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1. REPORT
ON
PRACTICAL TRAINING
A
SAIL( BHILAI STEEL PLANT)
Submitted in the partial fulfillment of
Bachelor of Technology Degree
of Jodhpur National University,
Jodhpur.
SUBMITTED To: SUBMITTED BY :
Ms.------------------ Narendra Singh Shekhawat
Seminar Incharge Roll No.: 14ET405205
Department of MECH 4th Year (7th semester)
DEPARTMENT OF ELECTRONICS & COMMUNICATION ENGINEERING
FACULTY OF ENGINEERING & TECHNOLOGY
JODHPUR NATIONAL UNIVERSITY, JODHPUR (RAJ.)
2015-2016

2. Acknowledgement
As the technologically advancement will enable us to get the environment
we desire. The basic beatitude, bliss, euphoria & our endeavor to achieve
complete and perfect knowledge in the field we choose that accompany the
successful completion of any task would not be complete without the
expression of appreciation of simple virtues to the people who made it
possible. So, with reverence honor I acknowledge all those guidance and
encouragement has made successful completion of training.
I am thankful to Mr. S.K.Marathe, H.R.D. Department, for his
constant cooperation and able guidance & without his support this work
would not have been so understandable.
I am also thankful to Ms¸ , HOD Mechanical
Department, JNU . who is always mentor to us.
I am also very thankful to all respected persons who have directly or
indirectly helped me in my earnest effort to accomplish this training.
Submitted By
Narendra Singh Shekhawat

3. Preface

4. Content
CHAPTER-1......................................................................................................1-5
1.1 INTRODUCTION..........................................................................................1
1.2 BHILAI STEEL PLANT................................................................................1
1.3HUMAN PROFILE........................................................................................ 3
1.4 BHILAI STEEL PLANT - MAJOR LANDMARKS....................................5
CHAPTER-2......................................................................................................6-8
2.1 ORE HANDLING PLANT .....................................................................6
2.2 SALIENT FEATURES OF OHP………………………………………….. 6
2.3 RECEIPT / UNLOADING OF RAW MATERIALS…………………….... 7
2.4 STORAGE / BEDDING -BLENDING OF RAW MATERIALS…………. 7
2.5 SUPPLY OF RAW MATERIALS TO CONSUMER SHOPS …………….7
2.6 OBJECTIVES OF OHP……………………………………………………. 8
CHAPTER-3....................................................................................................9-11
3.1 SINTERING PLANT -1.................................................................................9
3.2 FUNCTION....................................................................................................9
3.3 RAW MATERIALS RECEIVING SECTION..............................................9
3.4 RAW MATERIALS SCREENING AND FLUX CRUSHING...................10
3.4.1 SECTION........................................................................................10
3.5 FUEL CRUSHING & FLUX SCREENING SECTION..............................10
3.6 MACHINE BUILDING...............................................................................10
CHAPTER-4..................................................................................................12-14
4.1 SINTERING PLANT –II..............................................................................12
4.2 GENERAL....................................................................................................12
4.3 RAW MATERIALS.....................................................................................12
4.4 RAW MATERIAL SECTION......................................................................13
4.5 INSTALLATION OF RAW MATERIAL SCREEN................................. 13
CHAPTER-5..................................................................................................15-17
5.1 COKE OVEN...............................................................................................15
5.2 IMPORTANCE OF COKE IN IRON & STEEL INDUSTRY....................15
5.3 FUNCTION OF COKE OVEN..............................................................15
5.4 THE COKE OVEN DEPARTMENT SUB-SECTION .........................16
5.5 CONVERSION OF COAL INTO COKE..............................................16
5.6 COMPOSITIONOF COKE OVEN GAS ...................................................17

5. CHAPTER-6..................................................................................................18-24
6.1 BLAST FURNACE......................................................................................18
6.1.1 IRON PRODUCTIONBASICS...............................................................18
6.2 WHAT IS A BLAST FURNACE?..............................................................19
6.3 BLAST FURNACE CONSTRUCTIONALFEATURES...........................20
6.4 THE BASIC RAW MATERIALS AND THEIR FUNCTION...................21
6.5 DIFFERENT TEMPERATURE IN BF.......................................................22
6.6 VITAL FUNCTION OF THE HOT GAS ...............................................22
6.7 TAPPING................................................................................................23
6.8 REACTION IN THE THE BLAST FURNACE......................................23
6.8.1 UPPER STACK ZONE.............................................................23
6.8.2 MIDDLE STACK ZONE...............................................................24
6.8.3 LOWER STACK ZONE................................................................24
CHAPTER-7..................................................................................................25-30
7.1 STEEL MELTING SHOP-I .........................................................................25
7.1.1 MIXER............................................................................................26
7.1.2 STOCKYARD............................................................................... 27
7.1.3 FURNACE..................................................................................... 28
7.1.4STRIPPER YARD...........................................................................29
CHAPTER-8..................................................................................................31-35
8.1 MERCHANT MILL ....................................................................................31
8.2 RAW MATERIALS.....................................................................................32
8.3 IMPORTANT TECHNICAL PARAMETERS OF THE FURNACE........32
8.4 THE WORKING OF THE MILL.................................................................33
8.5 NOTES ON IMPORTANT MODIFICATIONS ........................................ 35
CHAPTER-9..................................................................................................36-64
9.1 STEEL MELTING SHOP-II.......................................................................36
9.2 BSP STEEL MAKING:CONV. & CONCAST ROUTE........................... 37
9.3 OPERATION CYCLE ................................................................................37
9.4 CONVERTOR SHOP: KEY POINTS ...................................................38
9.5 REACTIONS......................................................................................38
9.5.1 De-Siliconisation............................................................................ 38
9.5.2 De-Phosphorisation ........................................................................38
9.5.3 Manganese Removal ......................................................................39

6. 9.5.4 De-Carburization............................................................................ 39
9.5.5 De-Sulphurisation ...........................................................................39
9.6 SAMPLE ANALYSIS AND TEMP. MEASUREMENT .......................39
9.7CONCEPT OF RE-BLOW.................................................................... 40
9.8 TAPPING OF STEEL ..........................................................................41
9.9 SLAG SPLASHING............................................................................. 41
9.10DIFFERENT SECTIONS OF CONVERTER SHOP................................ 42
9.10.1 SCRAP YARD....................................................................... 42
9.10.2 MIXER SECTION........................................................................43
9.10.2.1 PURPOSE.......................................................................44
9.10.3 HOT METAL DESULPHURISATION .....................................45
9.10.3.1PROCESS STEPS ...........................................................46
9.10.4 LADLE PREPARATIONSECTION......................................... 47
9.10.4.1 ACTIVITIES ..................................................................47
9.10.5 SLAG POT HANDLING SECTION..........................................47
9.10.5.1ACTIVITIES....................................................................47
9.10.6 FERRO ALLOY HANDLING SECTION ................................47
9.10.7 BULK MATERIAL HANDLING SECTION ............................48
9.10.8 GAS CLEANING PLANT ..........................................................49
9.11 ARGON RINSING BAY ..........................................................................49
9.11.1 ARGON RINSING UNIT .....................................................50
9.12 SMS-II SECONDARY REFINING UNITS COMPRIS THREE UNITS 50
9.13 LF OPERATION........................................................................................51
9.13.1 LF OPERATION CYCLE........................................................52
9.14 OBJECTIVES OF RH DEGASSER..........................................................53
9.14.1 RH OPERATIONCYCLE………………………………………54
9.14.2DESIGNPARAMETERS OF RH DEGASSER.....................................55
9.15 CONTINUOUS CASTING SHOP............................................................ 55
9.16 TUNDISH PREPARATIONBAY ............................................................55
9.17CASTING BAY..........................................................................................57
9.18 GENERAL FEATURES OF BLOOM CASTER......................................58
9.19 FEATURES OF NEW No. 6 SLAB CASTER..........................................58
9.20 CASTING PROCESS ……………………………………………………60
9.21 LADLE SUPPORT...............................................................................61
9.22 TUNDISH........................................................................................... 61
9.23 MOULDS AND MOULD OSCILLATION..............................................62
9.24 TYPES OF COOLING PROCESS ............................................................62

7. 9.24.1 PRIMARY COOLING................................................................. 62
9.24.2 SECONDARY COOLING............................................................63
9.24.3 RADIATIVE COOLING..............................................................63
9.25 MAINTENANCE BAY............................................................................ 64
9.26 DISCHARGE BAY ..................................................................................64
9.27 SLAB & BLOOM STORAGEYARD ......................................................64

8. List of Figures
Figures=1 PLANT LAYOUT ........................................................................4
Figures=2 ORE HANDLING PLANT............................................................6
Figures=3 ELECTROTATIC PRECIPITATOR...........................................14
Figures=4 COKE OVEN.............................................................................15
Figures=5 CONVERSION OF COAL INTO COKE.........................................16
Figures=6 COKE OVEN LAYOUT...................................................................17
Figures=7 BLAST FURNACE......................................................................18
Figures=8 BLAST FURNACE CONSTRUCTIONALFEATURES................20
Figures=9 DIFFERENT TEMPERATURE IN BF...........................................22
Figures=10 STEEL MAKING ANIMATION..............................................24
Figures=11 STEEL MELTING SHOP-I............................................................25
Figures=12 FURNACE......................................................................................28
Figures=13 MERCHANT MILL........................................................................31
Figures=14 STEEL MELTING SHOP-II...........................................................36
Figures=15 STEEL MAKING:CONV. & CONCAST ROUTE........................37
Figures=16 CONCEPT OF RE-BLOW..........................................................40
Figures=17 SCRAP YARD................................................................................42
Figures=18 SCRAP YARD..............................................................................42
Figures=19 MIXER SECTION..........................................................................43
Figures=20 MIXER SECTION..........................................................................44
Figures=21 HOT METAL DESULPHURISATION..........................................45
Figures=22 HOT METAL DESULPHURISATION.........................................46
Figures=23 BULK MATERIAL HANDLING SECTION................................48
Figures=24 LF OPERATION............................................................................51
Figures=25 LF OPERATION CYCLE...............................................................52
Figures=26 OBJECTIVES OF RH DEGASSER..............................................53
Figures=27 RH OPERATIONCYCLE............................................................54
Figures=28 CASTING BAY.............................................................................56
Figures=29 CASTING PROCESS....................................................................60
Figures=30 TUNDISH:....................................................................................61
Figures=31 PRIMARY COOLING..................................................................62
Figures=32 SECONDARY COOLING............................................................63

9. List of Tables
Tables=1 BATTERY DATA..............................................................................17
Tables=2 OPERATION CYCLE........................................................................37
Tables=3 LF OPERATIONCYCLE..................................................................52
Tables=4 GENERAL FEATURES OF SLAB CASTERS.................................57
Tables=5 GENERAL FEATURES OF BLOOM CASTER...............................58
Tables=6 FEATURES OF NEW No. 6 SLAB CASTER...................................58