Industrial Training Report on Direct Reduced Iron Plant of Jindal Steel & Power Limited Raigarh Chhattisgarh

1. 1 | P a g e
20 days Industrial Training Report File
On DRI (18/02/2017-09/03/2017)
Submitted To Submitted By
Mr. MK Pyasi Shani Kumar Singh
General Manager Roll No-1344948
Direct Reduced Iron Plant-2 Branch-Mechanical
Jindal Steel and Power Ltd, Raigarh Semester-8th
College-CGC-COE, Mohali
Signature-

2. 2 | P a g e
Acknowledgement
It is matter of great pleasure and privilege for me to present this report of 20 days industrial
training in DRI-2.Though this report, I would like to thank numerous people whose consistent
support and guidance is standing pillar in architecture of this report.
To begin with, my sincere thanks to Ateet Namdeo, AGM-HR & ES of Jindal Steel and Power
Ltd for providing me an opportunity to get acquainted with various activities of different plant. I
express thanks to Mr. MK Pyasi, General Manager of DRI-2 for extending co-operation to enable
me to get acquainted with the various activities of their department.
I would like to express my sincere gratitude to my guide Mr. VP Mishra. I was privileged to
experience a sustained enthusiastic and involved interest from his side. I would like to mention
a great word of gratitude to Mr. Chandan Sahu and Mr. Atul Vyas sir to help me to understand
various activities of organization in details.
I would like to express my sincere thanks towards members of Maintenance, Operation &
RMHS department for making me a deep knowledge about various activities of DRI plant.
Shani Kumar Singh

3. 3 | P a g e
Index
1. Introduction of Jindal Steel and Power ltd
2. Facilities at Raigarh Plant Include
3. Introduction of DRI Plant
4. Sponge Iron or Direct Reduced Iron
5. Raw Material
6. Raw Material Handling Station(RMHS)
7. Process of DRI Plant
8. Process Flow Chart
9. Pump House
10. Product Handling System
11. Pollotion Control System
12. Hydraulic and Pneumatic Control System
13. Mechanical Equipments Used in DRI
a-Rotary Kiln
b-Feed Pipe
c-Shell air fan
d-Shell Air Tube
e-Secondary air fan
f-Inlet and Outlet Seal
g-Kiln Drive System
h-Gearth Gear
i-Kiln Support Roller
j-Thrust Roller
k-Coal Injector
l-Cooler
m-Grizzly
n-Double Pendulum Valve
o-Wet Scubber
p-Stacker and Reclaimer
q-Vibrating Screen
r-Belt Conveyor
s-Weigh Feeder
t-Magnetic Seperator

4. 4 | P a g e
Introduction of Jindal Steel and Power Ltd
 JSPL is an industrial powerhouse with a dominant presence in steel,
power, mining and infrastructure sectors.
 Turnover of approx. US$ 3.3 billion, JSPL is a part of about US$18 billion
diversified Jindal Group conglomerate.
 In terms of tonnage, it is the third largest steel producer in India.
 The company manufactures and sells sponge iron, mild steel slabs, ferro
chrome, iron ore, mild steel, structural, hot rolled plates and coils.
 JSPL operates the largest coal-based sponge iron plant in the world and
has an installed capacity of 3 MTPA (million tonnes per annum) of steel at
Raigarh in Chhattisgarh.
 JSPL has been rated as the second highest value creator in the world by
the Boston Consulting Group.
 The 11th Fastest growing company in India by Bussiness World and has
figured in the Forbes Asia list of Fab 50 Companies.
 In Oman(Middle East), the company has set up a US $ 500 million,1.5
MTPA gas-based hot briquetted Iron(HBI) plant.It has now added a
2MTPA integrated Steel Plant.
 Alongside contributing to India’s growth story the company is driving an
ambitious global expansion plan in Africa,Australia and Indonesia.
 It deploys its resources to improve infrastructure, education, health,
water, sanitation, environment and so on in the areas it operates in. It has
won several awards for its innovative business and social practices.

5. 5 | P a g e
Facilities at the Plant Include
 DRI Plant-4nos. of 500TPD (0.72 Million TPA) and 6nos. of 300TPD rotory
kilns (0.72 Million TPA)
 DRI Plant-4nos. of 500TPD (0.72 million TPA) and 6nos. of 300TPD rotory
kilns (0.72 million TPA)
 0.8 million TPA Coke Oven Plant
 2.5 million TPA sinter Plant
 1.25 million TPA and 0.42 million TPA Blast Furnace
 2.0 million TPA and 1.25 million TPA steel melting shop
 2 Vacuum degassing Unit
 RH degassing Unit
 1 No. Single strand slab Caster
 1 No. of 6-strand billet-cum-round Caster and 1 No. 6 Strand billet caster
 2 No of 4-strand combi-caster
 Rail and Universal beam Mill(RUBM) (0.75 million TPA)
 Plate-cum-coil MILL(1.0 million TPA)
 Submerged arc furnace(SAF)(0.03 million TPA)
 Oxygen Plant 37683 Nm^3 per hour
 Lime and Dolomite Calcination Plants(0.4165 million TPA)
 358 MW Captive Power Plant(CPP)
 0.7 million TPA medium and light structure mill

6. 6 | P a g e
Introduction of DRI Plant
Direct-reduced iron (DRI), also called sponge iron is produced from direct reduction of iron (in
the form of lump, pellets or fines) by a reducing gases produced from natural gas or coal. This
reduction takes place in the temperature range 800- 1050 degrees C when reducing gases;
mainly Hydrogen and Carbon-monoxide; react with the iron oxides to produce iron. The degree
of metallization, defined as the extent of conversion of iron oxide into metallic iron, is 92-96%
in a typical DRI process. This high percentage of metallization makes DRI a highly suitable input
for steel making. The specific investment and operating costs of DRI plants are low compared to
integrated steel plants and are more suitable for many developing countries where supplies of
coking coal are limited. This holds true for India where most of the coking coal has to be
imported.
Figure-DRI PLANT
SPONGE IRON –
Sponge- iron is a metallic product which is produced by reaction of iron oxide and
carbon mono oxide with the presence of essential temperature. This is a direct
reduction process where carbon mono oxide is acting as reducing agent and the
iron ore reduced in solid state as such it is also known as direct reduced iron (DRI).

7. 7 | P a g e
Hematite iron ore (Fe2O3) is used for reduction. After reduction of iron ore the product
resembles spongy because of pores left behind after removal of oxides as such it is
called sponge iron.
RAW MATERIAL USED IN DRI –
Coal Fines (0-5 mm in size) - Injection Coal from Kiln Outlet
Iron Ore(5-25 mm in size) – Raw material(Pellet) which is feed from Inlet
Dolomite(1-6 mm in size) - (For removing coal Sulphur)
Coal(3-20 mm in size) - Feed from Inlet
Coal Lumps(5-25 mm in size) - Feed from Inlet
RAW MATERIAL HANDLING STATION (RMHS)
Raw Material Handling Plant/Station is meant for storing & transporting raw materials from
Raw material yard to various process units of the plant.Raw material station is consist of Raw
material yard,Stacker and Reclaimer,Hoppers and Conveyor.Below picture shows the layout of
raw material station.

8. 8 | P a g e
PROCESS AND REACTION
#THE PROGRESSIVE STAGES OF REDUCTION ARE AS FOLLOWS: -
STAGES OF REDUCTION BY CARBON MONOXIDE
I II III
Fe2O3 Fe3O4 FeO Fe
Hematite Magnetite Wustite Iron
The direct reduction involves reduction of iron ore in solid phase by gaseous reducing agents
such as carbon monoxide and hydrogen at high temperatures.
Thus, the main reactions, with their heats of reaction at 25o
C are: -
1. 3Fe2O3 + CO ® 2Fe3O4 + CO2 DH = - 12636 Cal
2. Fe3O4 + CO ® 3FeO + CO2 DH = 8664 Cal
3. FeO + CO ® Fe + CO2 DH = - 4136 Cal
4. ¼Fe3O4 + CO ® ¾Fe + CO2 DH = 936 Cal
The Heats of reaction 1 & 3 are negative, which means that the reactions are exothermic,
whereas reaction 2 is endothermic. Because Wustite (FeO) is metastable below 570 o C, it is
generally thought that iron oxide reduction takes place in two stages at lower temperatures.
The Magnetite produced in first stage is reduced to iron bypassing the Wustite. This reaction is
also exothermic. Since CO is not freely available they are to be generated in the reaction
environment from carbon or hydrocarbon bearing material such as coal or natural gas.
Gasification reactions
C + ½ O2 → CO .H = -26418 Cal/mole
CO + ½ O2 → CO2 .H = -67500 Cal/mole

9. 9 | P a g e
C + O2 → CO2 .H = -92052 Cal/mole
CO2 + C → 2CO .H = 41200 Cal/mole
Thus, the process involves the formation of reducing gas CO and reduces the iron ore by the
reducing gases.
There are many basic aspects, which need to be considered for making sponge iron in rotary
kiln. The important are as follows.
#Thermodynamics and kinetics of reduction and gasification reaction.
Movement of solids in the rotary kiln and its residence time.
Gas evolution and flow rate.
Heat transfer and temperature profile.
Role of reducibility of iron ore and reactivity of coal char and thereby the basis selection of iron
ore and coal.
#The process therefore occurs in the following steps –
1. Raising the temperature of raw materials to the optimum reaction temperature.
2. Generation of reducing gases.
3. Adsorption of gases on the surface of ore to the reaction interface.
4. Reaction of gases with the oxide and release of products of reaction.
5. De-sorption of gaseous products from the reacted interface.
6. All the above steps result in travel of the reaction interface towards the core.

10. 10 | P a g e
PROCESS FLOW CHART –
PROCESS –
Iron-ore, wash coal & dolomite are fed in different proportions from the feed end. Injection
coal lumps & injection coal fines are injected from outlet, about 40-45% of the total coal is
charged from the feed end & remaining 55-60% of the coal is pneumatically injected into the
kiln from the discharge end, dolomite is fed in proportion of 2-4 % of iron ore.

11. 11 | P a g e
PUMP HOUSE-
Pump House is an a station from water supply at desired pressure and flow rate is maintained.
In DRI plant Pump house supplies cooling water for DRI cooler where surface cooling takes
place. Pump House also supplies water for cleaning of surface in DRI plant area.
#Cold Well Pump:1,2,3,4,5,6
Pump type:SCT 200/48
Head:55m
RPM:1490
Make:KIRLOSKAR
#ABC Pump:1,2,3
Pump type:125/27M7ST
Head:170m
Discharge:100m^3/hr
RPM:1470
Make:KIRLOSKAR
PRODUCT HANDLING STATION-
The product coming out from Cooler is discharges to the conveyor through Double Pendulum
(DP Valve) valve, here purpose of DP Valve is to create sealing so that the dust particles and the
product discharges uniformly on the conveyor belt through which product is transported to the
product handling station.
DRI discharge from Cooler through DP valve on
Conveyor
Vibrating Screen
Product Handling Station
Accretion Fines Lumps
Magnetic Separator Magnetic Separator
DRI Fines Char Lumps
Hopper Hopper Hopper Hopper

12. 12 | P a g e
Where product is discharges in the Hopper like structure at the bottom of which vibrating
screen of different size is mounted through which oversize products basically accretion is
separated or we can say products are separated in three forms accretion, fines and lumps. Fines
and lumps are passes through Magnetic separator from DRI lumps are separated from char and
also DRI Fines are separated from char. From here DRI fines and DRI lumps are stored in
Product hopper and supplied to SMS-2,JSPL or either in market according to demand and
requirement.
POLLUTION CONTROL SYSTEM –
Pollution is one of the major challenges in front of world. DRI plant is also contributing in
Pollution Control by Installing various systems like ID fan suction at each places where dust is
generated like at the end of weigh hopper, At the discharge of DRI from cooler and various
position at product handling station and so on. There is a bag filter which purpose is to filter
the dust coming through air and filter sir is discharge to atmosphere.
HYDRAULIC AND PNEUMATIC CONTROL SYSTEM
Hydaulic and Pneumatic control system has important role in controlling of flow and opening
and closing the valve inside the Industrial field and other field. In DRI plant Hydraulic system is
used for controlling the stack. Pneumatic system is used for sealing of Kiln inlet and outlet seal
and for cleaning purpose.
Max Hydraulic operating Pressure=210 bar
Working hydraulic Pressure=150 bar
MECHANICAL OBJECTS USED IN DRI–
ROTARY KILN – Kiln is the major equipment in DRI plant, which is also known as rotary furnace.
Kiln having cylindrical structure, aligned horizontally with specific inclination.
Dimensions of Kiln (500 TPD) –
Length – 82 meter
Internal Diameter from shell to shell – 4.8 meter
Kiln shell thickness – 25mm
Inclination of the Kiln – 2.5%
Kiln inlet opening – 3.0 meter
Kiln outlet opening – 2.3 meter
Capacity of the Kiln – 500 TPD

13. 13 | P a g e
KILN SUPPORT ROLLER – There are four pairs of Support rollers which support the kiln through
tyre shell. Kiln having four numbers of tyre shells. Solid lubricant like graphite is used for
lubrication in support roller.
SHELL AIR FAN – There are 08 numbers of shell air fans on the kiln. These all fans are used to
provide air inside the kiln for combustion and temperature control. These all fans are fixed in
kiln shell with specific distance and alternate opposite side. This arrangement helps in proper
circulation of air inside kiln. Damper is provided to each fan for control of air volume.
Shell Air Fan
Support Roller
Shell Tyre
Rotary Kiln
Shell Air Fan

14. 14 | P a g e
SHELL AIR TUBE – Every shell air fan joint with a shell air tube at the shell of kiln. This shell air
tube is responsible for the delivery and circulation of air inside the kiln coming from shell air
fans. Shell air tube consists of long body, dome and a nozzle (Swirler). Material of Air tube is HK
40 grade steel.
SECONDARY AIR FAN – Similar to the shell air fans the secondary air fan supplies air in to the
kiln inside from the discharge end. This fan is connected with the central burner pipe. Damper
is provided for control the air flow.
Shell Air Tube

15. 15 | P a g e
INLET & OUTLET SEAL – At the end of kiln inlet & outlet seals are provided so that flue gases
cannot passes through ends. these are also known as slip seals. These seals are provided with
the help of cylinders which hold the kiln in contact with stationary part of the kiln at inlet or
Outlet.
KILN DRIVE SYSTEM – There are to sets of drive system Main drive and Auxiliary drive. These
drives are responsible for rotation of Kiln with necessary RPM. Drive system rotate the pinion
and this pinion in turn rotate the Girth Gear which is mounted on Kiln shell.
Kiln Outlet Seal

16. 16 | P a g e
GIRTH GEAR – This is a gear system having spur type gear, mounted on kiln shell and used to
rotate the kiln. There is Lubrication system which performs periodic pumping of lubricant to
reduce the friction between gear teeth.
THRUST ROLLER – This is also a supporting roller which provides axial movement for Kiln. This
roller is working with the help of hydraulic system.
COAL INJECTOR – This object is used for better utilization of coal fines and volatile matter and
to ensure availability of carbon for the last stage of reduction. Coal injector delivers the coal
Girth Gear
Thrust Roller

17. 17 | P a g e
through injection pipe. This pipe also connects with the roots blower which provides pneumatic
pressure and by this pressure coal is injected in to the kiln from kiln outlet. Coal injector
periodically delivers the coal in to the pipe to avoid jamming.
COOLER – The cooler is a hollow cylindrical in which the temperature of the fresh hot sponge
iron is cooled down to 125C. The internal diameter of the cooler is 3.8m; length of the cooler
is 50mtr. By the help of the single pinion and girth gear the cooler rotates. The cooler is
supported at two support roller stations. Lubrication system for girth gear is available. The girth
gear of the cooler is having module 50. Cooler is responsible for indirect cooling of sponge iron.
It is done by falling water on the cooler shell.
Rotary Feeder

18. 18 | P a g e
GRIZZLY – Grizzly is located at the end of cooler. This is used to screen the oversize accretion
which is formed in the kiln. These accretions are waste product of sponge iron. Separated
oversize material will discard by fall shaft gate.
DOUBLE PENDULUM VALVE – This valve delivers the product in to discharge belt conveyor. DP
valve having two pockets which open alternate. Due to these pockets products deliver in belt
conveyor in limited quantity. This system helps to avoid the spillage of product.
WET SCRUBBER – This is a system which is used for remove the sediments which collected
from ABC, DSC & Back spillage chamber. Sediments are removed through help of drag chain.
This chain system operates by drives.
FEED PIPE – The feeding of raw material is done through the Feed pipe which is located at kiln
inlet. There is a fan which is provided to prevent the hot gases coming out from kiln.
STACKER & RECLAIMER – This object is used for stacking and reclaiming of raw materials.
There is wheel which picks the raw materials by the arranged buckets from the ground and
delivers on the conveyor belt. Stacker Reclaimer reclaimes materials from all over the stock
yard.

19. 19 | P a g e
VIBRATING SCREEN – This is type of screen used for separation of materials (Iron ore and Coal)
on the basis of their size. In DRI Iron Ore required size is 05 to 25mm and for coal is 03 to 20mm.
Separated lumps and fines are collected in separate hoppers and supplied by conveyors.
BELT CONVEYORS – The different conveyor belts are used for the transportation of the
different raw materials to the kiln and for the transportation of end products (sponge iron) to
the hoppers. These belts are running with the help of drives. Belt conveyors consist of many
equipments – Pulleys, idlers, Idlers frame, Drive system, Belt, Pull chord (For Safety).
WEIGH FEEDER - A weigh feeder is used to continuously feed bulk solids on to the belt
conveyor. Since Iron ore, dolomite and reduction coal are fed to the kiln at the same time, the
proportions of these raw materials plays a significant role in the direct reduction process. The
role of a weigh feeder is to ensure the proper proportions of the feed material by controlling
the discharge on to the belt conveyor.

20. 20 | P a g e
MAGNETIC SEPARATOR – Discharge product containing sponge iron (Morganatic part) and
char (Non magnetic part). Magnetic separator is used to separate the magnetic particles from
nonmagnetic parts. Both are collected in separate bins. Magnetic parts are further screened by
vibrating screen and separated in to lumps and fines. The fines parts are packed by packing
machine and the lumps parts are directly send to SMS as raw material.
TERMINOLOGY USED IN DRI –
DRI : Directly Reduced Iron.
Tc : Thermocouple.
QRT : Quick Response Thermocouple.
RPM : Revolutions per Minute.
ICW : Indirect cooling water.
CO : Carbon Mono-Oxide.
CO2 : Carbon Di-Oxide.
Fe(m) : Metallic Iron.

21. 21 | P a g e
Fe(t) : Total Iron.
DSC : Dust Settling Chamber.
ABC : After Burning Chamber.
ESP : Electro Static Precipitator.
LOI : Loss Of Ignition.
SAF : Shell Air Fans.
TDI : Thermal Degradation Index.
AFT : Ash Fusion Temperature.
BC : Belt Conveyor.
WHRB : Waste Heat Recovery Boiler.
DSC :Dust Settling Chamber.
ABC: After Burning Chamber.
DBC: Discharge Belt Conveyor.
DRC: Discharge Reversible Conveyor.
SMS: Steel Melting Shop.