA)
 0.8 million TPA Coke Oven Plant
 2.5 million TPA sinter Plant
 1.25 million TPA and 0.42 million TPA Blast Furnace
 2.0 million TPA and 1.25 million TPA steel melting shop
 2 Vacuum degassing Unit
 RH degassing Unit
 1 No. Single strand slab Caster
 1 No. of 6-strand billet-cum-round Caster and 1 No. 6 Strand billet caster
 2 No of 4-strand combi-caster
 Rail and Universal beam Mill(RUBM) (0.75 million TPA)
 Plate-cum-coil MILL(1.0 million TPA)
 Submerged arc furnace(SAF)(0.03 million TPA)
 Oxygen Plant 37683 Nm^3 per hour
 Lime and Dolomite Calcination Plants(0.4165 million TPA)
 358 MW Captive Power Plant(CPP)
 0.7 million TPA medium and light structure mill

6. 6 | P a g e
Introduction of Plate Mill
JSPL is equipped with India's first state-of-the-art plate mill that started producing plates
and coils of 5 meter and 3 meter width respectively, for the first time in the private sector.
The plate-cum-coil mill (steckle mill) of 1 MTPA capacity located at Raigarh, Chhattisgarh
produces plates ranging from 8 mm to 120 mm in thickness in widths of 1500 mm to 3500
mm and coils in thickness range of 8 mm to 25 mm in widths of 1500 mm to 2500 mm.
The mill is equipped with walking beam type of reheating furnace where slabs are re-heated
at a temperature of 1250 degree celsius and rolled in a mill with a 2 hi-reversing type
roughing stand and a 4 hi-reversing type finishing stand. To ensure excellent surface quality,
high pressure de-scalers are provided at the entry and exit points.
An auto level 2 width and thickness controlling system coupled with heavy leveler assures
close dimensional tolerances and an increased level of flatness control. Right from the slab
charging and plate production to the conclusive stage, fully equipped inspection facilities
are in place.
The plate mill at Angul, Odisha of 1.5 MTPA capacity produces plates in the thickness range
of 5-150 mm with a width of up to 5000 mm. The mill is equipped with latest equipment and

7. 7 | P a g e
technology like MULPIC cooling, online ultrasonic testing, trimming shear, slitting unit to
produce plates of high strength and excellent surface finish.
The plates and coils are of premium quality in terms of dimensional adherence and internal
soundness owing to its clean raw material, sound steel refining facilities and an efficient
rolling mill. These comply to IS 2062 specifications up to E450 grades besides a wide range
of international standards and steel grades as per EN, DIN, JIS, ASTM and so on.The mill is
approved by various societies such as LRS, DNV, ABS and GL for shipbuilding steel, besides,
having accreditations such as:
ISO 9001:2000, ISO 14001:2004 , OSHAS 18001, CE, ADW-2000 and certification by IBR for
boiler grade steel, besides being a well known steelmaker.
Highlights of Plate Mill
 Fully equipped sample preparation workshop
 Computerised tensile testing machine
 Digitalised hardness tester
 EN and ASTM impact testing machines
 100 T- bending-cum-folding machine
 High magnification metallurgical microscope with image analyser
 Direct reading optical emission spectrometer with gas analytical channel
 Online ultrasonic testing machine
 Drop weight tear test (DWTT) machine
 Chemical lab equipped with muffle furnace for research and development quality
Process & Flow Chart
Basically Plate Mill process starts from Continuous Slab Caster where slabs are casted in
different length and size according to requirements of the final product. There after that
slab is transported to Charging table through different mediai there after that slab is
charged in side the Reheating furnace with the help of Charging Machine. Reheating furnace
plays an important role in Hot Rolling Mills. It’s necessary to bring the hot metal above it’s
recrystalisation temperature so that hot rolling or we can say that plastic deformation can
occurs.
Reheating furnace consists of three zones ie preheating Zone, heating zone and soaking
zone in these zones slab are guided to pass so that the slab gets the acquired temperature.
It takes approx 2 – 2 and half hours to heat up homogenously.

8. 8 | P a g e
After that slab is extracted with the help of slab extractor Machine and the slab is kept on
roller table which convey the slab to the descaler where descaling is done after that the slab
is passes towards the roughing mills where in different no of passes through roughing mills
initial shape of the final shape of final product is given there after that slab is transferred
towards the finishing mill where the final shape of the final product is given which is either
coil or plate. If the final products are coils then where will be entry or exit coiler furnace
which purpose is to hold the entire length of the coil and heat so that the recrystalization
temperature after laminar cooling is done after that it transferd towards upcoiler where it
gets the shape of the coil. And if it is plate then it is tranfered to the heavy leveler where
straighting is done or after that with the help of divide shear that final plate cut in different
size there after it transfer to the transfer Bed.
Reheating Furnace
Reheating Furnace is the heart of Rolling Plant. In steel plants reheating furnaces are used in
hot rolling mills to heat the steel stock (Billets, blooms or slabs) to temperatures of around
1200 deg C which is suitable for plastic deformation of steel and hence for rolling in the mill.
The heating process in a reheating furnace is a continuous process where the steel stock is
charged at the furnace entrance, heated in the furnace and discharge at the furnace exit.
Heat is transferred to the steel stock during its traverse through the furnace mainly by
means of convection and radiation from the burner gases and the furnace walls.

9. 9 | P a g e
In reheating furnace the raw material coming from Steel melting shop is heated up to
1260 degree centigrade. Heating furnace consist of three zones i.e. Preheating Zone,
Heating Zone and Soaking Zone. In different zones certain temperature is achieved and in
final zone approx 1260 degree centigrade is achieved. For heating purpose mixture of Oil,
Blast Furnace gas and Producer gas is charged through different burner. There are 60
Burners in different zones which continuously heating the raw material.
The furnace material transfer mechanism is based on walking Beam or we can say that a
walking beam reheating furnace. A walking beam furnace represents the state-of-the-art of
efficient reheating furnaces. In a walking beam furnace, the stock is placed on stationary
ridges and a revolving beam walks the product along through the furnace until the exit
where the beam returns to the furnace entrance.
Preheating Zone Heating Zone Soaking Zone
Temperature
achived
1100° C 1200° C 1260° C
No of Burner 14 16 30
Descaling
Scale inevitably occurs when heating steel. Exposure of the iron to the oxygen in the air
results in oxide scales forming on the surface. This will affect the appearance and properties
of the steel. In the production of high-quality hot rolled products it is therefore imperative
to remove these impurities from the metal surface.
Reheating Furnace

10. 10 | P a g e
Descalers ensure a high surface quality in hot rolling mills. They blast the metal surface with
pressurized water to remove the scale. A descaler consists of one or several spray headers
with recessed spray nozzles directing jets of water diagonally at the material. Descalers are
typically operated with a water pressure of 100 to 400 bar and a water quantity of 200 to
700 m³/h. The high-pressure pump unit is therefore a fundamental part of a descaler.
Vertical Edger
Vertical edgers are rolling mill stands and are either attached to a horizontal stand or they
are free standing. Both work the edges during the rolling process, that is, a vertical edger for
rolling slabs rolls works the side of the slab. Contact Casey Equipment for a quote on used
vertical edgers for sale.
Vertical edger finalize the edges of slab which is to be processed for final Product. Vertical
edger are operated with the help of motor gear and shaft arrangement which is mounted on
the top of Vertical edger and for adjusting the gap between the vertical edger roll hydraulic
system is provided.
Roughing Mill
Roughing Mill is a two high roughing mill where initial shape of final product is given. . In
two high reversing rolling mills the rolls rotate ist in one direction and then in the other, so
that rolled metal may pass back and forth through the rolls several times. This type is used
in pluming and slabing mills and for roughing work in plate , rails, structural and other mills.
The roughing stands are used to reduce the thickness of the steel while at the same time
extending the overall length. As the name suggests, the roughing stands are used to form
the metal to roughly the final thickness. Since most of the reduction is made in the roughing

11. 11 | P a g e
mill, the speed of the process and the product quality is dictated by the metal temperature
and the desired reduction. The finishing stands are used to form the strip to the final
dimensions. A consistent metal temperature at this point in the process is critical for a
consistent surface finish and for consistent thickness.
Finishing Mill
Hot rolling is an essential industrial process in the production of sheet steel, a widely used
product in manufacturing and construction. A finishing mill performs a set of operations in a
hot strip rolling mill, and is a complex unit including many processes and control loops. Its
modelling is a challenging task due to the variety of phenomena that occur within the mill,
and variable transport delays. Model validation is also challenging due to a scarcity of
measurements. On the other hand, a dynamic model that adequately reflects the numerous
interactions between the mill units can be very useful for tasks such as high performance
control design or vibration analysis. In this study, a one-dimensional model has been
developed and validated against real plant data. The end use of the model is intended to be
looper control analysis, but the model is kept sufficiently general so that it can be used or
easily extended for other applications.
Vertical Edger
Roughing Mill

12. 12 | P a g e
Entry and Exit Coiler Furnace
For economy of operation, as much as possible of the total length of a steel strip being
rolled by a finishing mill should be maintained at an acceptably high temperature. To this
end, the trailing edge of the strip is drawn into the coiler furnace to the extent possible
without losing driving control of the strip. This is enabled by providing within or in close
proximity with the entrance/exit port of the coiler furnace a pair of preferably heated pinch
rolls that drive the trailing edge of the strip (that has just completed a pass through the
Steckel mill) into the coiler furnace as far as possible, leaving only a very short protruding
portion of that trailing edge outside the coiler furnace. The strip may be left idle within the
coiler furnace for as long a time as is required to bring the temperature of the wound strip
up to a target operating temperature. Then the same pair of pinch rolls in or near the
entrance/exit port of the coiler furnace drive the strip out of the furnace toward the
Finishing mill.
Laminar Cooling
The hot-rolled strip laminar cooling (HSLC) process is important to the production quality in
hot-rolled strip product line. How to monitor the strip's transient temperature and
accurately control the coiling temperature (CT) are the problems in HSLC since the strip
temperature can hardly be measured inside the cooling section. In this paper, a modified
EKF with trade-off feed-back coefficient is implemented to reconstruct the spatial
distribution of strip temperature. It has the advantages of simple designation, having
reasonable convergence rate and stability. Then a novel control strategy based on the
ExitCoiler FinishingMill
Entry Coiler

13. 13 | P a g e
designed EKF and model predictive control (MPC) is proposed for HSLC to improve the
precision of CT. In MPC, a predictor is employed to predict the future temperature sequence
at the inlet of fine cooling zone to further improve the performance of MPC. Finally, the
reliability and performance of the proposed monitoring and control method were
demonstrated by the experimentations in one HSLC manufactory.
Up Coiler
A drive shaft is surrounded by a winding drum, which consists of a plurality of axially aligned
drum rings. A plurality of pressure plungers are radially slidably mounted in said shaft and
radially aligned with all said drum rings and spaced apart in the peripheral and axial
directions of said shaft and arranged in groups disposed in respective sectors of said shaft.
Laminar Cooling
Up-Coiler

14. 14 | P a g e
Pressure-applying means for applying fluid pressure to said pressure plungers so as to force
them radially outwardly against said drum rings to hold the latter clear of said shaft
comprise a plurality of pressure fluid conduits for applying fluid pressure to respective
groups of said pressure plungers.
Heavy Leveler
The cold plate leveler is the best example for the high flexibility offered by Heavy leveler
machines. Heavy leveler offer high flexibility for efficient leveling of high- strength plates by
optimizing plate flatness and minimizing residual stresses. To achieve excellent leveling
results, the cold plate leveler. Flatness defects and internal stresses cannot be avoided in
the manufacture of hardened and tempered plates, even with the most up-to-date line
technology. Thus, it is essential to level the plate after heat treatment, reducing internal
stresses at the same time.
HeavyPlate Leveler