1) The document provides an overview of the internship and training that the author completed at Durgapur Steel Plant. 2) It includes a brief profile of Durgapur Steel Plant, describing its facilities and production of various steel products. 3) The process flow chart and descriptions of major units are given, outlining the production process from raw materials to finished steel products.

1. INDUSTRIAL INTERNSHIP TRAINING At DURGAPUR
STEEL PLANT, SAIL (Industrial Area, Durgapur, 713203)
A report submitted to NIT Durgapur
in partial fulfillment of the requirement for the degree of
Bachelor of Technology
In
Electrical Engineering
By
Name: DIPNARAYAN SAHA
Roll No:19EE8017
Department of Electrical Engineering
National Institute of Technology Durgapur
URL : https://nitdgp.ac.in
Durgapur-713209 , India
July 26, 2022

2. DURGAPUR STEEL PLANT LETTER HEAD
………………………………………………………………………………………………………………………….....................................
Date: 01/07/2022

3. NATIONAL INSTITUTE OF TECHNOLOGY, DURGAPUR
Acknowledgement
I am grateful to the career development centre of National Institute of
Technology Durgapur and Prof. Sankar Narayan Mahato, H.O.D. of
Electrical Engineering department for giving us the permission to
undergo this industrial training.
And also I would like to thank DSP, SAIL for giving me this
esteemed privilege to acquire knowledge about the industrial
methodology of work.
I will really cherish this experience of industrial training
throughout my life and hope that this will count a lot more in my future
career.
Name of the student: DIPNARAYAN SAHA
Roll No: 19EE8017

4. COMPANY PROFILE -- A BRIEF OVERVIEW

6. Durgapur Steel Plant (DSP) set up in late fifties is a leading producer of long products
and is the pioneer in manufacturing and supply of forged Railway Wheels & Axles in the
country. DSP started production with an initial crude steel capacity of 1 MPTA (million
ton per annum) in 1959, which has been progressively increased to 1.8 MTPA during
the modernization in nineties and further to 2.2 MTPA during recently completed
Modernization & Expansion Plan (MEP).
Broad facilities:
DSP produces liquid steel through conventional BF-BOF route, which is cast into billets,
blooms &rounds in its Billet Casters (2 Nos), Bloom Caster and Bloom cum Round Caster
(BRC). The finishing mills comprise of Merchant Mill to produces special quality EQR TMT
bars (20 &25 mm), Section Mill for medium structural sections and a state of art Medium
Structural Mill (MSM) to produce next generation parallel beams, channels and equal
angles.
Unique feature of this plant is its Wheel & Axle Plant for making forged wheels and axles
catering to Indian Railways. The product portfolio has evolved over the years with ever-
changing requirements of railways and includes a variety of loco and coach wheels. DSP
has successfully developed LHB wheels and LHB axles for Indian Railways.

7. Finished Steel
TMT Bars 20 mm, 25 mm in straight lengths of 12m
Medium
Structural
Equal Angle 90-200 mm, Medium Beam 100-300 mm ,Narrow parallel Beam (NPB) 100-300
mm, Wide Parallel Beam (WPB) 100-160 mm, Medium Channel 100-300 mm
Channels 200x75 mm, 150x75mm
Joists 200X100mm
Wheels
Coaching Wheels : BG,EMU, Metro, LHB (Developed), Loco Wheels: MG, BG, S-profile,
WAG9,WAP5, WDG 4(Developed)
Axles BG, BOX N (Developed), LHB (Developed)
Semi-finished Steel
Cast Billets 125 mm sq.
Cast Blooms 210x160, 230x160, 300x150, 350x150 , 350x240 mm
Cast round 340 m.m. dia.
By-products
Coal Chemicals Tar &Benzol products, Ammonium Sulphate
BF Granulated Slag Molten & Granulated Slag

11. PROCESS FLOW CHART : DURGAPUR STEEL PLANT

12. Major Units of Durgapur Steel Plant
• Raw Material Handling Plant
• Coke Oven and Coal Chemicals
• Sinter Plant
• Blast Furnaces
• Steel Melting Shop
• Merchant Mill
• Medium Structural Mill
• Section Mill
• Wheel and Axle Mill
• Engineering Shops
• Research and control Laboratory
➢ Raw Materials Handling Plant
Raw Material Handling Plant is one of
the most important of a integrated steel
plant. The major input for steel making
comes from mines to this section.
Raw Material Handling plant is meant
for transporting materials from Raw
Material yard /Base Mix yard to various
process units of the plant.
The Raw Materials Handling Plant
prepares blend mix for Sinter Plant and
also supplies raw material lumps to Blast
Furnaces and Steel Melting Shop. It has
3 nos. tipplers and 3 nos. blender-cum-
reclaimers.

13. ➢ Coke Ovens & Coal Chemicals
DSP is equipped with 5 nos. of Coke Oven batteries, out of which 4 batteries are in
operation and 1 battery is under cold repair. Each battery is of 4.45 Meter height and
comprises of 78 nos. of ovens. The Coke Ovens convert coking coal into coke, which is an
input for Blast Furnaces.
The Coke Ovens and Coal Chemicals
zone is divided into four basic sections
namely coal preparation plant, coal
carbonization plant, coke handling plant
and coal chemicals. The Blast Furnace
grade coke produced in Coke Ovens is
directly used in Blast Furnaces while
the undersized coke is used for sinter
making. The volatile matters, which
emanate during the process of coke
making subsequently produce a variety
of by-products like naphthalene oil,
heavy creosote oil, light oil, crude tar
partially distilled, ‘Raja’ brand fertilizer,
nitration grade benzene, nitration grade toluene, industrial grade toluene, light solvent
naphtha etc. The Coke Oven gas is generally used in combination with the Blast Furnace
gas and BOF gas as fuel and is carried through pipelines to different areas of the plant. The
adjoining Alloy Steels Plant under SAIL also gets this fuel gas from DSP.
➢ Sinter Plant
The Sinter Plant coverts blend mix into sinter, an
agglomerated input for Blast Furnaces. In order to
enhance the productivity of the blast furnaces, a
high percentage of sinter charge is a prerequisite.
Sinter is an agglomeration of iron ore fines, coke and
limestone in the form of cakes. DSP has three sinter
machines: 2 nos. with hearth area of 142.7M2 each
and 1 no. with hearth area of 198M2. Annual
capacity of Sinter Plant is 3.30 MT.
➢ Blast Furnaces
The Blast Furnaces produce liquid hot
metal, which is an input for Steel Melting
Shop. DSP has 3 Blast Furnaces of useful
volume of 1400 Mᶟ (BF No.2), 1400 Mᶟ (BF
No.3), 1800 Mᶟ (BF No.4) and working
volumes (W.V.) of 1207 Mᶟ, 1204 Mᶟ & 1539
Mᶟ respectively. The respective BF
productivitiesare 1.71, 1.82 & 1.69
T/Mᶟ(W.V.)/day. Annual hot metal
production capacity is 2.40 MT.The BF Slag

14. (granulated) is sold to the cement manufacturing companies.
➢ Steel Melting Shop
The Steel Melting Shop converts hot metal into
liquid steel, which is primarily processed through
Continuous Casting Plant (CCP). The Steel
Melting Shop (SMS) has 3 nos. 110/130 T Basic
Oxygen Furnaces (Converters), 1 no. of 110/130T
Vacuum Arc Degassing (VAD) unit and 3 nos. of
110/130T Ladle Furnaces for nominal heat size
of 120 T. The CCP is equipped with 2 Billet
Casters, 1 Bloom Caster and 1 Bloom-Cum-
Round Caster (BRC).In addition, SMS has
facilities forbottom pouring ingot casting for
vacuum-degassed loco wheel heats for Wheel &
Axle Plant of DSP and special steels for Alloy
Steels Plant (ASP).
➢ Merchant Mill
The Merchant Mill produces Earthquake Resistant (EQR)
Thermo Mechanically Treated (TMT) bars of different sizes,
which are used for construction and infrastructure
development. Its installed capacity wasoriginally 280,000
TPA. With phasing out of 16 mm TMT bar and maximising
production of 20 mm & 25 mm TMT bars, the mill capacity
is augmented to 360,000 TPA.
➢ Medium Structural Mill
DSP is equipped with new Medium Structural Mill (MSM) of 1.0
Million Tonne capacity. The new generation medium structural
produced in the mill are targeted for use in construction and
infrastructure development sectors, like parallel beams,
channels and equal angles.

15. ➢ Wheel & Axle Plant
The Wheel & Axle Plant produces forged and
machined wheels and axles for Indian Railways.
This includes wheels for Locomotives, BG
Coaches and EMU Coaches. DSP has
manufactured wheels for LHB coaches & Metro
Coaches as well. DSP produces BG Axles as per
Railway requirement. DSP Has also successfully
developed BOX N as well as LHB axles.
➢ Section Mill
The Section Mill rolls out light and medium structural like
joists, channels and angles, which is also used for
construction and infrastructure development.
➢ Engineering Shops
Durgapur Steel Plant has a number of captive engineering shops for repairs and supply of
spare parts. The Central Engineering Maintenance has a Machine Shop, Structural Shop,
Fitting and Assembly Shops. The Foundry produces Ingot moulds and bottom plates for the
Steel Melting Shop. There are also Auxiliary Repair Shops such as Electrical, Wagon and
Loco Repair Shops.
Electrical Repair shop

16. ➢ Research and Control Laboratory
The Research & Control Laboratory is well equipped for carrying out sophisticated
chemical, metallurgical and other tests both for better process control and improved quality
of products.
➢ Power Management Dept.
In Power Management dept. load
sharing of different mills, units of whole
steel plant is manged.
33 KV Substation

17. NATIONAL INSTITUTE OF TECHNOLOGY, DURGAPUR
DECLARATION
I affirm that the Industrial Internship Training report titled “INDUSTRIAL INTERNSHIP
TRAINING At DURGAPUR STEEL PLANT, SAIL “ being submitted in partial fulfillment of the
requirements for the award of the Degree of BACHELOR OF TECHNOLOGY IN
ELECTRICAL ENGINEERING is the original work carried out by me. It has not formed the
part of any other project work submitted for award of anydegree or diploma, either in this
or any other Institution.
……………………………………….…….………………………………………
Signature
Name of the student: DIPNARAYAN SAHA
Roll No: 19EE8017