This document provides an overview of the industrial training presentation given by Khagendra Kumar Dewangan at Bhilai Steel Plant. The training focused on two main plants: 1) Refractory Materials Plant-II which produces lime and dolomite bricks, and 2) Foundry & Pattern Shop which produces castings. The presentation covered the processes, departments, and safety procedures at each plant.

1. Industrial Training Presentation
ON
MECHANICAL DEPARTMENT,
BHILAI STEEL PLANT
Student Name: KHAGENDRA KUMAR DEWANGAN
Roll No: 13119040
Department: Mechanical Engineering (NITRR)
Training Company: BSP
Training Course: 4th Sem. 2014/2015

2. Presentation Info
Summary:
I had my industrial training in “BHILAI STEEL PLANT”.
My work was focusing on observation and inspection of two
plants-
1.REFRACTORY MATERIALS PLANT-II
2. FOUNDRY & PATTERN SHOP

3. In first week
Application, documentation and gate pass procedures
were going to be processed and general overview and
safety techniques about the plant were studied

4. BSP-AN OVERVIEW
Bhilai Steel Plant –
A symbol of Indo-Soviet Techno-economic collaboration, is one of
the first three integrated steel plants set up by Government of India to build up
a sound base for the industrial growth of the country. The agreement for
setting up the plant with a capacity of 1 MT of Ingot steel was signed between
the Government of erstwhile U.S.S.R. and India on 2nd February, 1955 and
only after a short period of 4 years, India entered the main stream of the steel
producers with the commissioning of its first Blast Furnace on 4th February,
1959 by the then President of India, Dr. Rajendra Prasad. Commissioning of
all the units of 1 MT stage was completed in 1961. A dream came true-the
massive rocks from the virgin terrains of Rajhara were converted into
valuable iron & steel.

5. In the initial phase the plant had to face many teething problems, mostly unknown to the workforce at the
time, but by meticulous efforts and teamsprit, these problems were surmounted and the rated capacity
production was achieved only within a year of integrated operation of the plant. Thereafter, the plant was
expanded to 2.5 MT capacity per year, and then to 4 MT of crude steel per year, with Soviet assistance. All
the units of the plant have been laid out in sequential formation according to technological inter-
relationship so as to ensure uninterrupted flow of in-process materials like Coke, Sinter, Molten Iron, Hot
Ingots, as well as disposal of metallurgical wastages and slag etc., minimizing the length of various inter-
plant communications, utilities and services.

6. Safety (Do’s and Don’ts) in
the Industry
 Do’s-
 Punctuality (timeliness),
 Maintaining healthy and cordial relationship with the people in
organization.
 Understanding the work culture.
 Obeying direct orders from the seniors.
 Showing a sense of belonging with the organization.
 Maintaining proper Line and Staff Relationship with the seniors and
subordinates (If Any).
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7. Do’s and Don’ts in the
Industry
 Don’ts
 Do not take the training lightly and casually.
 Do not give an impression that you are doing the training just for
the sake of it. Put your heart and soul.
 Do not involve in internal politics.
 Do not reveal you weaknesses.
 Do not lie to your seniors.
 Do not waste your time.
 Do not copy any material. Be original.
 Do not go for leave unless it is indispensable.
 Do not ask for favours.
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8. In second week
 We came to visit various departments of the plant.
 The main two plants were allotted us.
The first plant was-
REFRACTORY MATERIALS PLANT-II

9. REFRACTORY MATERIALS PLANT-II
Refractory Materials Plant (RMP-II) was set up during 4 MT expansion of BSP to prepare and
supply the required quantity of Lime, Sintered Dolomite and Tar Bonded Dolomite Bricks to SMS-
II.
It has three main units :
1. Lime Shop
2. Rotary Kiln
3. Brick Shop
1.0 Lime Shop :
1.1 The Kilns :
There are two nos. of identical vertical shaft kilns commissioned in year 1984,with capacity
330 T/DAY for each kiln. One kiln is to make Lime and other Calcined Dolomite for Converters.

10. 1.2 The process :
Low Silica lime stone of feed size (30-50 mm) or Dolomite having feed size 30-60mm are
weighed and charged to skip charging bunker. The limestone is charged at common service hopper
at kiln top, and from this material is fed into kiln shaft. The charged limestone burns in parallel
flow, while the combustion air get heated when passing through column of limestone above the
burners. The waste gases are conducted to the other shaft, which pass their sensible heat to the
limestone in the preheating zone. The burning in parallel flow allows a very high heat exchange.
The hot flame comes in contact with the crude limestone avoiding over burning. Final calcination
of charge is carried out by waste gases. Lime is soft-burnt. High combustion air temperature and a
very favourable fuel consumption are achieved through regenerative preheating where waste heat is
almost completely utilized. The two shafts are filled with the charge and connected to each other by
a channel. Only one of the shafts is heated by fuel and other is heated by the waste gases coming
out through the channel from fuel-heated shaft. Lime is simultaneously burnt in both the shafts.
At fixed intervals reversal takes place. During reversal, the two shafts are alternately charged and
burnt lime is continuously discharged from both shafts. Since the temperature is high, cool air is
blown from below in both the shafts for cooling the product, which is then discharged.

12. 2.0 Rotary Kiln :
2.1 Brief description :
There is one Rotary kiln for production of calcined lime for SP-3 Rotary kiln was
commissioned in the year 1985. The capacity of kiln is 200 T/day of calcined lime and other
details of kiln are as below :
A. Length of Rotary kiln = 82.5 M
B. Dia. of Rotary kiln = 3 M
C. Length of Rotary cooler = 22.5 M
D. Dia. of Rotary cooler = 3 M
E. Charging system = by scooping device
2.2 Principle of working :
Weighed raw material is fed with the help of scooping device and fuel is fired from
discharge end. Material travels during slow rotation of kiln and heat is transferred to material
due to radiation from refractory, final product is discharged into Rotary cooler and after
cooling, product is continuously discharged on conveyor belt.

13. 3 Brick Shop:
3.1 INTRODUCTION :
Brick Shop was commissioned in the year 1985. The main function was to
produce Tar Bonded Dolomite Bricks for converter vessel of Steel Melting Shop No.2.
The production of tar bonded dolomite bricks for converter was stopped in the year 1987
because of poor life and production of Magnesia-Carbon Bricks started in the year 1996.
Some refractory masses were developed in the year 1990.
At present shop is producing following refractory items which
affect cost savings.
S.No. Item/Product Used at
1. Magnesite Mass SMS-II
2. Runner Mass B.F.
3. Twin Hearth sleeve SMS-I
4. Well filler Mass SMS I
5. Magnesia Carbon Bricks SMS-II

14. In second week
The second plant
we visited was-
FOUNDRY & PATTERN SHOP

15. FOUNDRY & PATTERN SHOP
Foundry & Pattern shop is an important Engineering Shop, set up to
meet the requirement of various ferrous and non-ferrous castings and cast
blanks required for the plant and other Engineering Shops especially machine
shops, for manufacture of spares. It comprises two major parts, the Pattern
Shop and the Foundry Shop.
THE PATTERN SHOP:
The pattern shop is designed to produce patterns for foundry needs.
The annual output is rated at 220 Cu. meters. The shop works in G shift. It is
equipped with modern set of working machine tools. Handling of heavy
patterns at the shop and storage is carried out by overhead travelling crane
operated from floor level. The patterns are painted according to a code,
ticked, labelled and stored, to enable the patterns to be issued to foundry as
and when required, according to a well-laid out procedure. The pattern

16. FOUNDRY SHOP:
The foundry shop is laid out in five bays, each of length 270 meters.
Various types of castings and their usage is as follows :
Iron Castings : ( Capacity 79000 T/year)
i) Spare parts for machines / equipments.
ii) Ingot moulds.
iii) Bottom Stools.
Steel Castings : ( Capacity 6500 T/ year)
i) Spare parts for machines/equipments.
ii) Twin hearth-charging boxes.
iii) Skull cracker balls.
iv) Spares for Mould bogie.
v) Ladle covers for SMS, Lip ring for CCS.
vi) Pig casting moulds.
vii) Alloy steel Ingots.

17. Non - Ferrous Castings : ( Capacity 515 T/ Year)
i) Bushings, slide blocks for machines/ equipments.
ii) Monkey for BF & Hollow shaft for SMS.
iii) L.N. body & covers.
iv) Al. Cubes & Al. Shots for SMS-I & SMS-II.

18. Main Sections of Foundry Shop :
1)Charging and Moulding Material Store :
The charging and moulding material storage is designed to hold 15 days supply of all
raw material used in foundry. The storage bay is served by overhead travelling cranes with
removable magnets. With the help of electric grabs, all the raw materials are stored in bins &
bunkers.
2) Sand Preparation Section :
In this section, preparation of moulding sands and core sand mixture for all types of
castings is done. The raw silica sand is received from Sambalpur and Allahabad. Quartzite sand
is supplied by Crushing Plant. The new sand, if wet, is dried in a rotary dryer in which sand is
heated to 200-250 deg.C. The dried sand is fed in the feeding hoppers, over the sand mixers of
20 cu.m/hr capacity.
In the sand mixer ; various moulding materials like fire clay, bentonite, molasses, saw dust
etc. are added and mixed. The sand so prepared is distributed by the system of conveyor belts
throughout the cast-iron, steel and core section. 130 T of mixed sand is produced by sand
mixers for preparing different types of sand mixtures for core section (about 5 T per day).

19. 3) Iron Foundry :
The Iron foundry can be divided in to the following sub-sections.
i) Cast Iron section.
ii) Mixer section
iii) Moulding section
iv) Ingot Moulds
v) Mould drying chambers.
The estimated annual requirement of the metal is about 1,00,000 tons and the
daily requirements is 270 tons. The moulding section prepares moulds for all types of
castings required under the schedule or special work requiring upto 30 tons liquid metal.
The Ingot Mould section produces the Ingot Moulds required by the plant. Each Ingot
Mould weights 8.8. T or 9.3 T and the daily production of Ingot Moulds are 17 nos. on
average. Ingot Moulds are rammed on two 30 tones jolting machines in the Ingot Mould
section. Top box is prepared for using at top of Ingot Mould for pouring. The mould drying
chambers are used for drying the moulds in the chamber type drying ovens at the
temperature of 300-350 degree cel. There are 6 drying ovens. The 4 drying ovens are of
130 Cu.m. capacity and the other 2 of 60 cu.m. capacity for drying small castings. These
ovens have been provided with an arrangement for the re-circulation of the products of
combustion. Coke oven gas is used for heating purpose.

20. Blast Furnace Diagram:

21. Industrial Training Objectives fulfilled.
Problems faced during training.
Project Fulfillment:
Importance of Project for plant visit.
Door still open for improvement.
Alternative designs.
Benefits from Training outside.
Acknowledgements.
Conclusion

22. Thank you for listening,
Any Questions..?