A presentation on Vizag Steel Plant

1. A Presentation On
The Study tour conducted
for 2nd. Year (Mechanical Branch) students

2. Programme schedule Mechanical-I Mechanical-II
Left college 5.30A.M. reached Vizag at 3.20P.M.by
train. Visited Beach in the evening
14.02.2013 15.02.2013
Visited Vizag Steel Plant 10.00A.M to 1.00 P.M.
In the second half visited Kailash Giri and Marine
Park(submarine)
15.02.2013 16.02.2013
In the morning visited Simanchalam ,the god
Nurshingha nath from 9.00A.M to 12.30 P.M.
Left Vizag at 3.20 P.M reached BBSR at 12.15 A.M
16.02.2013 17.02.2013
Faculty accompanied
Mechanical-I Mechanical-II
K.N.Hota K.K.Dash
R.C.Parida R.N.Bag
A.Samanta M.K.Panigrahy
P.R.Mahapatra
Number of students-45 Number of students-45

3. A Presentation On

4. Introduction
Visakhapatnam :-
• Visakhapatnam (Vizag) is second largest city in
Andhra Pradesh with an area of 550km² and eleventh
largest city in India.
• In the 1950s and 1960s the government and the
private sector set up large scale basic industries like
Bharat Heavy Plates and Vessels (B.H.P.V.),
Hindustan Zinc Ltd., Caltex oil refinery (later
acquired by government as H.P.C.L.), Coromandel
fertilizers, and Andhra Polymers (now LG Polymers).
The 1980s saw a major development with the
development of the Visakhapatnam Steel Plant and
other major industries.

5. Introduction
Vizag Steel Plant (VSP):-
• Visakhapatnam Steel Plant, popularly known as
Vizag Steel Plant is the first shore based Integrated
Steel Plant in India with the help of German & Soviet
technology which is situated at a distance 16km from
Visakhapatnam.
• VSP is having a capacity of 2.656 million tonnes of
saleable steel and a Initial capacity of 3.0 million
tonnes per annum of liquid steel Later enhanced to
6.3 millions tonnes with US$2.59 billion.
• It is the only integrated steel plant in India to be
certified with ISO-9001(for quality),ISO-14001(for
Environmental Management) and OSHAS-18001
(for safety).

6. History
• On 17th April 1970, the then prime minister of India,
Late Mrs. Indira Gandhi announced the
government's decision to establish a steel plant at
Visakhapatnam.
• The foundation stone was laid by Smt. Gandhi On
20th January 1971.
• On 18th Feb 1982 the responsibility of constructing ,
commissioning & operating was transferred to
Rashtriya Ispat Nigam Ltd (RINL) from SAIL.
• Rashtriya Ispat Nigam Ltd (RINL), was made the
corporate entity of Visakhapatnam Steel Plant in
April 1982.
• In July 1992The plant was dedicated to nation by the
then prime minister of India, Late Sri. P.V.N.Rao.

7. • To be a continuously growing world class company
Mission:-
• To attain 16 million tonne (Mt) liquid steel capacity
through technological up-gradation Operational
efficiency and expansion; to produce steel at international
standards of cost and Quality; and to meet the aspirations
of the stakeholders.
Vision:-

8. • Located at southeast coast of India
• Nearby Airports are Vizag (19 km) ,BBSR(454 km)
Vijayawada (339 km), Hyderabad(611km)
• VIZAG Steel also Maintaining an AIR STRIP
• 24km away from Visakhapatnam railway station
LOCATION:-

9. LOCATION MAP:-

11. SATELLITE VIEW:-
Vizag Steel Plant (VSP):-

12. MAJOR SOURCES OF RAW MATERIAL:-
RAW MATERIAL SOURCE
Iron ore Lumps & Fines Bailadilla,MP
BF Lime Stone Jaggayyapeta,AP
SMS Lime Stone UAE
BF Dolomite Madharam,AP
SMS Dolomite Madharam,AP
Manganese ore Chipurupalli,AP
Boiler Coal Talcher,Odisha
Coking Coal Australia
Medium Coking Coal Gidi/ Swang/ Rajarappa/
Kargil

13. • Raw Material Handing Plant (RMHP)
• Coke Oven & Local Chemical Plant
• Steel Melting Shop (SMS)
• Sinter Plant
• Blast Furnace
• Continuous Casting Department
• Rolling Mills
• Light & Medium Merchant Mills (LMMM)
• Wire Rod Mill (WRM)
• Medium Merchant And Structural Mills (MMSM)
• Power Generation and Distribution
• Water Management
MAJOR DEPARTMENTS OF VSP :-

14. MAJOR UNITS OF THE PLANT:-
DEPARTMENT ANNUAL
CAPACITY(IN MT)
UNITS (3.0 MT
STAGE)
Coke ovens 2.261 4 Batteries of 67
ovens & 7 mtrs.
Height
Sinter plant 5.256 2 sinter machines of
312m² grate area
each
Blast furnace 3.4 2 furnaces of
3200m3 capacity
SMS 3.0 3 LD converters
each 133m3 & 6
strand bloom
casters
LMMM 0.71 4 Stand finishing
mill
WRM 0.85 4×10 stand
finishing mill
MMSM 0.85 6 stand finishing
mill

15. MAIN PRODUCTS OF THE PLANT:-
Steel products By-products Others
Angles Nut coke Granulated slag
Billets Coke Dust Lime fines
Channels Coal Tar Ammonium
Sulphate
Beams Anthracene
Squares HP Napthalene
Flats Benzene
Rounds Toulene
Re-bars Xylene
Wire rods Wash oil

16. Water Supply:-
• Water requirement of the steel plant is being met from
the yeleru water supply. There is a storage reservoir at
yeleswaram and a 15kms long lined canal to the plant site
apart from Kanithi balancing reservoir.
Kanithi balancing reservoir

17. Power Supply:-
• The plant has in-plant power generation from a power
plant having 3no’s of 60MW and one 64.7MW sets
installed. Additional requirement of operational power,
around 150MVA is being met from the APTRANSCO
grid.
APTRANSCO GRID

18. PROCESS LAYOUT OF VSP:-

19. Major Departments:-
1.Coke ovens & coal chemical plant:-
• Coal is converted into coke by heating the coal blend charge in
the coke ovens in the absence of air at a temperature of 10000c -
10500c for a period of 16/18 hours. The volatile matter of coal
liberated during carbonization is collected in gas collecting mains
in the form of raw coke oven gas passing through stand pipes and
direct contact cooling with ammonia liquor spray. The gas cooled
from 8000c to 800c 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.

20. Coke ovens & coal chemical plant

21. 2.Blast Furnace:-
•Iron is made in the blast furnaces by smelting iron bearing
materials with the help of coke and air. The solid charge materials
like sinter, sized iron ore, etc. are charged in the vertical shaft of the
Blast Furnace at top and hot air blast is blown almost from the
bottom. The oxygen from the hot air combines with the carbon of
the coke and generates heat and carbon monoxide. The gases while
ascending upwards react with the charge. Eventually the charge
melts and hot metal and slag are produced and tapped out. The
cooled gas is also used as fuel in the plant. The Paul- wurth, bell loss
top system is installed for furnace charging.
•The two furnaces with their novel circular cast house with four tap
holes each are capable of producing 9720 tonnes of hot metal daily
or 3.4 MT of low sulphur hot metal annually.

22. Blast Furnace

23. 3.Steel melting shop & continuous casting(SMS):-
• Steel is melt in the SMS in the refractory lined vessels called LD converters by
blowing oxygen through the hot metal bath. While iron making is a reduction
process, steel making is an oxidation process. The oxygen reacts with the
carbon in the hot metal and this reaction releases large quantities of gas rich in
carbon monoxide along with huge amount of dust. The gases released from the
converter are collected, cooled, cleaned and recovered for use as fuel in the
steel plant. The entire molten steel at VSP is continuously cast at the radial
type continuous casting machines resulting in significant energy conservation
and better quality steel. 100% Continuous casting on such a large scale has
been conceived for the first time in India.

24. Steel melting shop & continuous casting(SMS)

25. LD PROCESS

26. Wire Rod Coils in process Wire Rods
Products of VSP:-

28. Environmental Management:-
•At VSP, an initial investment of Rs.468 crores was made on
environment protection systems in the existing units which was
5.5% of the total project cost. For 6.3Mtpa expansion project, an
amount of Rs.1292crores constituting 10.3% of the project cost is
being spent for pollution control systems.

29. Air pollution control measures:-
•Cyclones, scrubbers, bag filters & electrostatic precipitators are
provided to cover and recycle the dust generated.

30. Water pollution control measures:-
•Twenty water recirculation systems are provided for water
conservation. Eight waste water treatment plants are provided for
suspended colloidal solids.
•Chemically contaminated water is first treated in Mechanical,
Biological, & chemical treatment plant & then further treated in the
effluent treatment plant along with plant sewage water to bring
down the contaminants down then discharged to the Bay of Bengal.

31. Noise pollution control measures:-
•Provision of acoustic hoods, silencers, vibration isolators
•Maintaining the speed of rotating equipments<1500rpm
•Liberal sizing of pipes to ensure low velocities
•Insulation pipes
•Air conditioning & insulation of control rooms

32. Achievements & awards:-
•Indira Priyadarshini Vriksha award
•Nehru Memorial national Award for pollution control
•Golden Peacock(1st prize) “National quality Award”
•Steel ministers’ Trophy for “Best safety performance”
•World quality commitment award of Spain
•Ispat Suraksha Puraskar (1st prize) for longest accident free period
•PM trophy for “Best Integrated Steel Plant” twice
•Vishwakarma Rashtriya Puraskar award
•National award for Excellence in water management
•ICWAI award for Excellence in cost management
•FAPCCI best industrial productivity award
…….so on

33. Expansion plan:-
PRODUCTS PRESENT
CAPACITY
in MT
CAPACITY
AFTER
EXPANSION
in MT
ADDITIONAL
FACILITIES
Hot metal 4.0 6.5 BF with 3800 m3
capacity
Charged
sinter
5.26 8.5 SMS-2 with two 150 m3
converters. Two 6 std
Billet casters & one std.
round caster
Liquid steel 3.7 6.3 Sinter plant of 400 m2
area
Saleable steel 3.34 5.72
Wire rods 1.05 1.65 WRM of
6000,000T/annum
Bars &
structurals
1.95 3.4 SBM of
750,000T/annum SM of
700,000T/annum

34. Production performance (in MT) :-
Year Hot Metal Liquid
Steel
Saleable
steel
1999-00 2.943 2.656 2.382
2000-01 3.165 2.909 2.507
2001-02 3.485 3.083 2.757
2002-03 3.941 3.356 3.056
2003-04 4.055 3.508 3.169
2004-05 3.92 3.56 3.173
2005-06 4.153 3.604 3.237
2006-07 4.046 3.606 3.29
2007-08 3.913 3.322 3.074
2008-09 3.456 3.145 2.701
2009-10 3.9 3.399 3.167

35. Commercial performance (Rs. In crores) :-
Year sales Domestic
sales
Exports
1999-00 3,037 2,677 295
2000-01 3,436 3,122 322
2001-02 4,081 3,710 371
2002-03 5,059 4,433 626
2003-04 6,174 5,406 768
2004-05 8,181 7,932 249
2005-06 8,469 8,026 443
2006-07 9,151 8,726 425
2007-08 10,433 9,878 555
2008-09 10,411 10,343 78
2009-10 10,635 10,285 350

36. Financial performance (Rs. In crores) :-
Year Gross
Margin
Cash
Profit
Net profit
1999-00 252 -130 -562
2000-01 504 153 -291
2001-02 690 400 -75
2002-03 1,049 915 521
2003-04 2,073 2,024 1,547
2004-05 3,266 3,093 2,008
2005-06 3,383 1,355 1,251
2006-07 2,633 1,700 1,363
2007-08 3,515 3,483 1,943
2008-09 2,355 2,267 1,336
2009-10 1,460 1,130 797

37. GALLERY:-
VIZAG STEEL PLANT

38. VIZAG STEEL PLANT

39. SUBMARINE

40. R.K. BEACH & GOLCONDA BEACH

41. KAILASH HILLS

42. SIMANCHALAM

43. Thank You