A Summer Training Report on Bokaro Steel Plant

1. ON
“STEEL MELTING SHOP”
AMIT KUMAR
B.TECH.(MECHANICAL FINAL YEAR)
ROLL NO.- 1443140014
B.N.COLLEGE OF ENGINEERING AND TECHNOLOGY
LUCKNOW (U.P)

2. ACKNOWLEDGEMENT
I have taken efforts in the training. However, it would not have
been possible without the kind support of senior officers and
area incharge. I would like to extend my sincere thanks to all of
them.
I am highly indebted to Mr. Abhineet Singh their guidance and
constant supervision as well as for providing necessary
information regarding the training & also for their support in
completing the training.
I would like to express my gratitude towards my parents and
members of BOKARO STEEL PLANT,(SAIL) for their kind co-
operation and encouragement which help me in completion of
this training.
I would like to express my special gratitude and thanks to
industry persons for giving me such attention and time.
AMIT KUMAR
B.TECH.(MECHANICALFINAL YEAR)
B.N. COLLEGE OF ENGINEERING AND TECHNOLOGY
LUCKNOW (U.P)

3. CONTENTS
 Bokaro Steel Plant
 History
 Facilities
 Products
 What is Steel
 Uses of steel
 Steel products
 Steel ManufacturingProcess
 How is Steel made
 Steel Making Plant
 The blast furnace
 Steel Making Shop (SMS)
 Steel sectors

4. BOKARO STEEL PLANT
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 4.5 MT of liquid steel. The plant is undergoing a mass
modernisation drive after which its output capacity is expected to cross
10 MT
The plant's yearly profit stood at ₹11.2 billion (US$170 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.
History
Bokaro Steel Plant, the fourth integrated plant in the Public Sector,
started taking shape in 1965 in collaboration with the Soviet Union. It was
originally incorporated as a limited company on 29 January 1964, and was
later merged with SAIL, first as a subsidiary and then as a unit, through
the Public Sector Iron & Steel Companies (Restructuring & Miscellaneous
Provisions) Act 1978. The construction work started on 6 April 1968.
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. Its first Blast Furnace started on 2 October 1972 and the first phase
of 1.7 MT ingot steel was completed on 26 February 1978 with the
commissioning of the third Blast Furnace.
All units of 4 MT stage have already been commissioned and the 90s'
modernisation has further upgraded this to 4.5 MT of liquid steel. The
new features added in modernisation of SMS-II include two twin-strand

5. slab casters along with a Steel Refining Unit. The Steel Refining Unit was
inaugurated on 19 September 1997 and the Continuous Casting Machine
on 25 April 1998.Modernisation work in various departments is in
progress.
Facilities
Bokaro is an Integrated Steel Plant, housing many virtual enterprises
within Bokaro Steel. Some 9 MT of different raw materials viz. Iron ore
fines and lumps, Limestone (BFand SMS grade), Dolomite lumps and
chips, hard Coal and Manganese ore are handled here every year.
The Coke Oven battery has 8 batteries with 69 ovens each, maintained in
terms of fugitive emission control, use of phenolic water and other
pollution control measures. Bokaro Steel Plant Main Gate Bokaro has five
2000-cubic metre Blast Furnaces that produce molten iron - Hot Metal -
for steel making. Bellless Top Charging, modernised double Cast Houses,
Coal Dust Injection and Cast House Slag Granulation technologies have
been deployed in the furnaces.
Bokaro has two Steel Melting Shops - SMS-I and SMS-II. SMS-I has 5 LD
converters of 130T capacity each. It is capable of producing Rimming steel
through the ingot route. SMS-II has 2 LD converters, each of 300 T
capacity, with suppressed combustion system and Continuous Casting
facility. It produces various Killed and Semi-Killed steels.
The Continuous Casting Shop has two double-strand slab casting
machines, producing slabs of width ranging from 950 mm to 1850 mm.
CCS has a Ladle Furnace and a Ladle Rinsing Station for secondary refining
of the steel.CCS produces steel of Drawing, Deep Drawing, Extra Deep
Drawing, Boiler and Tin Plate quality. It also produces low alloy steels like

6. LPG, WTCR, SAILCOR and API Grade. Slabbing Mill transforms ingots into
slabs by rolling them in its 1250 mm Universal Four-High Mill.
The rolling capacity of the Mill is 4 MT per annum. The shop has Hot and
Cold Scarfing Machines and 2800 T Shearing Machine. Slabs from
Continuous Casting Shop and Slabbing Mill are processed in the Hot Strip
Mill. The fully automatic Hot Strip Mill with an annual capacity of 3.363
million tonnes has a wide range of products - thickness varying from 1.2
mm to 20 mm and width from 750 mm to 1850 mm. The Hot Rolled Coil
Finishing shop has two shearing lines with capacities of 6,45,000 Tonnes/
year and 4,75,000 Tonnes/ year respectively.
The Cold Rolling Mill at Bokaro produces sheet gauge material, Tin Mill
Black Plate and Galvanized Products. The Hot Dip Galvanizing Complex
integrated with the CRM produces zinc-coated Cold Rolled strips resistant
to atmospheric, liquid and soil corrosion. Bokaro Steel has a vast
networked of railway tracks and over 40 diesel locos to run its operations.
The Oxygen Plant provides Oxygen, Nitrogen and Argon for processes like
steel making and annealing. Water Management looks after the huge
water requirements of the plant and the township, providing different
grades of water and taking care of recycling needs.
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

7.  Tin mill black plates (tmbp)
 Galvanised plain and corrugated (gp/gc) sheets
 Oxygen Gas Produced in Oxygen Plant.
 Hydrogen Gas
 Coke Oven by products
What is Steel
Steel is an alloy of carbon and iron having carbon upto 1.5% in combined
form of iron carbide. These steels are known as plain carbon steels
because their properties are mainly due to carbon content. Steels can be
classified on the following basis;
 Depending upon the %age of carbon
1. Dead mild steel: Carbon is upto 0.15
2. Low carbon steel or mild steel: Carbon range from 0.15-0.3%
3. Medium carbon steel: Carbon range from 0.3-0.6%
4. High carbon steel: Carbon range from 0.6-1.5%
 Depending upon eutectoid reaction
1. Hypoeutectoid steel: Carbon %age is less than 0.8%
2. Eutectoid steel: Carbon %age is 0.8%
3. Hypereutectoid steel: Carbon %age range from 0.8 to1.5
 Depending upon contents
1. Plain carbon steel
2. Alloy steel

8. Uses of Steel
 The structures such as oil platforms, catalytic converters, paper
clips, mounts for electronic chips...are all made of steel.
 In the construction of bridges or buildings...
 In the automobile sector for the manufacture of automobile parts

9.  For everyday uses: cans,pots,containers,etc..
Steel products
Semi-finished products(continuous cast steel)

10. Steel Manufacturing Process Infrastructure
 Coke Ovens And Coal Chemical Plant
 Sinter Plant
 Blast Furnace
 Steel Melt Shop And Continuous Casting
 LMMM
 WRM
 MMSM
ConversionOf Coal into Coke
It Can Be Achieved By Using Coke Ovens And Coal Chemical Plant
Heating the blended coal charge in absence of air at a temperature of
1000o
C-1050o
C for a period of 16/19 hours.

11. The volatile matter of coal liberated during carbonization is collected in
gas collecting mains and cooled with ammonia liquor spray.
The gas cooled from 800o
C to 80o
C is drawn to Coal Chemical Plant by
Exhauster.
The residual coke is pushed out of the oven by pusher car through a guide
into coke bucket.
The red-hot coke is taken to coke dry cooling plant for cooling.
By products
 Ammonium Sulphate (NH4)2SO4
 Crude Tar
 Crude Benzol and
 Cleaned coke oven gas.
 Cooled Coke from CDCP (Coke Dry Cooling Plant) is separated
into 3 Fraction

12.  BF Coke i.e. +25-70mm which is sent to Blast Furnace
 Coke Breeze i.e. +0-15mm which is sent to Sinter making
 Nut coke i.e., +15-25mm, which is also used in the Blast furnace.
How is Steel made
Flow Chart-

13. Steel Making Plant
 Electric Arc Furnace
 Ladle Furnace
 Continuous Casting Machine

14. The Blast furnace
• Blast furnace is used to reduce and convert iron oxides(ore) into
liquid iron called "hot metal".
• The blast furnace is a huge, steel stack lined with refractory brick.
• Iron ore, coke and limestone are put into the top, and preheated air
is blown into the bottom
• The charge is than allowed to soak the heat and after some time full
blast is turned on. After the blast has been opened for about 10
minutes molten metal starts accumulating in the wall.

15. Why does Iron have to be extracted in a Blast
Furnace???
• Iron have to be extracted in the blast furnace because it can be
displaced by carbon.
• This is more efficient method than electrolysis because it is more
cost effective.

16. The Method
Three substances are needed to enable to extraction of iron from its ore.
The combined mixture is called the CHARGE.
• Iron ore, haematite - often contains sand with iron oxide, Fe2O3
• Limestone (calcium carbonate).
• Coke - mainly carbon
The charge is placed a giant chimney called a BLAST FURNACE. The blast
furnace is around 30 metres high and lined with fireproof bricks. Hot air is
blasted through the bottom.