Whole Process of Steel Production at SAIL

1. A Presentation on
Topic:- Steel Production
at
BY:- SAURABH SHANKAR
M.L.V.TEXTILE AND ENGINEERING COLLEGE, BHILWARA

2. CONTENTS
1. Introduction
2. Steel Making Flow Chart
3. Raw Material and Material Handling Plant
4. Sintering Plant
5. Coke Oven and By-Product Plant
6. Blast Furnaces
7. Steel Melting Shop
8. Slabbing Mill
9. Hot Strip Mill
10. Cold Rolling Plant
11. Finished Products and Projects

3. Bokaro Steel Plant (SAIL) is 26th largest
steel producer in world and 2nd largest in
India.
 It was originally incorporated as a limited
company on 29th Jan1964, and was later
merged with SAIL.
Annual Production Capacity-13.5 million
tones.
Turnover 2013-14 – Rs. 49350 Crores.
5 Integrated Steel Plants and 3 special
Steel Plants.
PRODUCTION IN Q4
FY 2016-17
SALES in
million
tone
Hot Metal Production 15.7 MT
Crude Steel
Production
14.3 MT
Saleable Steel
Production
12.4 MT
Semis Component In
Production
3.2 MT
Value added
production
5.1 MT
Production through
concast Route
10.8 MT
Saleable Steel Sales 12.1 MT

4. RAW MAERIALAND
MATERIAL HANDLING
PLANT
SINTERING PLANT
COKE OVEN AND BY
PRODUCTS PLANT
BLAST FURNACES
STEEL MELTING SHOP
SLABBING MILL HOT STRIP MILL
COLD STRIP MILL
2. STEEL MAKING PROCESS OVERVIEW

5. 2.1. Flow Chart in Detail

6.  Receives, blends, stores and
supplies plant requirements.
 Some 9 MT of different raw
materials viz. Iron ore fines
and lumps, Limestone,
Dolomite lumps and chips,
hard Coal and Manganese
ore.
3.Raw Materials & Material Handling Plant

7. Iron Ore(Lump + Fines),
Limestone, Dolomite from mines
Wagon tippler/ Track Hopper
Designated Belts
Bedding and Blending
Dispatch to Customer
Screening
Unit
Base Mix
Preparation
Unit
Sampling
Unit
3.1.Flow Chart Material Handling Plant

8.  2– Sinter machine, capacity 6.25
million ton per annum.
 Production of sinter per day
1800T
 Capacity 300 to 450 T/hrs.
4.Sintering Plant

9. 4.1.Flow chart

10. 5.Coke Ovens & By-product Plant
Products Produced
 N G Benzoyl
 N G Toluene
 Xylene
 Naphthalene
 S B Oil
 Road Tar
 Coal Tar Wash Oil

11. 5.1. Flow Chart

12.  Five 2000-cubic meters Blast
Furnaces.
 Hot Metal Temperature 1460-
1480˚C
 Productivity is 1.4T/M3 /Day
 Wastes products like Blast
Furnace slag recycle/re-use.
6. Blast Furnace

13. 6.1. Flow Chart

14.  Two Steel Melting Shops - SMS-I and SMS-II.
 SMS-I has 5 LD converters of 130T capacity each.
 SMS-I produce Rimming steel through the ingot route
 SMS-II has 2 LD converters, each of 300 T capacity.
 SMS-II has suppressed combustion system and Continuous Casting facility.
 Produces various Killed and Semi-Killed steels.
7.Steel Melting Shop

15. 7.1.SMS II Flow Chart

16.  Rolling capacity of Mill 4 MT per
annum.
 Hot and Cold Scarfing Machines and
2800 T Shearing Machines.
 Slab Dimensions :
Thickness – 170 to 230 mm.
Width – 910 to 1850 mm
Length – 7.7 to 10.5.
Rolling temperature – 1300˚C
Soaker crane – 4 number of capacity
50/40 tones.
Soaking pits – 12 groups and each group
has 4pits.
8.Slabbing Mill

17.  Annual capacity of 3.363
million tones.
 Thickness varying from 1.2 mm
to 20 mm.
 Width from 750 mm to 1850
mm
 Rolling Speed is 20 m/s max. .
9.Hot Strip Mill

18.  High quality sheet gauge material, Tin Mill
Black Plate & Galvanized Products
 Capacity is 1.66 MT of Saleable CR
 CRM-I reduces thickness 2-4mm to 0.63-2 mm
 CRM-I reduces thickness 1.4-2mm to 0.63-1
mm.
10.Cold Rolling Mill

19. 11.Finished Products

20. 12. Present and Next Phase Projects
Last Modernization
 Con- cast facilities integrated with SMS-II
 Upgradation of Hot Strip Mill
 Next Phase Modernization
 New SMS-III with 3.8 MT Capacity
 New CRM-III with 1.2 MT Capacity
 Rebuilding of 3 CO Batteries
 Computerized Systems
 Sintering Area 252 m2 to 312m2