1) BHEL's Central Foundry Forge Plant (CFFP) produces large castings and forgings using electric arc furnaces to melt scrap steel and remove impurities. 2) In the steel melting shop, electric arc furnaces are used to melt scrap steel and add alloys, while a spectroscopy lab analyzes the composition. 3) Secondary steelmaking processes like vacuum oxygen decarburization and argon oxygen decarburization further refine the molten steel before casting.

1. BHARAT HEAVY ELECTRICAL
LIMITED
CENTRAL FOUNDRY FORGE PLANT
SUMMERTRAINING
Presented by :-sonam Priyadarshi
CSJMA15001390327

2. CONTENT
• Introduction to BHEL
• CFFP (central foundry forge plant)
• SMS (steel melting shop)
• EAF (electric arc furnace)
• Furnace operation
• Spectroscopy lab
• Secondary steel making

3. BHEL
• BHEL is stand for bharat heavy electrical limited.
• BHEL is engaged in the design , engineering, manufacturing,
construction , testing commissioning and servicing of a wide range of
products and servicing for the core sectors of the economy.
• BHEL is one the navratnas which is supported by government .
• It is divided into two units
1. HEEP (Heavy Electricals Equipment Plant)
2. CFFP (Central Foundry Forge Plant )

4. CFFP
• CFFP stand for central foundry forge plant.
• The Central Foundry Forge Plant (CFFP) is engaged
in manufacture of large size Castings and Forgings
of various types of steels like alloy steels, creep
resistant steel and supercritical grade steel .
• There are following shops :-
1. Steel melting shop
2. Steel foundry
3. Forge shop
4. Machine shop

5. SMS
• Steel melting shop is the shop where the
steel is produced from the iron ore and
the scrap. In BHEL scrap of different
grade is used. In steel making impurities
are removed such as nitrogen, silicon,
phosphorus and Sulphur and excess
amount of carbon. To form the molten
metal an alloying element is added to
enhance the properties such as
chromium, nickel, vanadium and
manganese.

6. • Steel meting shop consist :-
1.Electric arc furnace (10 tonn, 30 tonn, 70 tonn)
2.Ladle
3.Scrap
4.Spectroscopic lab
5.VOD (vacuum oxygen decarburizing)
6.VAD (vacuum arc degassing)
7.LRF (ladle refining furnace)
8.Mould for casting

7. EAF
• Electric arc furnace is use to
produce molten steel with the
help of arc.
• The main importance part of
electric arc furnace are side wall ,
electrode which are of graphite,
roof which is top of the furnace
from where the electrode is
inserted and hearth which is the
bottom of the furnace .

8. FURNACE OPERATION
• Charging:- this is the first step in steel
producing operation in which preparation of
furnace bucket is important. Scrap, flux
(lime and fluorspar) is added .
• Melting :- after adding all this, energy is
supply to the electrode and arc is
generated .
• Refining:- oxygen is provided to form oxide
Phosphorus, Sulphur, aluminium, Silicon,
Manganese and Carbon from the steel.
These oxide collected in slag.

9. • De-slaging:- once the slage is generated this slage is remove by tilting
the electric arc furnace .
• Tapping :- before tapping composition of molten metal was check in
spectrospopy lab. then the molten metal is remove from the electric arc
furnace into the preheated ladle for other operation .
• Before secondary operation, and after transferring the motel metal
into the preheated ladle De-oxidizers may be added to the steel to lower
the oxygen content for further processing. Common de-oxidizers are
aluminium or silicon Slag forming compounds are added in the ladle at
tap so that a slag cover is formed prior to transfer to the ladle furnace.

10. SPECTROSCOPIC LAB
• Optical emission spectrometer :- Optical emission spectroscopy using arc
and spark excitation is the preferred method for trace metal analysis to
determine the chemical compositions of metallic samples. In this we use two
Argon cylinder. One cylinder is use for generating spark and second is use for
creating vacuum.
• Vacuum emission spectrometer:- same as optical emission spectrometer. It
also determine chemical composition of metallic sample . Here the difference
is that it use only one cylinder of argon.
• Gas Analyzer:- It measure the gases present in material like hydrogen (H2),
nitrogen (N2), oxygen (O2). In this we use two cylinders of Helium and Argon.
Helium cylinder is use for melting.

11. secondary operation
• Secondary steel melting operation comes between the primary and casting
operation. This technique is use to produce high quality of steel. This process
involves refining of steel such as deoxidation, low level of hydrogen, nitrogen
and oxygen and impurities and also provide accurate temperature for casting
and etc [4].
• For secondary operation there are 2 VAD and 1VOD and 1LRF of 70 tonn.
1. VOD
2. VAD
3. LRF

12. • Vacuum arc degassing (VAD):- Used to remove oxygen, nitrogen and
hydrogen gases under vacuum and also removal for sulfur.
• Vacuum Oxygen Decarburizing (VOD):- Used to reduce carbon
content of steel.
• Ladle refining furnace :- In this oxygen , nitrogen and hydrogen is also
remove and excess amount of carbon is reduce .

13. CASTING
Casting is a manufacturing process in which
a liquid material is usually poured into
a mold, which contains a hollow cavity of the
desired shape, and then allowed to solidify.
The solidified part is also known as a casting,
which is ejected or broken out of the mold to
complete the process

14. CONCLUSION
In the Summer Training duration I observed and understood
different processes taking place in manufacturing of materials. It
showed the scope of Material Science and Metallurgy Engineering
and how the knowledge can be used in future for working in
industries.

15. REFERENCES
1. www.bhelhwr.co.in
2. www.electrical4u.com
3. www.wikipedia.com
4. Iron and steel making by Ahindra Ghosh and Amit
Chatterjee
5. Steel making by tupkary

16. THANK U!!!
:-D