this ppt is about the summer practical training seminar presentation on bokaro steel plant( a family of sail)

1. POORNIMA INSTITUTE OF ENGINEERING AND TECHNOLOGY
JAIPUR
DEPARTMENT OF ELECTRONICS & COMMUNICATION ENGG.
A
PRACTICAL TRAINING SEMINAR
ON
“BOKARO STEEL PLANT(SAIL)”
DELIVERED TO: DELIVERED BY:
DIPESH PATIDAR SARABJEET CHOUHAN
(ASTT. PROFESSOR,EC) BRANCH:-ECE
ANKUR SAHARIYA Reg. No:-PIET/EC/11/010
(ASTT. PROFESSOR,EC)

2. CONTENT
• INTORDUCTION
• HISTORY
• COMPANY PROFILE
• PROCESS FLOW
• FACILITIES
• BLAST FURNACE
• HOT STRIP MILL (HSM)
• COLD ROLLING MILLS (CRM)
• BY PRODUCTS
• CONCLUSIONS
• REFERENCES

3. INTRODUCTION
• STEELAUTHORITY OF INDIA LIMITED (SAIL) IS THE LEADING STEEL-MAKING COMPANY IN INDIA.
• SAIL IS INDIA'S LARGEST STEEL PRODUCING COMPANY WITH A TURNOVER OF RS. 47,042 CRORE.
• SAIL IS AMONG THE FIVE MAHARATNAS OF THE COUNTRY'S CENTRAL PUBLIC SECTOR ENTERPRISES.
• IT IS A FULLY INTEGRATED IRON AND STEEL MAKER.
• APPLICATIONS OF STEEL PRODUCTS:
 DOMESTIC CONSTRUCTION
 ENGINEERING
 POWER
 RAILWAY
 AUTOMOTIVE
 DEFENCE INDUSTRIES

4. HISTORY
• AFTER INDEPENDENCE, FOR RAPID INDUSTRIALIZATION OF THE COUNTRY, HINDUSTAN STEEL PRIVATE LIMITED
WAS SET UP ON JANUARY 19, 1954 AT ROURKELA(ODISHA).
• THE PRESIDENT OF INDIA HELD THE SHARES OF THE COMPANY ON BEHALF OF THE PEOPLE OF INDIA.
SAIL TODAY:
• IT IS ONE OF THE LARGEST INDUSTRIAL ENTITIES IN INDIA.
• IT HAS FIVE INTEGRATED PLANTS ,THREE SPECIAL STEEL PLANTS AND ONE SUBSIDIARY PLANTS.
• THESE ARE PRINCIPALLY LOCATED IN THE EASTERN AND CENTRAL REGIONS OF INDIA.

5. INTEGRATED STEEL PLANTS

6. SPECIAL STEEL PLANTS
Visvesvaraya Iron and Steel
Plant
(VISL) in Karnataka
Salem Steel Plant (SSP) in
Tamil Nadu
Alloy Steels Plants (ASP) in West
Bengal

7. COMPANY PROFILE

8. BOKARO STEEL
PLANT
• FOURTH INTEGRATED STEEL PLANT IN PUBLIC SECTOR, WELL KNOWN AS SWADESHI PLANT
• COLLABORATION AGREEMENT WITH SOVIET UNION (USSR) ON 25TH JAN, 1965 ( SAIL FOUNDATION DAY)
• TOTAL AREA 33,045.35 ACRES
• CAPACITY
• FIRST PHASE : 1.7 MT OF INGOT STEEL
• SECOND PHASE : 4.0 MT OF INGOT STEEL
• AFTER MODERNIZATION : 4.5 MT OF LIQUID STEEL
• ENOUGH SCOPE FOR FURTHER EXPANSION (PLAN FOR 7 MT)
• TYPES OF PRODUCTS
 FLAT PRODUCT
 ROLLED PRODUCT

9. PRODUCTS
Hot rolled sheets(HRS)Hot rolled coils(HRC) Galvanised plain and
corrugated (GP/GC) sheets
Cold rolled sheets (CRS) Cold rolled sheets(CRS) Tin mill black plates (TMBP)

10. Sintering Plant
BF1 BF2 BF3 BF4 BF5
Blast Furnace
300 T
Con-1
300 T
Con-2
Steel Melting Shop - 2
Steel Melting Shop - 1
130T
Con-1
130 T
Con-2
130 T
Con-3
130 T
Con-4
130 T
Con-5
Tandem Mill-1
Tandem Mill-2
Soaking Pit
ll
SPM 1 & 2
Hot Dip Galvanizing Line
Galvanized Sheet Shearing Line
Galvanized Sheet Corrugation Line
HR Coil
HR PLATE /
SHEET
CR Coil
CR Sheet GP Coil
Galvanized Corrugated
& Plain Sheet
Iron Ore
Fluxes
O H P
Continuous
Casting
Department
Reheating
Furnace
SAIL
Bokaro
Pig Casting Machine
H R C F
PROCESS FLOW
BF Coke
Coking Coal
Coke Breeze
PL-II
PL-I
A
N
N
E
A
L
I
N
G CRCF
COKE OVEN BATTERIES
DCR Mill
Slabbing Mill Hot Strip Mill
Iron Ore, Lime Stone
& Dolomite Fines

11. FACILITIES
• RAW MATERIALS & MATERIAL HANDLING PLANT
• COKE OVENS & BY-PRODUCT PLANT
• BLAST FURNACES
• CONTINUOUS CASTING SHOP
• SLABBING MILL
• HOT STRIP MILL(HSM)
• COLD ROLLING MILL(CRM)
• AUXILIARY SHOPS

12. BLAST FURNACE
A Closer view of Blast
Furnace

13. BLAST FURNACE
• 5 BLAST FURNACES IN BSL
• EACH OF 2000 CUBIC METER USEFUL VOLUME AND 2640 T/DAY HM CAPACITY
• HOT METAL TEMPERATURE 1460-14800C
• BF PRODUCTIVITY: 1.4 T/M3/DAY
• CAPACITY OF B F 4.585 MT OF HOT METAL PER ANNUM

14. MATERIAL FLOW DIAGRAM FOR BLAST FURNACE
Sintering
Plant
Dust catcher
In BF
Gas Cleaning
Plant
RM & MHP
SP
Process
Steam
Net work
Stove of
BF
Charging
Section
of
Blast
Furnace Coke Ovens
For
Sale
Pig Casting
M/C
For
Distribution
Mixer of
SMS
IMF
Slag Dump
Yard
TBS
BFCHSG
/SGP
Blast Furnace
Hot Metal
Iron Ore
Lime Stone
Mn Ore
Sinter
Coke
Slag Granules
for Sale
Raw BF gas
Flue Dust
Cleaned
BF Gas
Partially
Cleaned BF
Gas
Iron Ore
(Lump)
Lime Stone,
Mn Ore,
Quartzite
Sinter
Coke
Cold Pig
Process
Steam
Hot air
Cold
air
Slag
Quartzite

15. Hot Metal being charged into the converter

16. HOT STRIP MILL (HSM)
• HOT ROLLING INVOLVES PLASTIC DEFORMATION OF A METAL UNDER SQUEEZING FORCE (A PAIR OF
ROLLS) ABOVE ITS RE-CRYSTALLIZATION TEMPERATURE.
• DESIGNED TO ROLL THIN & WIDE STRIPS
• CAPACITY: 3.955 MT OF HR COILS
• ROLLING SPEED: 20 M/SEC MAX.
• CONSTRUCTION
 3 WALKING BEAM REHEATING FURNACES & 1 PUSHER TYPE FURNACE
 VERTICAL SCALE BREAKER
 5 ROUGHING STANDS, 7 FINISHING STANDS
 HYDRAULIC AGC IN LAST FOUR STRANDS
 4 HYDRAULIC COILERS WITH AUTOMATIC STRAPPING & ROBOT MARKING

17. MATERIAL FLOW DIAGRAM OF HSM
Slab
yard
Furn
aces
Furn
aces
VSB R1 R2 R3 R4 R5
F. Shear
CC CC
Coilers
Finishing Stands
Roughing Stands

18. COIL DIMENSIONS
• STRIP THICKNESS 1.6 TO 16.0 MM
• STRIP WIDTH 910 TO 1,850 MM
• COIL INSIDE DIA 650 MM
• MAX COIL OUTSIDE DIA 2,300 MM
• MAX COIL WEIGHT 32 T
APPLICATION OF PRODUCT
• WAGON BUILDING
• TUBE & PIPE INDUSTRY
• DRUM & FURNITURE `MANUFACTURING

19. COLD ROLLING MILLS
• COLD ROLLING IS DONE TO PRODUCE THINNER GAUGE STRIP OF SMOOTH FINISH WITH
BETTER MECHANICAL PROPERTIES THAN THOSE OBTAINED BY HOT ROLLING
• CAPACITY: 1.66 MT OF CR SALEABLE
• IT CONSISTS OF TWO SHOPS:-
 CRM I (REDUCES THICKNESS 2-4.5MM THICK INTO 0.63-2MM THICK)
 CRM II (REDUCES THICKNESS 1.4-2MM THICK INTO 0.63-1.6MM THICK)

20. CR
M
IT CONSISTS OF :-
 H2SO4 PICKLING LINE
 4-STAND TANDEM MILL
 ANNEALING FURNACES
 SKIN PASS MILL-I & SKIN PASS MILL-II
 SHEARING LINE I & II
 SLITTING LINE AND SHIPPING LINE

21. PROCESS FLOW OF CRM
H2So4 Pickling
Line T1 T2 T3 T4 T5 ANNEALING
TANDEM MILL STANDS
(THICKNESS IS REDUCED )
SPM I & IIShearing Line I & II
SLITTING LINE
(CUTTING THE
COIL IN PROPER
SIZE)
SHIPPING
LINE

22. APPLICATION OF PRODUCT FROM CRM
Automobile Bodies
Drum & Barrels
Bending & Shaping Applications
Steel Furniture

23. BY PRODUCTS
• PRODUCTS PRODUCED FROM BY PRODUCT PLANT.
• N G BENZOL
• N G TOLUENE
• XYLENE
• L S NAPTHA
• S B OIL
• PCM
• ROAD TAR
• COAL TAR WASH OIL
• EXTRA HARD PITCH
• HARD MEDIUM PITCH
• HOT PRESSED NAPHTHALENE
• ALL BY PRODUCTS OF BY PRODUCT PLANT ARE SOLD THROUGH E- AUCTION.

24. CONCLUSIONS
ENGINEERING STUDENTS GAIN THEORETICAL KNOWLEDGE THROUGH BOOKS. IT IS VOLATILE AND NOT
OF MUCH USE WITHOUT KNOWING ITS PRACTICAL IMPLEMENTATION.
TRAINING IS ONE OF THE IMPORTANT ASPECTS FOR AN ENGINEERING STUDENT'S CARRIER TO
STRENGTHEN THE PRACTICAL CONCEPTS. IT WAS AN AWESOME EXPERIENCE IN TRAINING AS THE
THINGS WE ALL LEARNT IN OUR PREVIOUS YEAR WAS SEEN IMPLEMENTED PRACTICALLY. WE GOT TO
SEE THE LIVE PERFORMING EQUIPMENT LIKE BLAST FURNACE. HOT STRIP MILL( HRM), COLD ROLLING
MILL AND MANY MORE IN SAIL.

25. REFERENCES
www.sail.co.in
www.google.co.images