OBSERVATIONAL TRAINING AT SAIL,BOKARO

BOKARO STEEL PLANT

SUBMITTED BY:- GAURAV VERMAID:-2012UMT1719BATCH:-T-3

OBSERVATIONAL TRAINING AT SAIL,BOKARO

Introduction Steel Authority of India Limited, Bokaro (SAIL,Bokaro) is the fourth integrated plant in the public sector- started taking shape in 1965 in collaboration with the Soviet Union. The plant is hailed as the countrys first Swedish steel plant, built with maximum indigenous content in terms of equipment, material ,etc..,. Its first Blast Furnace started on 2nd October 1972 and 1st phase of 1.7MT ingot steel was completed on 26th Feb. 1978 with the commissioning of the 3rd Blast Furnace.

ProductsBokaro is designed to produce flat product like hot rolled coils, hot rolled plates, hot rolled sheets, cold rolled coils, cold rolled sheets, tin mill black plates (TMBP) and galvanized plain and corrugated (GP/GC) sheets. Bokaro has provided a strong raw material base for a variety of modern engineering industries including automobiles, pipe and tube, LPG cylinder, barrel and drum producing industries.

INDEXRaw Material Handling Plant (RMHP)Coke Oven & By Product Plant (CO & BPP)Sinter Plant (SP)Blast Furnace (BF)Steel Melting ShopHot Strip Mill (HSM)Machine Shop

RMHPs Raw Materials sources

Raw Materials

Iron ore fines

Iron ore lump

Lime Stone

pallets

sinterHard coke

Raw material handling plant( RMHP )Basic functions:Receive different raw materials from various mines through wagons and their unloading & stacking with the help of tipplers & stackers. Blend raw material by making layers in beds & cross section-wise cutting beds by re-claimer.Keep buffer stock to take care of irregularities and supply raw materials to different units as per their requirements.Basic facilities:4 rotary wagon tipplers - 20 wagons/hr each7 twin boom stackers - 1200 t/hr each1 bucket wheel type reclaimer - 500 t/hr5 barrel type reclaimers - 1000 t/hr each2 transfer cars, 10 shuttle conveyors, 11 cranes, 8 telphers.A wagon can rotate from 0-172 during tippling process.Unlocking time provided for one railway rake = 4 hoursRate of unlocking = 59 wagon*65 tones/4hours = 950 tones/hour

WAGON TIPPLER

RMHPs CUSTOMERS

Coke Oven & By Product Plant (CO & BPP)

In Coke Oven Plant ,coal is converted into coke by heating the prepared coal blend charge in the in the coke ovens in the absence of air at temperature of 1000 -1100c for period of 16 19 hours.The volatile matter of coal liberated during carbonization is collected in gas collecting mains. Gas cooled from 800 to 80c is draw to coal chemical plant by exhauster .Residue coke is pushed out of the oven by pusher car through a guide into coke bucket.The Primary by-product from crude coke oven gas are Ammonium sulphate ,crude tar, crude Benzol and cleaned coke oven gas.The size of Blast furnace coke is +25 -80, Nut coke +15 -25, Coke breeze +0 -15.

Production flow diagram

By ProductsPRODUCTS 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

CAPACITY :- 2500 TONESHEIGHT :- 38 METERDIAMETER :- 12 METERTOTAL NO. OF BATTERY:-8NO OF OVEN IN A BATTERY:-69HEIGHT:- 5 METERLENGTH:- 15METERCAPACITY :- 5000 TONES

SILOBATTERYWAGON PUSHER CARCONVEYER BELT

Sinter Plant (SP)

3 Sinter Machines: Capacity 6.25 million toNnes per annumSintering is the process where incipient fusion takes place by combustion of Coke within moving bed of loosely packed fines of mainly Iron ore, Coke & Flux so as to agglomerate into a compact porous mass called Sinter.75-80% Sinter is being used in the burden of BFArea of each SiNter belt is 252 sq.M.Productivity of Sintering Band : 1.2 T/M2/hr.Three SectionsRaw Material SectioNStock Bin & Proportioning SectionSinter Machine Section

A view of Sinter belt

Blast Furnace (BF)

5 blast furnaces in BSL.Each of 2000 cubic meter useful volume and 2640 T/day Hot metal capacityHot metal temperature 1460-14800CBF productivity: 1.4 T/m3/dayCapacity of B F 4.585 MT of hot metal per annumA top pressure of 1.60(maximum=1.80) bar is maintained at upper zone of the blast furnace to utilize co, which is comes out from blast furnace.

MATERIAL FLOW DIAGRAM FOR BLAST FURNACE

Sintering Plant

BF1

BF2

BF3

BF4

BF5

Blast Furnace

300 TCon-1

300 TCon-2

Steel Melting Shop - 2

Steel Melting Shop - 1

130TCon-1

130 TCon-2

130 TCon-3

130 TCon-4

130 TCon-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 CoilCR Sheet

GP CoilGalvanized Corrugated & Plain Sheet

Iron Ore

Fluxes

O H P

Continuous Casting Department

ReheatingFurnace

SAILBokaro

Pig Casting Machine

H R C F

PROCESS FLOWBF CokeCoking CoalCoke Breeze

PL-II

PL-I

ANNEALINGCRCF

COKE OVEN BATTERIES

DCR Mill

Slabbing MillHot Strip Mill

Iron Ore, Lime Stone & Dolomite Fines

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Steel Melting ShopSMS-I: 5 converters each of 100/130t capacity, 2 mixers each of 1300 t capacity (rated capacity 2.5 MT/yr).SMS-II: 2 converters each of 300 t capacity, 2 mixers each of 2500 t capacity (rated capacity 2.25 MT/yr).Total capacity 4.5 MT of liquid steel.Oxygen of high purity(99.9 %) is blown into the converter from the top through water cooled lance so as to remove the impurity of hot metal through oxidation.Impurities of Si, C& P are oxidised and forms slag with lime.Killed, semi-killed and rimming steels are made.SMS-II has got suppressed consumption system.Lining life :Sms-I=800-1000 heatsSms-II=2000-2500 heats

CONTINUOUS CASTING SHOPTwo twin strand curvilinear casters with capacity to produce 2.16 MT of slabsSteel refining unit (SRU) with LF/LRF for treatment of steel before casting On-line slab cutting Steel killed with Al/Si to 2