1 week plant visit

1 WEEK PLANT VISIT 2017
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“REPORT ON SUMMER INTERNSHIP TRAINING
PROGRAMME "
"PROJECT : 1 WEEK PLANT VISIT ”
SUBMITTED BY:
ASHISH JAISWAL
USN : 1DS15ME019
DAYANANDA SAGAR COLLEGE OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
Shavige Malleshwara Hills, Kumaraswamy Layout, Bangalore-78

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ACKNOWLEDGEMENT
I would like to express my special thanks of gratitude to
my guide Mr. Dipansu Laskar (AGM ,HR), and Mr. Sourav
Bagchi (Senior Officer ,HR) who gave me the golden
opportunity to do this wonderful project on 1 WEEK
INDUSTRIAL VISIT also helped me in doing a lot of
depth search in field and came to know about so many
new things. I are really thankful to them. Secondly we
would also like to thank my parents and friends who
helped me a lot in finalizing this project within the limited
time frame.

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ABOUT COMPANY:
INTRODUCTION:
A multi-billion-dollar conglomerate, JSW Group is a part of O.P. Jindal Group
and played a key role inIndia's growthstory. Rankedamong India's top business
houses, JSW's innovative and sustainable forays into the core sectors of Steel,
Energy, Cement and Infrastructure are helping build a new nation. The Group
continues to strive for excellencewithits strengths, differentiated product mix,
state-of-the-art technology, excellence in execution and focus on sustainability.
With a diverse workforce of over 40,000 individuals, JSW is known to be the
“strategic first mover” to venture away from status quo, have the conviction to
make fundamental changes and drive operational excellence.
The flagship company of JSW Group - JSW Steel, is India’s leading primary and
integrated steel producer. It has a production capacity of 18 MTPA with plants

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located across six locations in South and West India, namely, Karnataka, Tamil
Nadu and Maharashtra.
Incorporated in 1994, JSW Energy is the power utility arm of the JSW Group. The
Company is engaged in power generation, power transmission, mining, power
trading and equipment manufacturing. JSW Energy operates 4,531 MW of power
generation capacity with the vision to achieve 10,000 MW by 2020. The
Company’s presence extends across several Indian states and includes stakes in
natural resource companies in South Africa.
JSW Group's new business foray- JSW Cement, envisions a self-reliant India. Since
its inception in 2009, JSW cement entered the market with a vision to ensure a
sustainable future for the country by producing eco-friendly cement. At
Vijayanagar in Karnataka, Nandyal in Andhra Pradesh and Dolvi in Maharashtra,
JSW Cement utilises slag cement from Group's steel plants to produce green
cement. It is currently upgrading production capacity to 30 MTPA by 2020.
Recently, JSW Group diversified into new age businesses like fund management.
JSW Ventures partners with ambitious and growth oriented entrepreneurs who
leverage technology to build long-term capital efficient businesses. The fund
supports ventures and ideas with JSW Group’s expertise in building scalable and
profitable businesses.
Meanwhile, a commitment to the nation, JSW Infrastructure is dedicated to
developing seaports and terminals, shipyards, port-based special economic zone
(SEZ), industrial clusters and last mile connectivity projects like road, rail, pipeline,
coastal shipping and inland water transport. JSW Infrastructure has plans to
create 200 MMT capacity by 2020 to become one of the India’s leading player in
the infrastructure sector.

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JSW STEEL PRODUCT

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1 WEEK PLANT VISIT FLOW CHART
Unique features:

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Regarded as the world’s Corex showpiece; it was the first Greenfield
project in India and among the first in the world to have successfully used
this technology to produce “green steel”
Houses India’s largest blast furnace and the widest hot strip mill
The only plant in India with pair-cross technology and twin-stand reversible
cold-rolling mill
The highest productivity steel plant in India, producing 800-plus tones per
person per annum
Recognized for its ‘zero-effluent discharge’ status; it reuses more than 95
per cent of process waste
Low carbon footprint as it recycles 96% of coke oven gas for power
generation
Uses sophisticated ambient air control infrastructure beyond and has
reduced gas flaring to lower levels.
Vision 2020:
 Establish state-of-the-art infrastructural facilities in India
 Create port capacity of 100 million tons per annum through
Greenfield and Brownfield expansions
 Ensure effectively mechanized operations
 Be the benchmark global company in the area of operations
 Be environment friendly
 Be socially sustainable
Milestones:
Founded in 1984
Commissioning of first and only UOE Pipe Mill manufacturing

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LSAW Pipes in Kosi Kalan, India with a capacity of 250,000 M.T
P.A, located about 1200 Kms from nearest west coast port of India
API Line Pipe production commences
First order for ONGC casing Pipe completed
Three major offshore projects awarded by ONGC under
international competitive
bidding - Italian and Japanese being L2 and L3 bidders
Seamless Pipes and Tubes Division commissioned at Nashik.
First Coating plant commissioned at Kosi Kalan
Received first export order
First Induction bending plant commissioned at Kosi Kalan
Commissioning of second LSAW pipe manufacturing facility as
100% export oriented unit using JCO forming process at
Nanakapaya, Mundra to meet the export market with a capacity of
300,000 MT per annum close to Port Mundra – The first major
private port on west coast of India.
Internal coating plant commissioned at Kosi Kalan Commissioning
of second Coating plant at Nanakapaya – Port Mundra
Concrete weight coating plant commissioned at Nanakapaya – Port
Mundra

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Commissioning of third Coating plant at Samaghogha, Mundra
Commissioning of third Pipe mill manufacturing LSAW Pipe using
JCO forming process in Samaghogha, Mundra with a capacity of
250,000 MT per annum.
Commissioning of fourth Pipe mill manufacturing HSAW (Spiral)
Pipe at Samaghogha, Mundra with capacity of 150,000 MT per
annum
Start up of Integrated Pipe Unit Ductile Iron Pipe manufacturing
plant of 200,000 capacity along with Blast Furnace of 250,000 MT
per annum capacity and a Coke Oven plant
Commissioning of fifth & sixth Pipe mill manufacturing HSAW
(Spiral) pipe at Bellary - Karnataka and Samaghogha-Mundra with a
combined capacity of 390,000 MT per annum. Second Induction
bending plant commissioned at Samaghogha, Mundra
Commissioning of seventh Pipe mill manufacturing LSAW using
JCO forming in Nanakapaya - Port Mundra with capacity of 300,000
MT per annum
Commissioning of 8th Pipe mill manufacturing HSAW (Spiral) pipe
at Kosi Kalan, Mathura, U.P. with capacity of 150,000 MT per
annum This mill is commissioned to cater to the water section with
capacity of 150,000 MT per annum This mill is commissioned to

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cater to the water sector
RawMaterialHandlingSystem:

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Ratedcapacity: 6-7 million TPA
Raw materials handled: Iron orelump and fines
Pellets
Limestone
Dolomite
Quartzite
Manganeseore
Non coking coal
Coke
Major units: 2 wagon tippler
3 stacker cumreclaimer
1 barrelreclaimer
Salient technical feature: Approximately 17 kmlong
Conveyor System
COKEOVEN:

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Introduction:
A world class blast furnaceoperation demands the highestquality of raw
materials, operation, and operators. Cokeis the most important raw material fed
into the blast furnacein terms of its effect on blast furnaceoperation and hot
metal quality. A high quality cokeshould be able to supporta smooth descent of
the blastfurnace burden with as little degradation as possiblewhile providing the
lowest amountof impurities, highest thermal energy, highest metal reduction,
and optimum permeability for the flow of gaseous and molten products.
Introduction of high quality coke to a blast furnacewill resultin lower coke rate,
higher productivity and lower hot metal cost.
Coke Production:
The coke making process involves
carbonization of coal to high
temperatures (1300°C) in an oxygen
deficient atmospherein order to
concentrate the carbon. The
commercial coke making process
can be broken down into two
categories: a) Recovery Coke
making and b) Non-Recovery Coke
making.

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Pellet
Plant:
Ratedcapacity: 4.0 million TPA
Pellet size: 6 to 16 mm
Pelletization
Pelletization is the technological process designed to transform fines into 8 to 16
mm size balls with the help of balling disc or balling drum.
Three stages of pelletization process
1. Raw material preparation
2. Formation of green balls
3. Induration of green balls
Raw material
• CAPACITY
• RAW MATERIAL
• DRYERS EACH
• GRINDING
• MIXER
• BALLING DISCS
• INDURATION
• STACKER/RECLAIMIN
G
• FUEL CONSUMPTION
• POWER CONSUMPTION
• EMISSION
• PARTICULATE
• 4.2 MILLION TONNE PER YEAR,
• ORE FINES FROM JVSL MINES
• 2 NOS OF 4.6 M DIA 27.5M LONG, 225 TPH
• BALL MILL (2 NO) 208 TPH
• LITTLE FORD MAKE 600 TPH
• 5 NOS , 7.5 M DIA
• GRATE AREA -464 M2, 4 M WIDE CARS
• 700 TPH / 1100 TPH
• < 0.2 GigACal/TONNE
• < 54 KWH/TONNE
• < 100 mg/Nm3
• < 80 microgram/nM3

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1. Iron ore fines
2. Limestone (Additive)
3. Bentonite (Binder)
4. Corex sludge
SinterPlant:
Salient Features :
Sinter Machine SuctionArea 204 m
2
Sinter Machine Width 3 m
Sinter Machine Length 77 m
Side wall Height of Pallets 700 mm
SuctionbelowGrate 160 mbar

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Process Gas Volume 1.2 x 10 ^6 m
3
/h
Combined Mixing and Nodulizing
Drum 4.2 m dia x 15 m length
Energy Consumption for Ignition
(Corex Gas) 15,000 Kcal /t of Gross Sinter
Sinter Cooler Type Annular Circular Pressure Cooler
Effective Cooling Area 202 m
2
; Diameter: 22.5 m
Waste Gas cleaning System Electrostatic Precipitators
Production(tpd) 6984 tonnes
Annual production 2.3 MTPA
Power Consumption < 35 Kwh/t
Gas Consumption < 15000 Kcal/t
The Sintering Process
• Sintering is an agglomeration process which produces strong and porous
lumps from a powdered uncompacted mass of iron ore with the application
of heat to the stage of incipient fusion.
• Necessary heat is supplied by the combustion of coke breeze.
• The process is performed on a travelling grate on which 500-600 mmthick
sinter mix consisting of iron ore, flux, coke breezeand industrial wastes
along with moistureare fed continuously.
The complete combustion of coke breeze, initiated in the top layer
produces a temperature of 1200-1300°Cand is maintained continuously by
sucking air through the bed

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• The suction of air makes the combustion zone travel through the bed
raising its temperature layer by layer to sintering temperature.
• Process completes when combustion zonereaches to the lowest layer of
the bed.
• Sinter cake is tipped fromthe grate in hot condition, broken, screened and
cooled to producedesired fraction.
Sintering Process
• Feed preparation
• Proportion of raw materials
• Moistureaddition and mixing
• Layering on sintering machine
• Ignition of top layer
• Sintering- suction of air through bed
• Dischargeof sinter frommachine
• Cooling of sinter
• Screening of product
Raw Materials for Sintering
The source of iron
• The source of flux and
• The source of heat.
 In addition a large number of in plant wastes containing various quantities
of iron, flux and fuel values are also being included.
Sintering Reaction
• The sintering reaction starts with reduction of the hematite and formation
of the low melting liquid mono calcium ferrite (CaO.Fe2O3) at around
1200ºC by reaction with lime which absorbs silica and more of iron oxide.
• The melt so formed attacks the grain boundaries of hematite and the grains
dislodge into the melt forming CaO.2Fe2O3, 2FeO.SiO2, CaO.FeO.SiO2,
2CaO.Fe2O3, etc..

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• With increase of temperature more and more hematite along with gangue
goes into solution resulting in more of slag bonded complex sinter structure
SFCA (silica-ferrite of calcium and aluminums).
• At basicity levels of more than 2 calcium ferrite and dicalcium silicate forms
and at lesser than 1.6, glassy silicate and secondary hematite and
magnetite forms.
BlastFurnace:
The purposeof a blast furnaceis to chemically reduce and physically convertiron
oxides into liquid iron called "hot metal". The blast furnaceis a huge, steel stack
lined with refractory brick, whereiron ore, coke and limestone are dumped into
the top and preheated air is blown into the bottom. The raw materials require 6
to 8 hours to descend to the bottom of the furnacewherethey become the final
productof liquid slag and liquid iron. These liquid products are drained from the
furnaceat regular intervals. The hot air that was blown into the bottom of the
furnaceascends to the top in 6 to 8 seconds after going through numerous

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chemical reactions. Oncea blast furnaceis started it will continuously run for four
to ten years with only shortstops to performplanned maintenance.
Iron oxides can come to the blast furnaceplant in the formof raw ore, pellets or
sinter. The raw ore is removed fromthe earth and sized into pieces that range
from0.5 to 1.5 inches. This ore is either Hematite (Fe2O3) or Magnetite (Fe3O4)
and the iron content ranges from 50% to 70%. This iron rich ore can be charged
directly into a blastfurnace withoutany further processing. Iron orethatcontains
a lower iron content mustbe processed or beneficiated to increaseits iron
content. Pellets are produced fromthis lower iron content ore. This ore is crushed
and ground into a Powder so the wastematerial called ganguecan be removed.
The remaining iron rich powder is rolled into balls and fired in a furnaceto
producestrong, marble-sized pellets that contain 60% to 65% iron. Sinter is
produced fromfine raw ore, small coke, sand-sized limestone and numerous
other steel plant wastematerials that contain someiron. These fine materials are
proportioned to obtain desired productchemistry then mixed together. This raw
material mix is then placed on a sintering strand, which is similar to a steel
conveyor belt, whereit is ignited by gas fired furnaceand fused by the heat from
the cokefines into larger sizepieces that are from0.5 to 2.0 inches. The iron ore,
pellets and sinter then become the liquid iron
Produced in the blast furnacewith any of their remaining impurities going to the
liquid slag
The coke is produced froma mixture of coals. The coal is crushed and ground into
a powder and then charged into an oven. As the oven is heated the coal is cooked
so most of the volatile matter such as oil and tar are removed. The cooked coal,
called coke, is removed fromthe oven after 18 to 24 hours of reaction time. The
coke is cooled and screened into pieces ranging fromone inch to four inches. The
coke contains 90 to 93% carbon, someash and sulfur but compared to raw coal is
very strong. The strong pieces of coke with a high energy value provide
permeability, heat and gases which are required to reduce and melt the iron ore,
pellets and sinter.
The final raw material in the iron making process in limestone, the limestone is
removed from the earth by blasting with explosives. Itis then crushed and
screened to a sizethat ranges from0.5 inch to 1.5 inch to become blast furnace
flux.

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Since the limestone is melted to become the slag which removes sulfur and other
impurities, the blast furnaceoperator may blend the different stones to produce
the desired slag chemistry and create optimum slag properties such as a low
melting point and a high fluidity.
All of the raw materials are stored in an ore field and transferred to the stock
housebefore charging. Oncethese materials are charged into the furnacetop,
they go through numerous chemical and physicalreactions while descending to
the bottom of the furnace.
Salient Features
Capacity 2.7 MTPA
Production Avg. 7800 t/working day
Working Volume 3445 m³
Productivity (WV) 2026 thm/m³/day
Inner Volume (IV) 4019 m³
Productivity (IV) 1.94 thm/m³/day
Availability 98%
Tuyeres 36
Top Pressure 2.5 bar
Hot Blast temperature 1250 ºC
Tap holes 4
Coolers (CastIron & Copper) Staves Type

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Top charging PW BLT Unit
Stoves 3 No.
SGP RASA Type
Stoves (combustion) InternalCombustion Type
Hearth bottomcooling Water Type
DirectReductionIronPlant:
DR plant will use100% pellet & COREX gas for making DRI, which will be used in
Electric arc furnace & BOF as coolant.
The Basic design parameters of the facility are summarized as follows:
Operating mode Continuous
Operating hours per annum 8,000 hrs
Number of modules One

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Export Corex gas available to DR plant 2, 80,000 NCMH
Annual rated production 1.2 MTPA of DRI
Design Feed mix (Pellet : lump ratio) 80 : 20
Productmetallization 92 % (min)
ProductCarbon content 1.0 % (min)
Major areas in the Plant
STEELMELTINGSHOP:
Ratedcapacity: 1.62 million TPA liquid steel
No. of units: 2
Heat size /capacity: 120 tonne
Tap-to-taptime: 45 min.
Major units: Hot metal desulfurising station
Hot metal mixer
Basic Oxygen Furnaces
Scrap Yard

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Ladle preparation and handling bay
Ladle furnace
Gas cooling and cleaning plant
Water recirculation system
Salient Technical features: Pre-treatmenthotmetal.
Bottom stirring with insertgas in BOF
Suppressed combustion systemof gas in BOF
WIRERODMILL:
ITEM Salient Featuers
Mill Type Single strand continous WRM
Mill Capacity 0.6 MTPA
Mill Speed 110 m/sec
Input Billet size 165 * 165 * 12000 mm
Product range 5.5 mm to 22 mm

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Finished coil weight 2500 kg
Grade carbon steel upto 0.85% C and various alloy steels
Applications of end product
Wire drawing , Fasteners,Welding electrode,Prestressed
concrete wire , spring wire, Rope wire etc
Associates
Equipment suppliers Morgan U.S.A,Techint Italy
Consultants Korus Engg solutions Pvt Ltd
BARMILL:
ITEM SalientFeatuers
Mill Type Re Bar Mill
Mill Capacity 1.0 MTPA
Mill Speed 38 m/sec
Input Billetsize 165 * 165 * 12000 mm
Product range
TMT 8mm to 40mm,Plain rounds 20mm to 63mm,RCS 40MM to 63mm,Equal
angles 50*50*5 to 90*90*9mm

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Finished bundleweight 2000 to 5000 kg
Automation Level 2 process
Metallurgical aspects
Low good water coolingfacilities to achievedesired microstructureas well as good
mechanical properties.
Applications of end product Construction industry,Automotive,Forging industries etc.
Associates
Equipment suppliers Morgan U.S.A,Techint Italy
Consultants Korus Engg solutions PvtLtd
HOTSTRIPMILL:

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 Rated Capacity: 2.5 MTPA
 Can roll 1.6mmto 12mm thickness & up to a width of 1290mm
 Rolling all grades including Micro-alloy, Ferritic, LPG and Line pipe
 Automatic Gauge Control, Coil Box, X-ray Gauge, Profile Gauge, Roll
Bending, Advanced Automation System.
COLDROLLINGMILL:
The CRM i.e. Cold Rolling Mill project. As the name indicating rolling is done at a
normal temperature like room temperature is called cold rolling (CRM). There are
various types of CR Mills are available like 20 Hi Mill, 6 hi Mill, 4 Hi Mill, 2 Hi Mill &
Tandam Mill. The names indicating on the basis of how many rollers are used in
the mill. In Tandam mill, series of stands are installed and coil will pass through
the mills one direction and giving the desired thickness of the coils.
Raw material for CRM is Hot Rolled Coils; it is received from HSM2/ HSM-1. The
product of CRM is called CR Coils. In CRM2, the thickness of the products varies
from 0.30 mm to 3.00 as per requirements of the customer. The maximum wide
of the coil is 1950 mm. Normal weight of each coil shall be 25-30 MT. Maximum
speed of our line is 1450mpm
The CR Coils is the raw materials for Galvanizing (GP Line) and CRCA (Cold Rolled
Closed Annealing). The GP Coils is used for making GC sheets, GP sheets,

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Insulation works, making house hold items etc. The CRCA sheet is using for mainly
automobile industries. The CRM2 is biggest plant in India by capacity 2.30 mpa.
And second biggest is M/s Tata Steel.
LEARNING:
I have learnt how the structure behaves in different circumstances
depending upon different loading conditions & the complete designing &
analysis of the steel structure.
CONCLUSION:
In review this internship has been an excellent and rewarding experience. I have
been able to meet and mingle with so many officials by which I could get help for
my internship.
One main thing that I have learned through this internship is time management
skills as well as self-motivation. When I first started I did not think that I was
going to be able to walk for eight hours a day, five days a week. Once I realized
what I had to do I organized my day and work so that I was not overlapping or
wasting my hours. I learned that I needed to be organized and have questions
ready for when it was the correct time to get feedback. From this internship and
time management I learned to inculcate the habit of being in the office for so
many hours and using the time preciously. The main thing that I came across is
about my working capacity within the given time. That really gives a good
meaning for the training. I came up with various proposals and ideas that the
company is still looking into. I am also sure that this internship training
programme will help me out in my future projects.

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My Sincere Thanks to:

1 week plant visit

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