The document provides an overview of the steel melting shop (SMS) at Jindal Steel and Power Limited (JSPL). It describes the key equipment in the SMS including electric arc furnaces, ladle refining furnaces, vacuum degassing units, and continuous casters. It also summarizes the main processes like primary refining at the electric arc furnace and secondary refining at the ladle refining furnace. Safety rules and precautions for working in the SMS are highlighted at the end.

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PREPARED BY: - A.Aditya Sharma
Aditya Pratap Singh
Anand Prakash Singh
Ankita Agrawal
Anurag Gupta
Bhupendra Kumhare
Deepak Patel

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-: ACKNOWLEDGEMENT: -
I want to express my gratitude towards all the seniors
and associated members of SMS-2 who have given me
guidelines and their valuable times during my training
period.
Moreover, I want to thank all the persons of HRD
department of J.S.P.L. for such a wonderful
cooperation during this period.
Last but not the least, my thanks to all my dear batch
mates and all the people who have directly or indirectly
contributed towards successfully completion of this
report.
-: Contents: -

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1. About JSPL
2. Function of SMS department
3.Equipments & Capacity of:- Electric arc Furnace
Ladle Refining Furnace
Vacuum Degasser & RH degasser
Casters {Billet, Combi, Slab}
4.SMS processes
5.Raw Materials
6. Different sections at SMS: -PQ Bay
Electric Arc Furnace:- Tapping
EAF processes
EAF Advantages
7.Ladle Refining Furnace:- LRF processes
8.Vacuum Degasser
9.RH Degasser
10.Continous Casting:- Billet Caster
Combi Caster
Slab Caster

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ABOUT J.S.P.L: -
Corporate profile
Jindal Steel and Power Limited is the most valuable private steel
producer in India, with an annual turnover of over US $2.1 billion (Rs.
10,000 crore), Jindal Steel & Power Limited (JSPL) forms a part of the
US $12 billion (over Rs. 60,000 crore) Jindal Group. JSPL is a leading
player in Steel, Power, Mining, Oil & Gas and Infrastructure. Mr.
Naveen Jindal, the youngest son of the legendary late Shri. O P Jindal
drives JSPL and its group companies Jindal Power Ltd, Jindal
Petroleum Ltd., Jindal Cement Ltd. and Jindal Steel Bolivia with a
belief in the concept of self-sufficiency
Technical Profile
• 2 MTPA cement plant.
• Additional power generation of 540 MW.
• Medium structural mill.
• Pipe conveyor from mines to plant.
• Mini blast furnace up-gradation
• Fabrication unit in the industrial estate.
•
AWARDS: -
• JSPL India ‘s fastest growing large size company by dalal
street, 2006
• Gold prize –greenstick environmental excellence award 2006
• Golden peacock environmental award 2006
• IIM quality award 2002-2003, by the Indian institute of metals

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National safety award2003-2004, by ministry of labour and many more
awards
Function Of Department...
Steel Melting Shop: Pig iron, sponge iron, limes and ferroalloy is
charged from the top of Electric Arc Furnace. Arcing melt the
contents. Oxygen blowing is done. Steel is tapped and chemistry
correction is done in ladle refining furnace. Liquid steel is casted.
Slag is taken out from slag door.
The basic function of the Steel Melting Shop is the refining of
steel before casting. Basically the refining of steel in SMS can be
divided into two segments:
1. Primary Refining- It is done at Electric Arc Furnace, where the hot
metal is De-Phosphorised, De-carburized, and melted along with
charge (i.e. DRI, Lime and Dololime) and CPC (calcined petroleum
coke)
2. Secondary Refining- It is done at Ladle Refining Furnace, where the
molten steel from EAF is De-sulphurised, & De-oxidized, in an
oxidizing atmosphere
Electric Arc Furnace
EQUIPMENT CAPACITY
ELECTRIC ARC FURNACE ALTERNATING CURRENT By
DANIELI
TAPPING WEIGHT 100MT
TRANSFORMER
CAPACITY
100MVA
ACTIVE POWER INPUT 23MW

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SECONDARY VOLTAGE 500 V
SECONDARY CURRENT 33KA
SHELL DIAMETER 5.6 METER
ELECTRODE DIAMETER 24 INCH
LADLE REFINING FURNACE
EQUIPMENT CAPACITY
LADLE FURNACE 100T
TRANSFORMER CAPACITY 18MVA
ELECTRODE DIAMETER 16INCH
TREATMENT TIME 30-35 MIN
VACUUM DEGASSING
EQUIPMENT CAPACITY
VACUUM DEGASSING UNIT 100T
MAKE GA DANIELLI
CASTER
EQUIPMENT CAPACITY
BEAM BLANK/BLOOM/ROUND 4 STRAND 12 METER RADIUS
SLAB CASTER 12 METER
BILLET 12 METER 6 STRAND

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SMS Processes

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RAW MATERIALS
HOT METAL
DRI
SKULL
SCRAP
LIME
DOLOMATIC LIME
HOT METAL (COMPOSITION &ELEMENT USE)
C- 3.5-4%
SI- 0.7-0.8%
MN- VERY LESS
S- 0.02-0.05%
P- 0.08-0.1%
FE- 98.50-99.75%
DRI (50-55 TONN)
FE- 81%
OXIDE- 9-10%
C- 0.2%
SI- 3.2-3.5%
SCRAP(1.54-2.0%)
LIME(CAO)
CAO- 83-84%
MGO- 1.65%
SI – 1.5%
DOLOMATIC LIME
CAO- 63-66%
MGO- 16-18%
SI- 3.5-4.0%

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DIFFERENT SECTIONS AT SMS
PQ Bay (Torpedo)

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The torpedo ladle transfers the pig iron from the blast
furnace to the steel plant. It is used for transportation over
greater distances.
Steel Ladle
The steel ladle is very demanding on refractory products:
As the liquid steel is dropped from an enormous height, it requires the
greatest possible mechanical resistance. Metallurgical processes at
temperatures of over 1,600°C require maximum refractoriness.

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EAF (ELECTRIC ARC FURNACE)

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EAF AT J.S.P.L.

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Tapping Process
An electric arc furnace (EAF) is a furnace that heats
charged material by means of an electric arc.
Arc furnaces range in size from small units of approximately
one ton capacity (used in foundries for producing cast
iron products) up to about 400 ton units used for
secondary steelmaking. Electric arc furnace temperatures can
be up to 1,800 degrees Celsius.

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EAF Processes
Dephosphorization
Decarburization
Melting
Advantages of electric arc furnace
The use of EAFs allows steel to be made from a 100% scrap
metal feedstock, commonly known as 'cold ferrous feed' to
emphasize the fact that for an EAF, scrap is a regulated feed
material. The primary benefit of this is the large reduction in
specific energy (energy per unit weight) required to produce
the steel. Another benefit is flexibility: while blast furnaces
cannot vary their production by much and are never stopped,
EAFs can be rapidly started and stopped, allowing the steel
mill to vary production according to demand. Although
steelmaking arc furnaces generally use scraps steel as their
primary feedstock, if hot metal from a blast furnace or
direct-reduced iron is available economically, these can also be
used as furnace feed.
A typical steelmaking arc furnace is the source of steel for a
mini-mill, which may make bars or strip product. Mini-mills can
be sited relatively near to the markets for steel products, and
the transport requirements are less than for an integrated

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mill, which would commonly be sited near a harbor for access.
to shipping
EAF Productivity
The EAF - productivity depends on:
Ö Metallic Input: - Hot Metal (60-65 tonn)
DRI (50-55 tonn)
Scrap (adequate(up to 5 tonn))
Ö Equipment (Transformer capacity 100MVA/T)
Ö Oxygen blowing
Ö CPC & Lime Addition
All these contributes to
Tap To Tap Time (Minimum- 40-50min(approximate))
Working Temperature (1550-1600˚C)

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L.R.F. (Ladle Refining Furnace)
Function of LRF
The Ladle furnace is used to heat the steel and achieved the
final composition of steel by adding Ferro alloy,
Argon bubbling is applied to homogenize the steel composition
and temperature.
Heating of up to 3˚C per minute is achieved by a set of
graphite electrode, which are lowered into the slag layer,

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Just above the molten steel surface
Another purpose of the ladle furnace is to act as a holding
furnace between the EAF and continuous casting machine.
LRF Processes
Deoxidization
Desulphurization (through lime addition)
Chemical Adjustments (through addition of Fe alloys)
Refining
Temperature Control
Homogenization of Compositions (through Argon Purging)
V.D. (Vacuum Degassing)
Function of V.D.
Vacuum treatment of the steel is the most important
secondary metallurgical process. The tank degasser is used to
remove gaseous element, non-metallic inclusion and Sulphur
from the steel. The removal of Non-metallic inclusion is
achieved through slag metal interactions, which are promoted
by strong argon flushing within the vacuum tank.

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Internal Structure of V.D.

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RH-Degasser
Sectional View of R.H. Degasser

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Function Of RH-Degasser
The main functions of the RH degasser are for hydrogen
removal, forced decarburization and the chemical heating of
the steel.
The widespread use of the RH-degasser makes extraordinary
demands on the refractory material.
Continuous Casting

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Continuous casting (also called strand casting) is the process
whereby molten metal is solidified into a "semi finished" billet,
bloom, or slab for subsequent rolling in the finishing mills.
This process is used most frequently to cast steel (in terms
of tonnage cast).
Equipments
1. Ladle 2. Stopper 3. Tundish
4. Shroud 5. Mold 6. Roll support

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7. Turning zone 8. Shroud 9. Bath level
10. Meniscus 11. Withdrawal unit 12. Cutting zone
A. Liquid metal
B. Solidified metal
C. Water-cooled copper plates
D. Refractory material
Types of Casting
• Billet Casting

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• Billet casters cast smaller section sizes, such as below
200 mm square, with lengths up to 12 m long. Cast speeds
can reach up to 4 m/minute.
• Combi casting

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• The machine will be modified in such a way that it will be
capable of simultaneously casting up to four bloom
strands. External mold stirring will be provided to ensure
a homogeneous internal strand quality of the high-carbon
rail-steel and tube-steel grades to be produced.
Installation and modification work will be carried out to
the greatest extent possible during regular casting
operations; however, a caster-shutdown period of about
60 days will be necessary.
• The caster design is characterized by curved molds,
radius of caster 12 m and a metallurgical length of 17.1 m.
• Slab Casting

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Slab casters tend to cast sections with an aspect ratio that is
much wider than it is thick:
• Conventional slabs lie in the range 1500-2600 mm wide by
180–250 mm thick and up to 12 m long with conventional
casting speeds of up to 1.4 m/minute, (however slab widths
and casting speeds are currently increasing).
• Thin slabs: 1520×215 mm
Slab Segments

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Safety rules & precautions

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• Wearing Helmet(ISI certified) properly is a must.
• Wearing Thick jeans Jacket for protecting body parts
• Roaming here and there inside the industry without
having proper guidance could be dangerous.
• Following the safety precautions written in every section
would be beneficial.
• Observing the surrounding changes by listening &
watching carefully could save us from any accident