The document provides information about Bhilai Steel Plant located in Bhilai, India. It is India's first and main producer of steel rails. The plant produces steel rails up to 260 meters long, as well as wide steel plates and other steel products. It also produces and sells chemical by-products from its coke ovens and coal chemical plant. The plant was established in 1955 with assistance from the Soviet Union. It is the largest and most profitable facility of Steel Authority of India Limited.

1. A VOCATIONAL TRAINNING REPORT
Submitted in partial fulfillment of the requirements for
the award for the degree
Of
BACHELOR OF TECHNOLOGY
In
CHEMICAL ENGINEERING
By
AMAN KUMAR KESARI
INSTITUTE OF TECHNOLOGY
GURU GHASIDAS VISHWAVIDYALAYA, BILASPUR
05/05/2015 – 30/05/2015

3. A Brief Introduction To Bhilai Steel
Plant
The Bhilai Steel Plant, located in Bhilai, in the Indian
state of Chhattisgarh, is India's first and main producer of
steel rails, as well as a major producer of wide steel plates and
other steel products. The plant also produces and markets various
chemical by-products from its coke ovens and coal chemical plant.
It was set up with the help of the USSR in 1955.
The plant is the sole supplier of the country's longest
rail tracks, which measure 260 metres (850 ft). The plant also
produces products such as wire rods and merchant products.
Bhilai Steel Plant has been the flagship integrated steel plant unit
of the Public Sector steel company, the Steel Authority of India
Limited and is its largest and most profitable production facility. It
is the flagship plant of SAIL, contributing the largest percentage of
profit.

4.  VISION:
• To be a respected world class corporation and the
leader in Indian steel business in quality,
productivity, profitability and customer
satisfaction.
 CREDO:
• Building lasting relationships with customers
based on trust and mutual benefit.
• Uphold highest ethical standards in conduct of
our business.
• Create and nurture a culture that supports
flexibility, learning and is proactive to change.
• Chart a challenging career for employees with
opportunities for advancement and rewards.
• Value the opportunity and responsibility to make
a meaningful difference in people's lives.

5. FLOW CHART OF BHILAI STEEL
PLANT

6. CO & CCD DEPARTMENT
The main function of Coke Ovens is to
convert coal into coke which is used as a fuel and
reducing agent in the Blast Furnace. Its secondary
function is to recover Volatile Matter and CO gas from
coal and extract chemicals known as Coal Chemicals.
CO gas produced is used for heating purposes in the
plant.
The Coke Ovens and Coal Chemical Department has
three main sections viz.
I. Coke Ovens
II. Coal Chemicals
III. Maintenance and Repairs
The description of each of these sections is given
below :
COKE OVENS :

7. Various sub-sections of Coke Ovens and their functions
are as follows :
1. Coal Handling Plant (CHP-I) and
Coal Preparation Plant (CPP-II) :To prepare coal blend
suitable for carbonisation in Coke Ovens Batteries to
produce BF coke.
2. Partial Briquetting : To prepare briquettes of coal to
charge along with coal into the oven.
3. Coke Oven Batteries : To convert coal into coke by
carbonising coal in absence of air and thereby distilling
the volatile matter out of coal. The resultant coke oven
gas is treated in CCD for recovery of chemicals.
4. Coke Sorting Plant : To crush and screen coke to 25-
80mm size required by blast furnaces. The 0-10 mm
fraction is used in sinter making and 10-25 mm fraction
(nut coke) is added along with sinter supplied to Blast
Furnace.

9. RAW MATERIALS USED FOR
COKE PRODUCTION
 PRIME COKING COAL
MEDIUM COKING COAL
 IMPORTED COKING COAL
 SOFT COKING COAL
COAL PROPERTIES
PCC MCC ICC SOFT
ASH 18-24 19-24 8.5-11.0 8.5-11.0
VM 24-25 27-29 22-24 32-35
MMR 1.0-1.1 0.9-1.0 1.15-1.30 0.85-0.95
SULPHUR 0.5-0.6 0.5-0.6 0.65-0.95 0.6-0.7

10. PARTIAL BRIQUETTING OF COAL CHARGE :
The basic process involves briquetting
a part of coal charge (28% by weight) with coal
tar (soft pitch) and charging the briquettes and
fine coal in a pre-determined ratio (25 : 75). The
rationale for using briquettes in charge is to
increase the bulk density of coal charged into
the oven and to improve the micum index and
crushing strength of coke.
COKE OVEN BATTERIES :
There are eight coke oven batteries
4.3 M tall having 65 ovens in each battery (in 2.5
MT stream) and two batteries 7 M tall having 67
ovens in each (4.0 MT stream). These are twin
flue regenerative, compound PVR (Pair Vertical
recirculation) and side fired type.

11.  The temperature of control verticals flues on pusher
side is 1175°C to 1225°C and 1200°C to 1250°C on
coke side. These however can be increased or
decreased depending upon the coking time.
 Coke ovens are mainly constructed of silica, fireclay,
high alumina and ordinary insulating bricks. The coke
oven chimney is made of concrete lined with fireclay
bricks. Normal life of a coke oven battery under
indian condition is considered to be 25 years.
 The heating of ovens is done from both the sides in
side fired batteries with reversal of heating.
 The coal is taken in charging car from the coal tower
and is charged into the empty oven. Each oven has
three charging holes and each charging car has three
bunkers for charging of coal into the ovens.
 Coke is made by heating coal in the absence of air (
carbonization / destructive distillation of coal) in a
series of ovens called batteries.

12. Coal blend to
Battery
Coal in an oven
converted to coke
Coke pushing
The process of conversion ….

13. Firing of spilled
Coke
Mechanized door
cleaner
Manual cleaning
of frame

14. IMPORTANT DATA OF BATTERIES
ANALYSIS OF COKE OVEN GAS
 Methane - 26.0%
 Hydrogen - 56.5%
 Hydrocarbons - 2.3%
 Carbon-monoxide - 8.5%
 Carbon dioxide - 3.0%
 Oxygen - 0.4%
 Nitrogen - 3.3%
 Density - 0.4848 kg/ m3
Description Battery(1-8) Battery(9&10)
Total length of oven 14,080 mm 16,000 mm
Total height of oven 4300 mm 7000 mm
Useful height 4000 mm 6700 mm
No. of ovens 65 67
Width on Pusher side 382 mm 385 mm
Width on Coke side 432 mm 485 mm
Average Width 407 mm 410 mm
Useful volume 21.6 Q.M. 41.6 Q.M.

15. IMPORTANT SAFETY RULES FOR WORKING IN
CO&CCD
• Do not travel on belt conveyors.
• If some Coal/Coke piece enters the eye, do not rub.
Wash it with water and go to medical post.
• Beware of free moving wagons.
• Do not stand on any machine tracks.
• Quenching car and pusher car, power trolley lines which
are within the reach of hands should not be touched.
• Do not go under quenching tower. Do not put your hands
in hot quenching water.
• Do not stand over a charging hole lid.
• Double security check is exercised for entry to benzol
rectification plant. Persons with matches or nailed shoes
are not permitted to enter the area.
• In case of acid burn, wash in running water and rush to
hospital.
• Wear cotton clothes only.
• All PPE (Personal Protective Equipments) provided by the
management be utilized without fail.

16. BLAST FURNACES
INTRODUCTION – Iron Production Basics:
BF is a counter current heat and mass
exchanger, in which solid raw materials are charged from
the top of the furnace and hot blast is sent through the
bottom via tuyeres. The heat is transferred from the gas to
the burden and oxygen from the burden to the gas. Gas
ascends up the furnace while burden and coke descend
down through the furnace. The counter current nature of
the reactions makes the overall process an extremely
efficient one.
In the blast furnace process iron ore and
reducing agents (coke, coal) are transformed to hot metal,
and slag is formed from the gangue of the ore burden and
the ash of coke and coal. Hot metal and liquid slag do not
mix and remain separate from each other with the slag
floating on top of the denser iron. The iron can then be
separated from the slag in the cast house. The other
product from the Blast Furnace is dust laden blast furnace
gas, which is further cleaned in the gas cleaning plant and is
used as a fuel all over the plant.

17. Blast Furnace constructional features:
A blast furnace has a typical conical shape. The sections
from top down are:
 Throat, where the burden surface is.
 The shaft or stack, where the ores are heated and
reduction starts.
 The bosh parallel or belly and
 The bosh, where the reduction is completed and the
ores are melted down.
 The hearth, where the molten material is collected
and is cast via the taphole.
Fig1: Schematic
cross- section of blast
furnace

19. BLAST FURNACE PROCESS:
The basic raw materials and their functions:
Iron Ore: Iron bearing materials; provides iron to
the Hot Metal.
Sinter: Iron bearing material. Fines that are
generated in the plant are effectively utilized by
converting them to sinter. Provides the extra lime
required for the iron ore that is charged in the
blast furnace.
Coke: Acts as a reductant and fuel, supports the
burden and helps in maintaining permeable bed.
Limestone: Acts as Flux. Helps in reducing the
melting point of gangue present in the iron
bearing material.
Manganese Ore: Acts as additive for the supply of
Mn in the Hot Metal.
Quartzite: Acts as an additive.
Coal Dust: Acts as an auxiliary fuel, reduces coke
consumption in the BF.

20. Coal Tar: Acts as an auxiliary fuel, reduces coke
consumption in the BF.
Pellets: Iron bearing materials. Although not in
use right now, there is a proposal to utilize the
fines below the sinter grade for pellet
manufacturing and the pellets formed are going
to be charged in the BF.
Reactions in the Blast Furnace:
UPPER STACK ZONE
 Reduction of Oxides
3 Fe 2O3 + CO = 2 Fe3O4 + CO2
Fe3O4 + CO = 3FeO + CO2
FeO + CO = Fe + CO2
 Decomposition of Hydrates
Water - Gas Shift Reaction
CO + H2O = CO2 + H2
 Carbon Deposition
 Decomposition of Carbonates

21. MIDDLE STACK ZONE
 Direct / Indirect Reduction
FeO + CO = Fe + CO 2
CO2 + C = 2CO
FeO + C = Fe + CO
 Gas utilization
LOWER STACK ZONE
 Calcination of Limestone
 Reduction of Various elements
Reduction of unreduced Iron
Reduction of Silicon
 Reduction of Mn, P, Zn etc. .
 Formation / melting of slag, final reduction of FeO and
melting of Fe.

22. COMBUSTION ZONE
 Burning and combustion of Coke
C + O2 = CO2 + 94450 cal (direct reduction)
CO2 + C = 2CO - 41000 cal (solution loss reaction)
 Complete reduction of Iron Oxide
RACEWAY
 Coke and Hydrocarbons are oxidized.
 Large evolution of heat.
HEARTH
 Saturation of Carbon with Iron.
 Final Reduction of P, Mn, Si and Sulphur.
 Reaction impurities reach their final
concentrations.
 Falling/drop of Metal and Slag bring heat down
into the Hearth.

24. HOT METAL SLAG BF GAS
Si 0.5-0.8 % SiO2 32-33 % CO 25-26 %
Mn 0.8-1.0 % Al2O2 19-20 % CO2
15 -16
%
S
0.04 %
max. CaO 31-33 % N2 55-57 %
P 0.20% MgO 9-10 % H2 2-3 %
C 4-5% MnO <1%
Basicity:
CaO/SiO2 0.98
ANALYSIS OF HOT METAL, SLAG AND TOP GAS