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

1. 1 | P a g e
One week Industrial Training Report File
On Rolling Mill (25/04/2017-01/05/2017)
Submitted To Submitted By
Mr. N Rajkumar Shani Kumar Singh
Executive Vice President(EVP) Roll No-1344948
Rail and Universal Beam 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 in Rail and Universal Beam Mill (RUBM).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. N Rajkumar, EVP of RUBM 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. DP Singh. 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 RUBM.
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 RUBM
4. Highlights of RUBM
5. Process Flow chart
6. Major Equipments and station
 Reheating Furnace
 Descaleing/Descaler
 BD Mill
 KV Mill
 Tandem Mill
 Stamping M/c
 Technogama
 Rail Head Hardening Heater & Cooling Module
 Hot Saws
 Cooling Bed
 Straightening M/c
 Vertical Straightening
 NDT

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 RUBM
Commissioned in 2003, the mill has a wide range of products ranging from long rails up to
121 meter to medium and large size parallel flange beams and columns. The product mix
includes: track rails, crane rails, parallel flange beams and columns and channels.
To enhance its productivity and consistency in quality, the new tandem mill, the first of its
kind in India, was purchased from SMS Meer, Germany, and installed and commissioned in
November 2006, in which its patent X-H technology is adopted for rolling of beams and
columns. Other sections like rails and channels are also rolled via the universal route.
Highlights of RUBM
 Successful Commissioning of Rail Head Hardening Project On 20th April 2016 for the
first time in India.
 Ever Highest yearly Rail Production achieved of 202155 MT on February 2016-17.
 Ever Highest yearly Rail Dispatch achieved of 177544MT on February 2016-17.
 First time in JSPL, Dispatch UIV60E1 18M track Rail with both side drill to export Iran,
cross one Lakh Ton (123809 MT & Sake 123256 MT) completed by (Aug 16-Mar 17)
 Successful development of new sections:
 NPB500 X 180 & 500 X 150
 Crane Rail CR 120 (118Kg/M) & A 150(150 Kg/M)
 Angle 250 X 250 24 MM(89.7 Kg/M)

7. 7 | P a g e
 New grade Developmentof R350HT for (Rail HeadHardeningIranorder)
Process & Flow Chart
In RUBM or Rolling Mill Plant the Raw material like Bloom, Billet or Beam Blank of different
size is coming out from Steel Melting Shop according to requirement or need of final
Product of RUBM.
Rolling Mill Process starts from Reheating Furnace. Where the raw material coming from
Steel Melting Shop is heated inside a furnace up to 1260 degree centigrade. There after that
heated raw material extracted from furnace with the help of extractor kept roller table
further with the help of High pressure water descaling process is done there After that
heated raw material passes through Breakdown Mill where 30% size is reduced as
compared to Initial one. There after that material is passes through BD Saw Mill if it lighter
section otherwise it directly goes to Conventional Mill where it gets up to 60% of final
product shape. After that it transferred to the Tandem Mill where with the help of three
stands i.e. Universal Roll, Edger Roll and Universal Finishing Roll which are in series
respectively, the final product shape and finishing is done after that it passes through
Stamping Machine where heat no is mention on product there after it forwarded to
Technogama where product profile is checked with the help of High resolution Camera
further that product is transferred to the Universal Mill(KV-0 Mill) if the product is channel,
angle otherwise it passes to Hardening and Cooling Module according to demand or
requirement of customer. Further with the help of Hot saws(Moving and Fix) a sample
piece is cut from each product section to check the profile of product manually to ensure
that we are exactly getting the shape which our customer demand after that the product is
transferred to the Cooling Bed where temperature product is brought below 100 degree
centigrade there after that product passes through straightening Machine where the
product straightening of product is done with the help of Roller arrangement after that it
Passes trough vertical straightening where lateral straightening is done there after it passes
through T2 Bed from where product handling is started for final dispatch to the customer if
required then it cut in different length size according to demand of customer or it forwarded
for Non Destructive Testing(N.D.T) after that final inspection it is dispatch to the customer.

8. 8 | P a g e
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.
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 40
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.

9. 9 | P a g e
Preheating Zone Heating Zone Soaking Zone
Temperature
achived
1100° C 1200° C 1260° C
No of Burner 14 12 14
Length 15.5m 9.5m 7.5m
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.
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.
Charging Table
Reheating Furnace
Reheating Furnace

10. 10 | P a g e
Breakdown Mill (BD Mill)
Break Down Mill is also called Roughing Mill. It 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.
Descaleing
Descaler
BD Mill

11. 11 | P a g e
Conventional Mill(KV-1 Mill)
It’s a 2 high universal mill where the the bloom coming from Breakdown Mill is further
process or we can say it passes through rolls to and fro up to so that 60% of the final shape
of the product is achived in certain no of passes.
Tandem Mill
A tandem mill is a special type of modern rolling mill where rolling is done in least no of
pass. In a traditional rolling mill rolling is done in several passes, but in tandem mill there are
several stands (>=2 stands) and reductions take place successively. The number of stands
ranges from 2 to 18. Tandem mills can be either of hot or cold rolling mill types. RUBM has
installed three stand tandem mill to enhance productivity. It’s three stand are tabulated
below. Different stand have different purpose to shape the product.1st two stand for giving
final shape of the product and last one to provide finishing to the product.
Universal Roughing Mill (UR) 4 Roll 2 Vertical, 2 Horizontal
Edger Mill 2 Roll 2 Horizontal
Universal Finishing Mill (UF) 4 Roll 2 Vertical, 2 Horizontal
Entery Temperature at Tandem Mill -972° C (Approx)
Exit Temperature at Tandem Mill-847° C (Approx)
KV-1 Mill
KV Mill Rolls

12. 12 | P a g e
Stamping Machine
Stamping (also known as pressing) is the process of placing flat sheet metal in either blank
or coil form into a stamping press where a tool and die surface forms the metal into a net
shape. With the help of Stamping Machine marking of heat No on the final product is done.
Technogama
Technogama is used to check the profile of the final product which is coming out from
Tandem Mill so that exact desired product will obtained according to coustmer
requirement. For this purpose there are four High resolution camera is installed so that
profile of the product can be closely monitored.
Rail Head Hardening Heater and Cooling Module
As per customer requirement of product quality hardening is done. For this purpose a Rail
Head hardening Machine is installed. In metro Rail head hardened rail is preferred to meet
the customer requirement hardening of the rail is done.
UR
Edger
UF

13. 13 | P a g e
Hot Saws
Hot saws are provided at end of cooling Module for cutting a the final product in desired
size or cutting small piece of product for analysis of its dimension or pofile so that the final
product dispatched to the customer is exactly to their requirements. There are two saws
one is movable and another is fixed. One of them or both can be used according to the
requirement and scenario.
Rail Head Hardening Heater and
Cooling Module
CoolingModule
Rail Head Hardening Heater
Hot Saws

14. 14 | P a g e
Cooling Bed
Cooling Bed is used to cool the the final finished product of tandem mill below 100° C so
that it can be forwarded for further finishing or dispatch. For this purpose there is bed which
is divided in to 9 parts which is drive trough gear arrangement or we can say that there is a
walking beam which is drived through gear drive to transfer the product from one end to
another end.
Length of the Bed=121m
Width of the Bed=40m
Drive System=Walking Beam with Gear Drive
For transferring the material from roller table to Cooling Bed or Vice-Versa Skid is provided
which is operated through rope or gear drive.
Straightening M/c
Straightening M/c consist of 9 Horzontal roll which purpose is to straight the the rail and
create the exact depth of the rail. For this purpose load is applied according the SMS MEER
CoolingBed
CoolingBed
Rail
Skid

15. 15 | P a g e
load table and gradually increases up to desired load so that proper straightness can be
achived.
Vertical Straightening Machine
Vertical straightening is used to straight the sides of the Rail or other Product. For this
purpose a arrangement of roller which is vertically arranged is used between which rail is
passed.
Straightening Machine

16. 16 | P a g e
Non Destructive Testing
Flatness Measurement Gauge-The flatness measurement gauge is an Optoelelectronic
flatness measurreing instrument. It is designed to perform contactless fully automated
measurements of Rail in nearly real time.
Eddy- Current testing Machine-This testing machine is made by Forester(Germany). It’s
purpose is to check the bottom of flange and foot corner of rail. The base and Head of Rail is
inspected by 4-Channel rotating probe system for longitudinal defects and lower edges with
two LMD segment coils.
Ultrasonic Testing Machine-This equipment is made by Krautkramer (Germany).It’s function
is to check the internal imperfection of rail. The test employes the pulse reflection method
with TR & Angle process which are coupled to the Rails by means of water Gap(0.3-
4mm).Signals are displayed on the monitor further this signals are analysed.