JSPL DRI#1 Training Report 2017

OP JINDAL UNIVERSITY
OP Jindal Knowledge Park, Punjipathra, Raigarh – 496109. (C.G.)
t: +91 7762 304 000 www.opju.ac.in
JINDAL STEEL & POWER LIMITED
RAIGARH (C.G.) 496001
INDUSTRIAL TRAINING REPORT
SESSION 2017-18
DRI#1
A
DEPARTMENT – ELECTRICAL & ELECTRONICS ENGINEERING
Submitted By
Name: Abhishek Prajapati
University Roll No.:01UG15030004 Semester/Branch: 5th
/EEE
SUBMITTED TO:
School of Electrical & Electronics & Engineering
O P JINDAL UNIVERSITY
Raigarh (Chhattisgarh)

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ACKNOWLEDGMENT
JINDAL STEEL & POWER LTD
J.S.P.L is one of the leading companies in steel & power sector. JSPL
is part of the US$ 6 billion Jindal organization. Located at Raigarh in
state Chhattisgarh on main railway track Mumbai - Howrah. It is not
pioneer in steel & power sector but also producing sponge iron, Ferro
chrome & heavy machinery & under the leadership of Mr. NAVEEN
JINDAL, EVC & MD.
This training report provides the Acknowledgment about the DRI-1
(Direct Reduced Iron) section. Which I learn during the period of 4
weeks, under valuable guidance very senior members of the
organization at various departments, hence I could get clear details of
DRI-1.
I am very much thankful to all above senior faculties who spared their
valuable time & guide me to understand the system. This training was
not possible without the kind permission of Mr. Vivek Garg (HOD-
G.M., DRI-1, JSPL, Raigarh) who given an opportunity to complete
my training at JSPL.
UNDER GUIDANCE
Mr. Vivek Garg
(HOD-GM, DRI-1, JSPL, Raigarh, C.G.)
Mr. Shalendra Pratap Singh
(AGM, DRI-1, JSPL, Raigarh, C.G.)

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Always hold onto the railing
Take care not to slip or trip
Choose a safe location to have a phone call
Park your car in the designated spot
Ask for permission to take photos
Find out the nearest exit and the place
of assembly
Remember that use of alcohol and
drugs is prohibited in the plant area
Smoke only in the designated areas
Personal protective equipment
Safety glasses, shoes
Safety Jackets
Helmet
Reflective vest
Hearing protector in noisy areas
Additional protective equipment on
worksites as instructed by the visit’s host

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PROFILE OF JINDAL STEEL & POWER LIMITED
Jindal Steel and Power Limited (JSPL) is an Indian steel and
energy company based on New Delhi, India. With turnover of approx.
US$ 6 billion, JSPL is a part of about US$18 billion diversified Jindal
Group conglomerate. JSPL is a leading player in steel, power, mining,
oil and gas and infrastructure in India. The company produces steel
and power through backward integration from its own captive coal
and iron-ore mines.
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 and
coal-based sponge iron plant.
History: In 1969, O. P. Jindal (1930–2005) started Pipe Unit Jindal India
Limited at Hisar, India. After Jindal's death in 2005, much of his assets
were transferred to his wife, Savitri Jindal. Jindal Group's management
was then split among his four sons with Naveen Jindal as the Chairman of
Jindal Steel and Power Limited. His elder brother, Sajjan Jindal is the head
of JSW Group, part of O.P. Jindal Group.

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Contents:-
Sr. No. Topic
1. DRI (Direct Reduced Iron)
2. Flow chart of DRI
3. Raw Material
4. Primary Air
5. Secondary Air
6. Injection Coal
7. Rotary Kiln
8. Rotary Cooler
9. DRI – Power System Distribution
10. Transformer
11. Power Transmission
12. Motors used in DRI
13. HTPCS
14. LTPCS
15. PCP
16. PMCC
17. MCC
18. PDB
19. PLC
20. CPU Mode
21. Power Supply Module
22. DCS Structure

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D.R.I (DIRECT REDUCED IRON)
Direct-reduced iron (DRI), also called sponge iron, is produced from the direct reduction of iron
ore (in the form of lumps, pellets or fines) to iron by a reducing gas or elementary carbon
produced from natural gas or coal. Many ores are suitable for direct reduction.
Reduced iron derives its name from the chemical change that iron ore undergoes when it is
heated in a furnace at high temperatures in the presence of hydrocarbon-rich gases, carbon
monoxide or elementary carbon. Direct reduction refers to processes which reduce iron oxides
to metallic iron at temperatures below the melting point of iron. The product of such solid state
processes are called direct reduced iron. The reducing gas is a mixture of gases, primarily
hydrogen (H2) and carbon monoxide (CO). The process temperature is typically 800 to 1200 °C.
Direct reduction processes can be divided roughly into two categories, gas-based, and coal
based. In both cases, the objective of the process is to drive off the oxygen contained in various
forms of iron ore (sized ore, concentrates, pellets, mill scale, furnace dust etc.), in order to
convert the ore, without melting it (below 1200 °C), to metallic iron.
The direct reduction process is comparatively energy efficient. Steel made using DRI requires
significantly less fuel, in that a traditional blast furnace is not needed. DRI is most commonly
made into steel using electric arc furnaces to take advantage of the heat produced by the DRI
product.

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 Direct-reduced iron has about the same iron content as pig iron, typically 90–94% total
iron (depending on the quality of the raw ore) as opposed to about 93% for molten pig
iron, so it is an excellent feedstock for the electric furnaces used by mini mills, allowing
them to use lower grades of scrap for the rest of the charge or to produce higher grades of
steel.
 Hot-briquetted iron (HBI) is a compacted form of DRI designed for ease of shipping,
handling, and storage.
 Hot direct reduced iron (HDRI) is iron not cooled before discharge from the reduction
furnace that is immediately transported to a waiting electric arc furnace and charged,
thereby saving energy.
 The direct reduction process uses pelletized iron ore or natural "lump" ore. One exception
is the fluidized bed process which requires sized iron ore particles.
 The direct reduction process can use natural gas contaminated with inert gases, avoiding
the need to remove these gases for other use. However, any inert gas contamination of the
reducing gas lowers the effect (quality) of that gas stream and the thermal efficiency of
the process.
 Supplies of powdered ore and raw natural gas are both available in areas such as Northern
Australia, avoiding transport costs for the gas. In most cases the DRI plant is located near
natural gas source as it is more cost effective to ship the ore rather than the gas.
 This method produces 97% pure iron.
Advantage of DRI
 It allows steel making to dilute metallic residuals in scrap.
 Since it is manufactured it has a uniform composition.
 It has a uniform size.
 DRI has low sulphur and phosphorus content as compared to scrap.
 It allows improvement in BF productivity.

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PROCESS OF DRI
FLOW CHART OF DRI

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RAW MATERIAL
GENERAL
The major Raw Materials required for
production of Sponge Iron by the rotary kiln
process are: sized graded Iron Ore and Non-
Coking coal. Limestone, in small quantities,
is also required to scavenge the sulphur.
IRON ORE
The quality requirement of Sized ore for sponge iron production can be classified into:-
1) Physical requirements:-
Strength and granulometry are the two important physical requirements. The ore should be hard,
and possess high strength. The optimum tumbler strength of the ore should be 90 percent
minimum. Depending on the reducibility, closely calibrated ores in the size range of 5 to 20 mm
generally used.
2) Metallurgical requirements:-
The ore should be highly reducible, thermally stable and have a low tendency for sticking and
disintegration during heating and reduction.
3) Chemical requirements:-
Apart from the removal of oxygen, no other major chemical change takes place in direct
reduction. The gangue material in sponge iron, originating from Iron Ore, namely, silica and
alumina and the sulphur and phosphorous contents adversely affect the economics in subsequent
steel making operation. Therefore, the ore should be high in iron content and low in gangue.

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PHYSICAL & CHEMICAL SPECIFICATION:-
COAL
Non-coking coal is used as reluctant in the rotary kiln process.
Physical Specification
Size Lump - 5-20 mm
Fines - 0-5 mm
Contamination (Shale & Stones etc.) - < 3%
Chemical Specification-
Fixed Carbon - 45%
Volatile Matter - 25-30%
Ash - 20%
Moisture. - 8%
The major quality requirements of coal for Sponge iron Production are-
 Non-coking characteristics
 Low ash content
 Low sulphur content
 Good reactivity
 High ash fusion temperature
 Medium volatile matter
DOLOMITE/LIMESTONE:-
Limestone is used as a de-sulphuriser in the
production of sponge iron. It is a calcium magnesium
carbonate with a chemical composition of CaMg
(CO3)2. It is the primary component of the
sedimentary rock known as dolostone and the
metamorphic rock known as dolomitic marble.
Limestone that contains some dolomite is known as
dolomitic limestone.
Size 5-20 mm
Oversize < 5 % max
Undersize <5% max
Tumbler Index +90
Material Percentage
Silica 3 %
Contamination 5 %
Fe (total) 65 %
SiO2+Al2O3 5 %
Sulphur 0.01 %
Phosphorous 0.05 %
Moisture 1 %

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TYPICAL SPECIFICATION OF LIMESTONE IS GIVEN BELOW:-
CHEMICAL COMPOSITION: INDUSTRIAL USE OF LIMESTONE:-
MgO 22 %
CaO 28 %
PRIMARY AIR
 Primary air is used to combustion the injection coal
 Temperature in used below 950 C
SECONDARY AIR
 Secondary air is introduced axially in the direction of the gas flow
 The air supplied to the length of the kiln is metered for close control of temperature and
gas atmosphere in the kiln
 Heating zone extends from 25% to 40% along length of the kiln and in the reduction zone.
INJECTION COAL
 Coal Injection over a large range of size 0-20 mm
 Temperature combustion below 950 C
 Coal injection system makes use of voal volatiles for reduction, thereby reducing the coal
requirement to a minimum
 Coal Injection can decrease energy consumption.
Coal Crushing Combustion Injection to kiln

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ROTARY KILN
It is the heart of the coal based reduction process since the reduction reaction takes place in this
reactor. The diameter and the length of the kiln depend on its capacity. The kiln is generally
lined with high alumina castable refractories throughout its length with dams at feed end and
discharge end. The kiln is usually inclined at 2.5 degree downward slope and rests on two to
four support stations, depending on the kiln size. The transport rate of materials through the kiln
can be controlled by varying its slope and speed of rotation. There are inlet and outlet cones at
opposite ends of the kiln which are cooled by its individual fans. The kiln shell is provided with
small sampling ports. The longitudinal positioning of the kiln on its riding rings is controlled by
hydraulic systems.
The basic reduction reactions in a coal based DRI process is
as follows:-
C+ O2 = CO2
CO2 +C = 2 CO
3Fe2O3 + CO = 2Fe3O4 + CO2
Fe3O4 + CO = 3FeO + CO2
FeO + CO = Fe + CO2

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ROTARY COOLER
The product (DRI) along with coal ash, claimed dolomite and residual char is discharged from
the kiln at around 1000 degree Celsius. An enclosed chute at the kiln discharge end equipped
with a lump separator and an access door for removing lumps transfers the hot DRI to a rotary
cooler. The cooler is a revolving cylinder of appropriate size which is inclined at 2.5 degrees.
 The product is conveyed to the product separation and storage building
 The product is Sponge iron and char
 Place that spraying a controlled amount of water directly into hot solids and by spraying
additional water outside the cooler shell.
DRI POWER SYSTEM DISTRIBUTION
THREE-PHASE POWER DISTRIBUTION
FOR INDUSTRIAL ENVIRONMENT
Industries or factories are installed with three
phase power in order to connect heavy
machineries and equipment’s. Bus bars carries
this three phase power and from which
individual connections are brought out, to
individual loads, through cables. The figure
below shows schematic diagram for industrial 3-
phase wiring.

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TRANSFORMER
Two winding voltage transformer which can be used increase or decrease its secondary voltage
with respect to the primary supply voltage. But voltage transformers can also be constructed for
connection to not only one single phase, but for two-phases, three-phases, six-phases and even
elaborate combinations up to 24-phases for some DC rectification transformers.
If we take three single-phase transformers and connect their primary windings to each other and
their secondary windings to each other in a fixed configuration, we can use the transformers on
a three-phase supply.
Three-phase, also written as 3-phase or 3φ supplies are used for electrical power generation,
transmission, and distribution, as well as for all industrial uses. Three-phase supplies have many
electrical advantages over single-phase power and when considering three-phase transformers
we have to deal with three alternating voltages and currents differing in phase-time by 120
degrees as shown below.

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SILICA GEL USED IN TRANSFORMER
Whenever electrical power transformer is loaded,
the temperature of the transformer insulating oil
increases, consequently the volume of the oil is
increased. As the volume of the oil is increased, the
air above the oil level in conservator will come out.
Again at low oil temperature; the volume of the oil
is decreased, which causes the volume of the oil to
be decreased which again causes air to enter into
conservator tank.
The natural air always consists of more or less
moisture in it and this moisture can be mixed up
with oil if it is allowed to enter into the transformer.
The air moisture should be resisted during entering
of the air into the transformer, because moisture is
very harmful for transformer insulation. A silica gel
breather is the most commonly used way of filtering
air from moisture.
CONSTRUCTION OF SILICA GEL
The silica gel breather of transformer is very simple in the aspect of design. It is nothing but a
pot of silica gel through which, air passes during breathing of transformer. The silica gel is a
very good absorber of moisture. Freshly regenerated gel is very efficient, it may dry down air to
a dew point of below -40o
C. A well maintained silica gel breather will generally operate with a
dew point of -35o
C as long as a large enough quantity of gel has been used. The picture shows
a silica gel breather of transformer.
WORKING PRINCIPLE OF SILICA GEL
Silica gel crystal has tremendous capacity of absorbing moisture. When air passes through these
crystals in the breather; the moisture of the air is absorbed by them. Therefore, the air reaches
to the conservator is quite dry, the dust particles in the air get trapped by the oil in the oil seal
cup. The oil in the oil sealing cup acts as barrier between silica gel crystal and air when there is
no flow of air through silica gel breather. The color of silica gel crystal is dark blue but, when it
absorbs moisture; it becomes pink.

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POWER TRANSMISSION
Most transmission lines are high-voltage
three-phase alternating current (AC), although
single phase AC is sometimes used in railway
electrification systems. High-voltage direct-
current (HVDC) technology is used for greater
efficiency over very long distances (typically
hundreds of miles). HVDC technology is also
used in submarine power cables (typically
longer than 30 miles (50 km)), and in the
interchange of power between grids that are
not mutually synchronized. HVDC links are
used to stabilize large power distribution
networks where sudden new loads, or
blackouts, in one part of a network can result
in synchronization problems and cascading
failures.
Electricity is transmitted at high voltages
(115 kV or above) to reduce the energy loss
which occurs in long-distance transmission.
Power is usually transmitted through overhead
power lines. Underground power transmission
has a significantly higher installation cost and
greater operational limitations, but reduced
maintenance costs. Underground transmission
is sometimes used in urban areas or
environmentally sensitive locations.
High-voltage overhead conductors are not
covered by insulation. The conductor material is
nearly always an aluminum alloy, made into
several strands and possibly reinforced with
steel strands. Copper was sometimes used for
overhead transmission, but aluminum is lighter,
yields only marginally reduced performance
and costs much less. Overhead conductors are a
commodity supplied by several companies
worldwide. Improved conductor material and
shapes are regularly used to allow increased
capacity and modernize transmission circuits.
Conductor sizes range from 12 mm2
.

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MOTORS USED IN DRI
6An electrical motor is such an electromechanical device
which converts electrical energy into a mechanical
energy. In case of three phase AC operation, most widely
used motor is three phase induction motor as this type
of motor does not require any starting device or we can
say they are self-starting induction motor.
For better understanding the principle of three phase
induction motor, the basic constructional feature of this
motor must be known to us. This Motor consists of two
major parts:
Rotor of three phase induction motor consists of
cylindrical laminated core with parallel slots that can
carry conductors. Conductors are heavy copper or
aluminium bars which fits in each slots & they are short
circuited by the end rings. The slots are not exactly made
parallel to the axis of the shaft but are slotted a little
skewed because this arrangement reduces magnetic
humming noise & can avoid stalling of motor reworking
principle of three phase induction motor it may observed
that the rotor speed should not reach the synchronous
speed produced by the stator. If the speeds equals, there
would be no such relative speed, so no emf induced in the
rotor, and no current would be flowing, and therefore no
torque would be generated. Consequently the rotor
cannot reach the synchronous speed. The difference
between the stator (synchronous speed) and rotor speeds
is called the slip. The rotation of the magnetic field in an
induction motor has the advantage that no electrical
connections need to be made to the rotor.

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HIGH TENSION POWER CONTROL SYSTEM
High Volt Power & Control Systems Pvt. Ltd is a
trustworthy manufacturer of medium voltage panels
including ABB, HT Panel, VCB Panel, LT Panel etc.
We are India based company with high end facilities
and production DG Sets. High voltage products are
tested at CPRI / ERDA / ARAI. Our work and
products performance shows our quality and services.
With ISO 9001:2015 Certification we have achieve
immense accreditations for our products and we
strictly maintain international standards in our
company. We are experienced, innovative and sincere
towards our work. We maintain best quality by taking
take of each minute process and tests. The results we
get are highly suitable ABB, HT Panel, VCB Panel, VCB, LT Panel, Relay Control Panel,
Generator Control Panels, lighting relay panel etc. We maintain strict temperatures and vital
Clad Metal for necessary quality of our range.
LOW TENSION POWER CONTROL SYSTEM
A power distribution box provides DCS-power to all
30 chambers in a super module, whereby 4 doubly
redundant power control units independently switch
power for each of the 18 distribution boxes. Control
and monitoring of the hardware is fully implemented
as a detector oriented hierarchy of objects behaving
as finite state machines. PVSS II is used in the
supervisory layer. Communication to the hardware is
realized by a distribution information management
server. We report on the completed production of 18
power distribution boxes for the full TRD and focus
on its finalized control system. Applications at the
super module construction site at University of
Muenster, a recent test beam at the CERN Proton
Synchrotron and during a data run with cosmic events
with the ALICE detector are presented. These low
voltage panels are designed and developed as per the
requirements of our valued customers. Low voltage
panels offered by us are praised for their ease of
installation, efficiency and operational fluency. Our
offered product is customized as per client's
requirements.

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POWER CONTROL PANEL
We are one of the major manufacturers and suppliers of an
extensive range of Control Panel that are well-known for
their sturdy construction, longer functional life and reliable
performance. The proffered range of panels is designed and
developed as per the industrial guidelines. These efficient
control panels are widely demanded for their operational
fluency.
Features:
 Durable
 Efficient
 Reliable performance
POWER MOTOR CONTROL CENTRE
This power cum motor control centre (PMCC) panel is
widely used to allocate power through the panels. Later the
power gets distributed to various motor loads located at
different segments of the factory systems. These products
are manufactured by making use of premium grade raw
materials that is procured from reliable vendor base in the
market. Further, we make employ cutting-edge technology
to engineer these products. Henceforth, these are widely
appreciated in the industry.
MOTOR CONTROL CENTER
A motor control center (MCC) is an assembly of one or more enclosed sections having a
common power bus and principally containing motor control units. Motor control centers are in
modern practice a factory assembly of several motor starters. A motor control center can include
variable frequency drives, programmable controllers, and metering and may also be the
electrical service entrance for the building.
Motor control centers have been used since 1950 by the automobile manufacturing industry
which used large numbers of electric motors. Today they are used in many industrial and
commercial applications. Where very dusty or corrosive processes are used, the motor control
center may be installed in a separate air-conditioned room, but often an MCC will be on the
factory floor adjacent to the machinery controlled
Each motor controller in an MCC can be specified with a range of options such as separate
control transformers, pilot lamps, control switches, extra control terminal blocks, various types
of thermal or solid-state overload protection relays, or various classes of power fuses or types

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of circuit breakers. A motor control center can either be supplied ready for the customer to
connect all field wiring, or can be an engineered assembly with internal control and interlocking
wiring to a central control terminal panel board or programmable controller.
POWER DISTRIBUTION BOX
A distribution board (also known as panel board,
breaker panel, or electric panel) is a component
of an electricity supply system that divides an
electrical power feed into subsidiary circuits,
while providing a protective fuse or circuit
breaker for each circuit in a common enclosure.
Normally, a main switch, and in recent boards,
one or more residual-current devices (RCD) or
residual current breakers with overcurrent
protection (RCBO), are also incorporated.

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PLC
Programmable Logic Controller (PLC) is a
special computer device used in industrial
control systems. Due to its robust
construction, exceptional functional
features like sequential control, counters
and timers, ease of programming, reliable
controlling capabilities and ease of
hardware usage – this PLC is used as more
than a special-purpose digital computer in
industries as well as in other control-system
areas. Most of the industries abbreviate
these devices as “PC” but it is also used for
personal computers; due to this, many
manufacturers named these devices as
PLCs.
The programmable logic controller is used not only for industrial purpose but also in civil
applications such as washing machine, elevators working and traffic signals control. Different
types of PLCs from a vast number of manufacturers are available in today’s market. Therefore,
in the following paragraphs, let us study about programmable logic controller’s basics,
principles and applications.
PRINCIPLE OF PROGRAMMABLE LOGIC CONTROLLER:
Programmable Logic Controllers
are used for continuously
monitoring the input values from
sensors and produces the outputs
for the operation of actuators based
on the program. Every PLC system
comprises these three modules:
 CPU module
 Power supply module
 One or more I/O module
CPU MODULE:
A CPU module consists of central processor and its memory. The processor is responsible for
performing all the necessary computations and processing of data by accepting the inputs and
producing the appropriate outputs.

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POWER SUPPLY MODULE:
This module supplies the required power to the whole system by converting the available AC
power to DC power required for the CPU and I/O modules. The 5V DC output drives the
computer circuitry.
I/O MODULES:
The input and out modules of the programmable logic controller are used to connect the sensors
and actuators to the system to sense the various parameters such as temperature, pressure and
flow, etc. These I/O modules are of two types: digital or analog.
Communication Interface Modules: These are intelligent I/O modules which transfers
the information between a CPU and communication network. These communication modules
are used for communicating with other PLC’s and computers, which are placed at remote place
or far-off locate. The program in the CPU of programmable logic controller consists of operating
system and user programs. The purpose of the operating system with CPU is to deal with the
tasks and operations of the PLC such as starting and stopping operations, storage area and
communication management, etc. A user program is used by the user for finishing and
controlling the tasks in automation. The Principle of operation of the PLC can be understood
with the cyclic scanning also called as scan cycle
DCS STRUCTURE
A DCS typically uses custom-designed processors
as controllers, and uses either proprietary
interconnections or standard protocols for
communication. Input and output modules form
the peripheral components of the system.
The processors receive information from input
modules, process the information and decide
control actions to be performed by the output
modules. The input modules receive information
from sensing instruments in the process (or field)
and the output modules transmit instructions to the
final control elements, such as control valves.
The field inputs and outputs can either be continuously changing analog signals e.g. 4~ 20mA
dc current loop or 2 state signals that switch either "on" or "off", such as relay contacts or a
semiconductor switch.
DCS systems can normally also support such as Foundation Fieldbus, provirus, HART, Modbus,
PC Link and other digital communication bus that carries not only input and output signals but
also advanced messages such as error diagnostics and status signals.

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JSPL DRI#1 Training Report 2017

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