1

UNIT OPERATIONS OF BOKARO STEEL PLANT

AND THEIR ENVIRONMENTAL ASPECTS
A TRAINING REPORT SUBMITTED IN THE PARTIAL
FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF
BACHELOR OF TECHNOLOGY
IN

















2










CONTENT

1. COMPANY PROFILE Pgs.7-8
2. UNIT OPERATIONS & FACILITIES AT BSL Pgs. 8-11
3. RAW MATERIALS AND MATERIAL HANDLING PLANT (RM-MHP) Pgs. 12-14
4. COKE OVENS Pgs. 15-18
5. BY-PRODUCT PLANT Pgs. 19-20
6. BOD PLANT Pgs. 21-23
7. SINTER PLANT Pgs. 24-26
8. BLAST FURNACE Pgs. 27-29
9. STEEL MELTING SHOPS Pgs. 30-33
10. ENVIRONMENTAL POLLUTION & MONITORING Pgs. 34-37
11. WATER POLLUTION MONITORING Pgs. 38-48
12. STANDARD CERTIFICATIONS Pgs. 49-50
13. A BRIEF LOOK OVER INDUSTRYS ENERGY REQUIREMENTS Pgs. 51-52
14. INDUSTRIES DEPENDENT ON STEEL INDUSTRY Pgs. 53
15. REFERENCES Pgs. 54







3
















LIST OF FIGURES
1. A view of Plant Main Gate Fig.1
2. Process flow diagram summarizing all operations of steel plant Fig.2
3. Movement of Raw Materials from different Mines around Bokaro Fig.3
4. A schematic layout of RM&MHP Fig.4
5. A detailed diagram of Wagon Tippler with dimensions Fig.5
6. Coke oven Plant of Bokaro Fig.6-7
7. Material Flow chart of Coke oven Department Fig.8
8. B.F. Coke, Nut coke and Breeze coke Fig.9
9. Flow diagram for By-Product Plant Fig.10-11
10. Material flow diagram & Methods used in BOD Plant Fig.12-13
11. Flow diagram for Sinter Plant & Mechanism involved in ESP Fig.14-16
12. Design & Flow diagram for Blast Furnace and Slag Granulation Plant Fig.17-19
13. A picture of SMS-II shop and steel making process Fig.20-22
14. ECDs Functions and Objectives Fig.23
15. Equipments used in solids removal from gases Fig.24-25
16. Tables showing Data related to Solid waste management Fig 26
17. Plant water use diagrams for BPP,SP,BF,BOF,EAF &CCS Fig 27-30
18. Oxidation Pond Fig 31
19. SAIL Organization Level Objectives & Target 2011-12 Fig 32-33

4








THE BOKARO STEEL PLANT

History
The Bokaro Steel Plant is the fourth integrated plant in the Public Sector which started taking shape in
1965 in collaboration with the Soviet Union with the construction starting from 1968. Originally
incorporated as a limited company on 29th January 1964, it was later merged with SAIL, first as a
subsidiary and then as a unit, in the year 1978. The Plant is hailed as the countrys first Swadeshi steel
plant, built with maximum indigenous content in terms of equipment, material and know-how. Its first
Blast Furnace started on 2nd October 1972 and the first phase of 1.7 MT ingot steel was completed on
26th February 1978. All units of 4 MT stage have already been commissioned and the 90s'
modernisation has further upgraded this to 4.5 MT of liquid steel.
Bokaro has provided a strong raw material base for a variety of modern engineering industries including
automobile, pipe and tube, LPG cylinder, barreland drum producing industries. To keep pace with the
latest trends in steelmaking, the first phase of modernisation was sanctioned on 23rd July 1993.As the
benefits of the modernisation have been reaped, Bokaro Steel is continuously upgrading its various
production facilities to bring improvements in productivity and quality.
Modernisation
SMS-II was revamped initially during 1997 by supplementing it with two twin-strand slab casters along
with a Steel Refining Unit. The modernisation of the Hot Strip Mill saw addition of new features like high
pressure de-scalers, work roll bending, hydraulic automatic gauge control, quick work roll change,
laminar cooling etc. New walking beam reheating furnaces are replacing the less efficient pusher type
furnaces.
A new hydraulic coiler has been added and two of the existing ones revamped. With the completion of
Hot Strip Mill modernisation, Bokaro is producing top quality hot rolled products that are well accepted in
the global market. The modernisation plans are aimed at increasing the liquid steel production capacity,
coupled with fresh rolling and coating facilities. The new facilities will be capable of producing the most
premium grades required by the most discerning customer segments.

Products
5

The plant is designed to produce flat products like Hot Rolled Coils, Hot Rolled Plates, Hot Rolled
Sheets, Cold Rolled Coils, Cold Rolled Sheets, Tin Mill Black Plates (TMBP) and Galvanised Plain and
Corrugated (GP/GC) Sheets. Bokaro has provided a strong raw material base for a variety of modern
engineering industries including automobile, pipe and tube, LPG cylinder, barrel and drum producing
industries.
The Township
Bokaro Steel City is located in idyllic surroundings on the southern bank of river Damodar with Garga,
one of its tributaries, meandering along the southern and eastern outskirts of the city. On the north, the
city is flanked by the high ranges of the Parasnath Hills and on the south; just beyond the river Garga, it
is enveloped by the Satanpur Hillocks. The vast rolling topography of the city is interspersed by graded
valleys and winding rivulets typical of the Chhotanagpur Plateau. Within two decades of Bokaro Steel
coming into existence, the city has blossomed into a regional urban centre of over 8 lakhs people from
different parts of the country, making the city a Mini Bharat. Bokarois located on the Gomoh
Chandrapura-Muri railway line. Direct train services to all the four metros are available from Bokaro. It is
located centrally between the triangle of the other three major cities of Jharkhand - Ranchi, Jamshedpur
and Dhanbad - all of which are well connected by road and railway.
Housing
Permanent houses/hostels : 37,472
Total houses leased out : 4,773

The general plan of Bokaro Steel City covering approximately 10,114 acres provides for about 37,000
residential units. The city has a number of company run and public schools dispersed in various sectors
on the concept of primary and secondary school districts.
Medical facilities
The township has a modern 910-bed Bokaro General Hospital with specialised units like Critical Care
Unit, Intensive Coronary Care Unit, Haemodialysis Unit, Nuclear Medicine Laboratory, Intensive Burns
Unit, Special Care Baby Unit,

Beds in Bokaro General Hospital - 910

Sector Health Centres - 10

Primary Health Centres in Peripheral areas - 0 4

Occupational Health Services Centre - 0 1
To take care of the employees working in the plant, an Occupational Health Services Centre with
modern facilities has been provided within the plant premises.





6







UNIT OPERATIONS AND FACILITIES AT BSL
Raw Materials & Material Handling Plant
The Raw Materials and Material Handling Plant receives, blends, stores and supplies different raw
materials to Blast Furnace, Sinter Plant and Refractory Materials Plant as per their requirements. It also
maintains a buffer stock to take care of any supply interruptions. Every year approximately 9MT of raw
materials i.e. Iron ore fines and lumps, Limestone (BF and SMS grade), Dolomite lumps and chips, hard
Coal and Manganese ore are handled.
Coke Ovens & By-product Plant

The Coke Oven Complex converts prime coking coal from Jharia, Dugda and Moonidih and medium
coking coal form Kargali, Kathara and Mahuda, blended with imported coal, into high quality coke for the
Blast Furnaces, recovering valuable by-products like Anthracene Oil, Benzene, Toluene, Xylene, Light
Solvent Naphtha, Ammonium Sulphate and Extra-hard Pitch in the process. The Coke Oven battery has
8 batteries with 69 ovens each, maintained meticulously in terms of fugitive emission control, use of
phenolic water and other pollution control measures.

Blast Furnaces

Bokaro has five 2000-cubic metre Blast Furnaces that produce molten iron - Hot Metal - for steel making.
Bell-less Top Charging, modernised double Cast Houses, Coal Dust Injection and Cast House Slag
Granulation technologies have been deployed in the furnaces. The process of iron-making is automated,
using PLC Charging System and Computer Controlled Supervision System. The wastes products like
Blast Furnace slag and gas are either used directly within plant or processed for recycling / re-use.

Steel Melting Shops

Hot Metal from the Blast Furnaces is converted into steel by blowing 99.5% pure Oxygen through it in
the LD converter. Suitable alloying elements are added to produce different grades of steel. Bokaro has
two Steel Melting Shops - SMS-I and SMS-II. SMS-I has 5 LD converters of 130T capacity each. It is
capable of producing Rimming steel through the ingot route. SMS-II has 2 LD converters, each of 300 T
capacity, with suppressed combustion system and Continuous Casting facility. It produces various Killed
and Semi-Killed steels.

Continuous Casting Shop

7

The Continuous Casting Shop has two double-strand slab casting machines, producing high quality
slabs of width ranging from 950 mm to 1850 mm. CCS has a Ladle Furnace and a Ladle Rinsing Station
for secondary refining of the steel. The Ladle Furnace is used for homogenising the chemistry and
temperature. The concast machines have straight moulds, unique in the country, to produce internally
clean slabs. CCS produces steel of Drawing, Deep Drawing, Extra Deep Drawing, Boiler and Tin Plate
quality. It also produces low alloy steels like LPG, WTCR, SAILCOR and API Grade.

Slabbing Mill

Slabbing Mill transforms ingots into slabs by rolling them in its 1250 mm Universal Four-High Mill. The
rolling capacity of the Mill is 4 MT per annum. The shop has Hot and Cold Scarfing Machines and 2800 T
Shearing Machine. Controlled heating in Soaking Pits, close dimensional accuracy during rolling and hot
and cold scarfing help produce defect-free slabs.

Hot Strip Mill

Slabs from CCS and Slabbing Mill are processed in the Hot Strip Mill. The fully automatic Hot Strip Mill
with an annual capacity of 3.363 million tonnes has a wide range of products - thickness varying from 1.2
mm to 20 mm and width from 750 mm to 1850 mm. The mill is equipped with state-of-the-art automation
and controls, using advanced systems for process optimisation with on-line real time computer control,
PLCs and technological control systems.

Walking Beam Reheating Furnaces provide uniform heating with reduction in heat losses, ensuring
consistency in thickness throughout the length. High-pressure De-scaling System helps eliminate rolled-
in scale. The finishing group consists of a Flying Shear, Finishing Scale Breaker and seven 4-high
Finishing Stands. Hydraulic Automatic Gauge Control system in the finishing stands ensures close
thickness tolerance. The Work Roll Bending System ensures improved strip crown and flatness. The
Hydraulic Coilers maintain perfect coil shape with On-line Strapping system.
Hot Rolled Coil Finishing

All the Hot Rolled coils from the Hot Strip Mill are received in HRCF for further distribution or despatch.
HR Coils rolled against direct shipment orders are sheared and finished to customer-required sizes and
despatched to customers. The material is supplied as per Indian specifications and many international/
foreign specifications. The shop has two shearing lines with capacities of 6,45,000 Tonnes/ year and
4,75,000 Tonnes/ year respectively.

Cold Rolling Mill

The Cold Rolling Mill at Bokaro uses state-of-the-art technology to produce high quality sheet gauge
material, Tin Mill Black Plate and Galvanised Products. Cold rolling is done to produce thinner gauge
strips of very smooth and dense finish, with better mechanical properties than hot rolling strips. Rolling is
done well below re-crystallization temperature without any prior heating of the material. The products of
CRM are used for deep drawing purposes, automobile bodies, steel furnitures, drums and barrels,
railway coaches, other bending and shaping jobs and coated steels.

Hot Dip Galvanising Complex

The Hot Dip Galvanizing Complex integrated with the CRM produces zinc-coated Cold Rolled strips
resistant to atmospheric, liquid and soil corrosion. The Continuous Coil Corrugation Line in the HDGC
produces corrugated sheets and the Galvanised Sheet Shearing Line produces galvanised plain sheets
for a variety of applications.
Services - a valuable support network

8

The service departments like Traffic, Oxygen Plant, Water Management and Energy Management
provide invaluable support to this gigantic plant. Bokaro Steel has a vast networked of railway tracks and
over 40 diesel locos to smoothly run its operations. The Oxygen Plant provides Oxygen, Nitrogen and
Argon for processes like steelmaking and annealing. Water Management looks after the huge water
requirements of the plant and the township, providing different grades of water and taking care of
recycling needs. Energy Management juggles the supply and demand of by-product gases and their
demand as process fuel.





BOKARO STEEL PLANT (MAJ OR DEPARTMENTS)
Unit Number Capacity
(MT)
Product
Coke Ovens 8 Batteries of 69 Ovens 3.48 BF Coke
Sinter Plant 3 Machines of 252 m
2
area 6.20 Skip sinter
Blast Furnaces 5 furnaces of 2000 m
3
volume 4.585 Hot Metal
Steel Melting
Shop I
5 LD converters of 130 T 2.20 Ingot Steel
Steel Melting
Shop II
2 LD Converters of 300 T 2.25 Liquid Steel
Continuous
Casting
2 Double Strand casting m/c 2.16 Cast Slab
SMS+CCS ----------------------- 4.36 Crude Steel
Slabbing Mill 8X4 Soaking pits of 160 T & one
1250 mm universal Slabbing Mill
1.90 Rolled slab
Hot Strip Mill 4 reheating Furnaces, 5
roughing & 7 finishing stands
3.955 HR Coil
Hot Rolled Coil
Finishing
2 Shearing line & 1 Slitting Line 1.2 to
0.92
HR Plate/Sheet
HR Slit Coil
Cold Rolling Mill
1
Pickling Lines, Tandem
MillsAnnealing Furnaces, Skin
1.66 Saleable CR
Products CR
9

Cold Rolling Mill
2
Pass
Mills-2, Temper/DCR Mill-1,
Shearing lines-5, Slitting lines-3
& Hot Dip Galvanising Complex-1
coils/Slit coil/ CR
Sheet, Black
Plate, GP
Coil/GP&GC
Sheet



RAW MATERIALS & MATERIAL HANDLING
PLANT (RM-MHP)
Introduction:
The Raw Materials and Material Handling Plant receives blends, stores and supplies different raw
materials to Blast Furnace, Sinter Plant and Refractory Materials Plant as per their requirements. It also
maintains a buffer stock to take care of any supply interruptions.
Some 9 MT of different raw materials viz. Iron ore fines and lumps, Limestone (BFand SMS grade),
Dolomite lumps and chips, hard Coal and Manganese ore are handled here every year.
Function:
Basic functions of the RM-MHP involve
1. Unloading of the raw materials coming from different mines in wagons.
2. To do the blending by making homogenous pile of Raw Materials with the help of Stacker and
Reclaimer.
3. Supply of Raw Materials to different customer departments as per their requirement.
4. Keep a buffer stock of Raw Materials in order to take care of irregularities of supply.
Raw Materials handled in RM-MHP:
Name of Raw Material Sources Internal Customers
1. Iron Ore Lumps ( Size
>=10mm)
Kiriburu, Meghahataburu Blast furnace
2. Iron ore Fines ( Size
<10mm)
Kiriburu, Meghahataburu Sinter Plant
3. Limestone for Sinter Plant Bhawnathpur, Kuteshwar Sinter Plant
4. Dolomite for Sinter Plant Bhawnathpur, Birmitrapur,
Sonakhan, Rajganjpur
Sinter Plant
5. Limestone for RMP Jaisalmer RMP
6. Dolomite for RMP Baradwar RMP

Other Materials Handled in RM-MHP:
10

1. Coke
2. Sinter
3. Pellets
4. Quartzite

Waste Materials Handled in RM-MHP:
1. LD Slag: In order to utilize the residual Limestone and Dolomite Contained in LD Slag, it is
blended with the Iron Ore fines and reused in the Steel making process.
2. Flue Dust: The flue dust coming from the Blast Furnace is blended with the Iron Ore fines which
are then utilized in the manufacturing process.
3. Mill Scale: The scale, containing Iron Oxide, is removed from the mills through water jets and is
sent to the RM-MHP where it is blended with Iron Ore fines and is thus utilized in the steel
making process.


BED Preparation Plan:
Raw Material Number Of Beds Capacity
1. Iron Ore Lump 4 40,000T per bed
2. Iron Ore Fines 5 50,000T per bed
3. Sinter 1 25,000T per bed
4. Flux
( LS:DL = 45:55 )
4 30,000T per bed
5. Limestone for RMP 1.5 20,000T per bed
6. Dolomite for RMP 1.5 20,000T per bed

Size of beds = 280m (length) * 27.5m (width) * 6m (height)
Number of beds =18
Bed 1 for Sinter + Pellet
Bed 2 Bed 7 for Iron Ore Fines
Bed 8 Bed 10 for Iron Ore Lumps
Bed 11 Bed 14 for Flux (SP)
Bed 15 Bed 17 for Flux (RMP)
Bed 18 for Quartzite + LD Slag +Flux (RMP)

Main Equipments:
Equipments Function Number Manufacturer Capacity
1. Wagon
Tippler
To unload the wagons
bringing raw materials
mechanically.
4 HEC 20 Wagons per
hour
2. Stackers Pile raw materials on beds
with continuous blending.
6
1
TRF
WMI
1200T per hour
1200T per hour
3. Barrel
Reclaimer
To reclaim material from a
fully build up stock pile and
discharge it on conveyor
belt.
6 ELECON 1000T per hour
4. Bucket Wheel
Reclaimer
To reclaim material from a 1 MUKUND IRON 500T per hour
11

fully build up stock pile and
discharge it on conveyor
belt.
LTD.
5. Limestone
Screening
Plant
To screen out -25mm size
of SMS Limestone and
Dolomite and to send
+25mm size only in L.D.
Plant.
1 HEC 500T per hour
6. Lump Ore
Screening
Plant
1 IC INDIA LTD. 500T per hour



Different Systems Involved:
1. The functioning of RM-MHP begins with the bringing of raw materials in wagons to the tipplers
which unloads the raw materials from the wagons by separating and then tilting the wagon at an
angle of 170degrees.
2. The raw materials are then transported by conveyor belts through Junction Points to the
Screening Plants where the desired materials are screened and further sent to the Stackers.
3. The Stackers pile up the different raw materials on different beds as Stock Piles with continuous
and uniform blending.
4. The Reclaimer then reclaims the material from a fully buildup stock pile and discharges the
material on a reclaiming conveyor.
5. The materials are then transported to the different Internal Customers as per their requirement.

Wagon Tippling Conveying Stacking in Yard Reclaiming from Yard Conveying Customers
Department.

Quality Parameters:
In Iron Ore Lumps Al
2
O
3
/SiO
2
= 0.6 0.8
In Iron Ore Fines Al
2
O
3
/SiO
2
= 0.6 0.8
In Flux CaO/MgO = 2.9 3.0

New Initiatives:
1. Supply of screened Iron Ore lumps to Blast Furnace Improvement in productivity of Blast
Furnace
2. Modification of Wagon Tippler #1 to accommodate Higher size Rly wagon Savings in
Demurrage

Environmental Measures Taken:
1. The raw materials, before being unloaded from the wagons, are sprinkled with water so as to
allow the dust to settle down.
2. LD Slag, a by-product of the steel making process, was previously dumped at separate locations
resulting in the formation of large heaps which trap solar heat, making it difficult (although not
12

impossible) for vegetation to take root; this encourages erosion and creates dangerous, unstable
slopes. To prevent this, nowadays, LD Slag is blended with the Iron Ore fines since they contain
residual Limestone and Dolomite. This way not only waste is being managed but its hazardous
impacts are also taken care of.
3. The scale generated on the walls of mills contains Iron Oxide and therefore it is reutilized in the
manufacturing process. The scale is removed from the walls through water jets and then
transported to the RM-MHP, where it is blended with the Iron Ore fines and is thus further
utilized.




COKE OVENS

The Coke Oven Complex at Bokaro converts prime coking coal from Jharia, Dugda and Moonidih and
medium coking coal form Kargali, Kathara and Mahuda, blended with 70% of imported coal, coming from
Australia and New Zealand through Haldia, Paradeep and Vizag ports, into high quality coke for the
Blast Furnaces, recovering valuable by-products like Anthracene Oil, Benzene, Toluene, Xylene, Light
Solvent Naphtha, Ammonium Sulphate and Extra-hard Pitch in the process. Bokaro is situated in the
prime coal belt of the country.

All Metallurgical & Engineering industries generally require coke as a fuel. For the production of solid,
porous coke, coal of certain characteristics is needed. The entire resources of coal can be broadly
classified into 2 groups- coking and non-coking. If the coal, when heated to bright red heat in the
absence of air, softens, swells and eventually solidifies-into a more or less solid coke. This is classified
as coking or caking coal. Coking coal may be defined as that which on carbonization gives metallurgical
coke while non coking coal fails to produce to metallurgical coke on carbonization. Coking coal may
further be classified on the basis of their coking properties- prime coking coal, medium coking coal and
semi to weak coking coal.

Petrographic constituents of coal- Coal is a heterogeneous mixture of different proportions of
petrographic constituents such as Vitrinite, Exinite, Semi-fusinite, Micrinite etc and mineral matter. When
coal is washed, concentrations of certain petrographic constituents get increased in clean product
while the adventitious mineral matter is largely removed in the by-product fuels. Washed coal is has not
only lower ash but also better physical properties. Also for a better coke structure, it is necessary to
crush coals to some optimum degree of fineness and mix thoroughly, so that the petrographic
constituents are uniformly dispersed in the mixture before it is charged to the ovens.

Selection of coking coals- the concentrations of moisture, ash, sulfur & sometimes phosphorus & ash-
fusion temperature are important in determining the grades of coking coal since they influence the quality
of coke produced. Moisture-A high moisture content require more heat for its evaporation thereby
increasing the fuel consumption per unit charge. It also has detrimental effects on the brick walls of the
coke oven. Ash- for every 1% increase in ash, 2% extra fuel has to be burnt. Also ash-fusion
temperature should be more than the oven temperature otherwise the ash in coal will get fused and will
form clinkers while coking operation continues. Sulfur- it is an impurity which if present in excessive
13

amounts seriously reduces the quality of metallurgical coke produced. Sulfur is picked up from the coke
by the molten iron & tends to produce brittle iron. Sulfur content in coal should not exceed 0.7%.
Phosphorous- presence of phosphorous in metal gives rise to cold shortness and hence phosphorous
content in coal should be low and should not exceed 0.15%.
Coke making - coal carbonisation:
Coking coals are the coals which when heated in the absence of air, first melt, go in the plastic state,
swell and resolidify to produce a solid coherent mass called coke. When coking coal is heated in
absence of air, a series of physical and chemical changes take place with the evolution of gases and
vapours, and the solid residue left behind is called coke.
Conventional cokemaking is done in a coke oven battery of ovens sandwiched between heating walls.
They are carbonised at a temperature around 1000
o
-1100
o
C upto a certain degree of devolatization to
produce metallurgical coke of desired mechanical and thermo-chemical properties.

A schematic diagram of Coke Oven Battery is given in Fig.below.

Schematic Diagram of Coke Oven Battery

During carbonisation, coking coals undergo transformation into plastic state at around 350
o
-400
o
C, swell
and then resolidify at around 500
o
-550
o
C to give semi-coke and then coke. In coke ovens, after coal is
charged inside the oven, plastic layers are formed adjacent to the heating walls, and with the progress of
time, the plastic layers move towards the centre of oven from either side and ultimately meet each other
at the centre. During cokemaking, two opposite reactions take place, viz. condensation and pyrolysis.
The quality and quantity of plastic layer is of extreme importance and it determines the inherent strength
of coke matrix. For producing coke of good quality, coals should have certain degree of maturity (rank
1.1-1.3), good rheological properties (about 200-1000 ddpm by Gieseler Plastometer), wide range of
fluidity and low inerts.

The various modification in the coke making which have improved coke yield and reduced sp. Energy
consumption are:-

Partial Briquetting of Coal Charge (PBCC):
The technology involves charging about 30% coal blend in the form of briquettes. Briquettes are
prepared using a binder (pitch/ pitch+tar) upto 2. to 3.0% of charge. Coke quality significantly improves
as a result of increase in bulk density of charge.
Stamp Charging of Coal :
The technology basically involves formation of a stable coal cake with finely crushed coal (88-90% -
3mm) by mechanically stamping outside the oven and pushing the cake thus formed inside the oven for
carbonisation. Coal moisture is maintained at 8-10% for the formation of cake. Due to stamping, bulk
density of charge increases by 30-35% causing significant improvement in micum indices and CSR
values of coke. Oven productivity increases by 10-12% & there is a possibility of using inferior coking
coals to the extent of about 20%.
Selective Crushing of Coals :
14

In this technology, the aim is to improve homogeneity of reactive & inert components in coal by reducing
the difference properties of coarse & fine size fractions. For petrographically heterogeneous coals like
Indian coals, this technology is very helpful.
Dry Coke Quenching :
Dry quenching of coke is a major technology for the post-carbonisation treatment which involves cooling
of red-hot coke by inert gases, instead of conventional water quenching. It not only effectively utilises the
thermal energy of red-hot coke (80% of the sensible heat of coke can be recovered & made use of for
production of steam) but also results in improvement of the coke quality (M10 index can be improved by
1 point).
Process:
Coal Handling Plant receives different types of coal from various sources which are characterized by
following contents:
Agreed norm of
ash%
Volatile Matter% Agreed norm of
W.M%
Dugda 20.5+0.5 18-19 D1-7.0,D2-9.5
Kargali 18.25+0.25 20-22 6.5
Kathara 18.25+0.25 23-25 9.0
Moonidih 18.0+0.5 19-21 9.0
Mahuda 16.5 to 17.5 26-28
Imported 10.0 23-25 7.0

Washed coals are received in box wagons and unloaded in rotary wagon tippler(capacity being
1120tons/hr). From under tippler bunkers and coal bins, coal is transported via two conveyor routes of
1400mm wide belt up to the top of coal storage. Silos are provided with storing and proportioning
facilities. There is a provision of 46 silos in 4MT. stage, arranged in two rows each having a storage
capacity of 2500 tons. They are capable of supplying coal for 7 days consumption, provided all the silos
are full. Each silo is 38m high and 12m in diameter. The conveyor tracks b/w tippler to silo top are
equipped with electromagnetic separator for removal of metal parts from coal. The coal is discharged
from the bottom of the silos to the conveyors by means of dosimeters and electronic weigh feeder to the
crushing station. The function of dosimeters and electronic weigh feeders is to give set discharge of
particular grade coal as required in the coal blend. The capacity of each dosimeter is 100T/hr and of
each electronic weigh feeder is 125T/hr, but practically never exceeds 100T/hr. the blend consists of
35% prime coking coal, 25% medium one and 50% of imported one. The coal is crushed to -3.2mm size
and then transported to 4 coal towers of 3200T capacity each.

Tippler characteristics

Hammer crusher characteristics
Speed of rotation of motor 1.4rpm Rotor diameter 1500mm
Supply voltage 415V Effective length 1500mm
Normal(max) angle of tippling 170
0
(175
0
) Speed of rotor 1000rpm
No. of tippling/hr 20 Hammer weigth 20.2 kg

Our purpose is to produce quality coke in large qty. along with useful CO gas, while conserving limited
reserve of quality coking coal and practicing economy in energy conservation and environmental contol
measure. This is attained by feeding coal from coke towers into coke ovens in a controlled manner and
placing these ovens in a series form of battery. The Coke Oven battery is maintained meticulously in
terms of fugitive emission control, use of phenolic water and other pollution control measures. The
process of cola making consists of destructive distillation of coal in absence of air. In low temperature
carbonisation(final coke temp. <700
0
C),the qty. of gaseous products is small and that of liq. products is
excessively large while in high temp. carbonization(final coke temp.>700
0
C), the yield of gaseous
15

products is larger than the liq. products with the production of tar being relatively low. At Bokaro, the
carbonization temp. is 1200-1500
0
C which is the optimum temp. to get coke of uniform size from the
given coal input at B.S.L. The coke ovens where the gaseous products evolved during the carbonization
process are let into the atmosphere are called Beehive coke ovens & the coke ovens where the volatile
matter is recovered are called By- Product coke ovens. In Bokaro, by-product coke ovens are used for
making metallurgical coke. When the coking period is over, the heated coke is pushed from the oven into
the quench car. When the incandescent coke contacts air, it immediately starts to burn and the car is
then pushed to a quench tower where it is deluged with water and cooled to below ignition temperature
and then dumped onto a coke wharf for ultimate transfer to storage.

The design features of Bokaro Coke Ovens are:
Total no. of batteries 8 Oven centre to centre distance 1260mm
No. of ovens/battery 69 Heating system twin flue, under Jet
Height of coking chamber 5000mm Quenching system wet quenching
Length of coking chamber 15,040mm Hydraulic main both sides
Width of the chamber on P/S 390mm Charging hole 3 per oven
Width of the chamber on C/S 430mm BF Coke production/battery/year 0.479 MT(dry)
Volume of the chamber 27.3 m
3
Coal consumption/battery/year 0.740 MT(dry)
Taper 40mm Coking time 17-18 hrs.

For two coke oven batteries, there is one coal tower having 4 pockets: 3 rows in each pocket and 3
gates in each row. There is an additional bunker and a gate for the purpose of taking coal spillage which
occurs during leveling. All these pockets are provided with compressed air arrangements for pneumatic
coking and easy delivery of coal. Each oven is having three charging holes for the purpose of charging
of coal blend. The desired analysis of charge coal is as:
Analysis Ash content 160.5% Sulfur 0.56%
Moisture 6.0-7.0% Phosphorus 0.09%
V.M. 22-24%
Fineness 80% of -3.2mm size (78 to 82% of the coal blend)

Coal blend charged in the oven is being heated form the sides. At first, moisture from the coal is driven
off. As the temp. is raised, the aliphatic carbon to carbon bonds are first to break. C-H linkages are
broken as temp. reaches 600
0
C. the decomposition during carbonization are essentially the reactions
affecting the elimination of heterocyclic complexes and progressive aromatization. The avg.molecular
weights of the volatile intermediate products constantly decrease which is marked by the evolution of
water, CO, H
2
, CH
4
and other hydrocarbons. Final decompositions are max. at 600-800
0
C.
Analysis of coke ash content 20.00.5 Sulfur 0.56% max
Moisture 5% max Phosphorous 0.1% max
V.M. 0.50% max C.S.R 67% min
Porosity 40% min C.R.I 19% max
C.S.R (coke strength after reaction) and C.R.I (coke reactivity index) are new quality parameters which
are obtained by reacting the coke with CO
2
at 1100
0
C for 2 hrs and testing them for strength (C.S.R)
and calculating the loss in weight (%loss-C.R.I).
Screen analysis +80mm in B.F 14%max
-25mm in B.F 5% max
Yield of various products is obtained as practically achieved is:
Gross coke 77% of dry coal charge
B.F coke 87.2% of the gross coke
16

CO Gas 290nm
3
/ton of dry coal carbonized
Ammonia 3 kg/ton of dry charge
Tar 30 kg/ton of dry charge
Coke Sorting Plant:
It is material handling as well as material sizing plant. The aim is to aggregate and size the run of oven
coke in 3 gradations. The 3 grades are :- B.F coke +25mm to -80mm size
Pearl/Nut coke +15-25mm size
Breeze coke 0-15mm size
B.F coke is sent to blast furnace with the help of conveyor belts. Nut coke is loaded in wagons for
outside parties and Breeze is sent to sintering plant for making sinter. Screening is done with the help of
appropriate size Grizzly.

BY- PRODUCT PLANT

The coke oven by-product plant is an integral part of the by-product cokemaking process. In the process
of converting coal into coke using the by-product coke oven, the volatile matter in the coal is vaporized
and driven off. This volatile matter leaves the coke oven chambers as hot, raw coke oven gas. After
leaving the coke oven chambers, the raw coke oven gas is cooled which results in a liquid condensate
stream and a gas stream. The functions of the by-product plant are to take these two streams from the
coke ovens, to process them to recover by-product coal chemicals and to treat the coke oven gas
sufficiently so that it can be used as a clean, environmentally friendly fuel. It is in this process of cleaning
that gives rise to by-products like crude tar, crude benzol, ammonium sulphate etc. The primary and
secondary chemicals so produced are of great importance for the growth of chemical industry.

The yield of by-products on the basis of dry coal blend charge is tar(3.2%), ammonium sulfate(1.1%) and
crude benzol run up to 180
0
C (0.9%).
Raw coke oven gas coming from the coke oven battery has the following typical composition:
Dry
basis
Actual composition (water saturated
at 176F)
Water vapor - 47%
Hydrogen 58% 29%
Methane 25% 13%
Oxygen 0.3% -
Nitrogen 3.7% 5%
Carbon Monoxide 8% 3%
Carbon Dioxide 2.5% 2%
Hydrocarbons (ethane, propane
etc.)
2.5% 1%

Raw coke oven gas also contains various contaminants, which give coke oven gas its unique
characteristics. These consist of:
I. Tar vapors
II. Light oil vapors (aromatics), consisting mainly of benzene, toluene and xylene (BTX)
III. Naphthalene vapor
IV. Ammonia gas
V. Hydrogen sulfide gas
17

VI. Hydrogen cyanide gas

Gas Condensate section- In a by-product coke oven the evolved coke oven gas leaves the coke oven
chambers at high temperatures approaching 750-800
0
C. This hot gas is immediately quenched by direct
contact with a spray of aqueous liquor (flushing liquor). The resulting cooled gas is water saturated and
has a temperature of 80-82
0
C. The amount of flushing liquor sprayed into the hot gas leaving the oven
chambers is far more than is required for cooling, and the remaining unevaporated flushing liquor
provides a liquid stream in the gas collecting main that serves to flush away condensed tar and other
compounds. During gas cooling, the water vapours and the remaining part of tar gets condensed along
with some ammonia and other chemicals. From the coolers, the condensate(tar and ammonia water)
flows through the water seals into an intermediate tank and from here, it is pumped into mechanical
decanter. Cooled gas enters into ETP for purification from foggy tar. The purified CO gas passes through
the gas pipelines into the gas exhauster. After exhausters, the gas under pressure goes to the
installation for recovery of ammonia and then through a final cooler(naphthalene removal), a wash oil
scrubber and a desulphurizer before used a fuel. Water, tar and fuses(sludge) are settled in the
mechanical decanter as per their specific gravity.



Duties of the by-product plant:
In order to make raw coke oven gas suitable for use as a fuel gas at the coke oven battery and
elsewhere in the steelmaking facility the by-product plant must:
Cool the coke oven gas to condense out water vapor and contaminants
Remove tar aerosols to prevent gas line/equipment fouling
Remove ammonia to prevent gas line corrosion
Remove naphthalene to prevent gas line fouling by condensation
Other duties may include:
Remove light oil for recovery and sale of benzene, toluene and xylene
Remove hydrogen sulfide to meet local emissions regulations governing the combustion of coke
oven gas.
By-product plant typically consists of the following plants:-
1. Sulfuric acid plant
2. Ammonium sulfate plant or Ammonia recovery plant
3. Benzol recovery plant mixture of benzene, toluene, xylene and naphthalene are obtained
4. Benzol refining & rectification plant
In addition to treating the coke oven gas, the by-product plant must also condition the flushing liquor that is
returned to the coke oven battery, and treat the waste water that is generated by the coke making process.

Description of main technological equipments involved:
i. Primary Gas Cooler:- Cooling surface of the cooler 2950m
2

No.of tubes 5487
Height of the cooler 25125mm
Length of tubes 3010mm
ii. Electrostatic Precipitators:- Type C-7,2 Cross section area 72m
2

Gas capacity 35000 m
3
/hr No. of Precipitating tubes 148
Height 9460mm Height of precipitating tubes 3500mm
Diameter 4000mm Diameter of precipitating tubes 250mm

iii. Exhauster(electric):- Capacity 72000 m
3
/hr
Total pressure 2850 mm WC
Max. no. of revolutions 3905 rev per minute
Sub-Plants of the by-product plant:
18

5. Tar distillation plant hot pressed naphthalene, anthracene oil, wash oil, hard medium pitch,
extra hard pitch& road tar
6. BOD plant

A detailed description of by-product plant is depicted by fig. 3

The resultant main output streams of the majority of coke oven byproduct plants around the world are
shown in the table below:-
Coke oven gas Used as fuel gas at the coke oven battery and steel works
Flushing Liquor Recirculated back to the coke oven battery
Waste Water Discharged to BOD treatment plant
Tar Sold as product
Ammonia/Ammonium Sulfate Sold as product
Light Oil (if recovered) Sold as product
Sulfur/Sulfuric Acid (if gas is
desulfurized)
Sold as product

BOD PLANT:-
In an Integrated Iron & Steel Industry, wastewater generated from Coke Oven By-product Plant is
considered to be the most polluting. This wastewater contains toxic chemicals like phenol, cyanide and
ammonia, which are harmful to the receiving waterbodies when discharged untreated/partially treated.
Realizing the adverse impacts on the receiving environment, the pollution control authorities have
notified discharge norms exclusively for COBP wastewater, as shown in Table:-
Quality of Raw Effluent Quality of Treated Effluent
Temp. (
0
C) 35-50
pH 8-9
TSS (mg/l) 200
BOD (mg/l) 2000-2500
COD (mg/l) 4000
Phenol (mg/l) 400
Cyanide (mg/l) 50
Thiocyanate (mg/l) 150
Ammonia (mg/l) 400
Tar/Oil/Grease
(mg/l)
200

pH 6-8
TSS (mg/l) 100
BOD (mg/l) 30
COD (mg/l) 250
Phenol (mg/l) 1
Cyanide (mg/l) 0.2
Thiocyanate (mg/l) 50
Ammonia (mg/l) 50
Tar/Oil/Grease
(mg/l)
5


The effluents from coke-ovens and by-product plants are treated by biochemical oxidation of cyanide,
ammonia and phenol, where-in bacteria are grown which consume the pollutants as their food and grow,
multiply and die. The dead bacteria in the form of Suspended Solids from the biological reactors are
removed in the settling tanks and dewatered, sun dried and disposed off by mixing with coking coal and
charging back in the coke ovens. These Effluent Treatment Plants are commonly known as Bio-
chemical Oxidation & Dephenolisation Plants or BOD plants. The treated effluent from BOD
plant may be recycled for use in quenching hot coke in coke-ovens. The two most common processes
used for the treatment of CO effluents are: trickling filter and activated sludge process. Complete mixed
activated sludge system (CMASS) is also used for the treatment. The CMASS operates at low substrate
concentration and hence can tolerate the toxic wastes better. Apart from treatment, it is also necessary
to minimize discharge of wastewater and concentration of pollutants at the source itself.

19

BOD Plant in BSL is used to remove the phenolic wastes from the water. They are useful in reducing air
& water pollution. Main feature of this plant is the biological degradation of chemical wastes. The whole
process can be divided into 2 stages-

1.Pre-Treatment:
It helps in removal of suspended solids, removal/collection of oil, equalization of various effluent,
adjustment oxygen transfer, digestion of effluent, etc. Bar Screen and Grit Removal Mechanism is used
for removing the suspended particles in various definite sizes. Screening is a process by which materials
larger in size than the opening of the bar screen are strained out and then removed continuously or
manually. Phenolic waste water is delivered by pumping into the INLET CHAMBER and consequently
into TAR SETTLING TANKS. Tar along with heavier suspended solids get sedimented in this tank where
sufficient detention time is provided(approx. 4 hrs). This settled effluent is then treated in two
DISSOLVED AIR FLOATATION Units(DAFs) where, after coagulation and flocculation, oil will be
removed as a frothy scum and at the same time suspended solids will settle at the bottom. This process
involves the separation of small and medium sized solids by adhesion of controlled air with the help of
chemical dosing entrapment and adsorption of flocs. Tar& oil are removed by alum& polyelectrolytes
which increase the surface area and facilitates oil removal. DAF units are used for removing the COD,
BOD, suspended solids, oil and grease, metals and VOCs. This gravity separation system helps to float
the suspended material in the surface and thus results in a total recovery/removal of the floated
materials.
The settled and de-oiled effluent from the DAF unit will flow into an EQUALIZATION TANK
which is meant to even out the influent concentrations in the incoming phenolic wastes. The detention
time provided is 24 hrs divided into 2 tanks. The contents of this tank are kept in constant agitation by
blowing in air from an air blower. Concentrations of ammonia and other constituents are brought within
the norms set for the incoming effluent by the pollution control authorities either by alkaline
treatment(using solid NaOH/KOH) or acidic treatment(using orthophosphoric acid) depending upon the
pH of the incoming effluent. For ensuring proper biological treatment, pH is brought within the range of
7.2 to 8.0(ideally 7.8).
The effluent from the equalization tanks will flow by gravity into a flash mixer
followed by a CLARIFLOCCULATOR. The remaining suspended solids will be removed in this unit. The
final clarified effluent will be further processed for secondary biological treatment. This is a combination
of up-flow type and sold contact unit, slurry circulation unit, and sedimentation unit to take care of the
mass action effect floc formation. The vertical flow design and direct agglomeration design of floc with
direct contact is a specialized method of treating the effluent.
Pre-treatment is necessary for ensuring proper biological treatment because presence of tar and oil
severely limits the amount of oxygen available for the growth of bacteria.

2. Secondary biological treatment:
For the phenolic waste load to be handled, the most appropriate biological treatment is the activated
sludge process. This form of treatment has been provided into 3 stages. Surface aeration has been
envisaged by means of low speed surface aerators fitted in these aeration tanks.
In the first stage, the removal of phenols and part of cyanides and organic BOD is carried out
with a hydraulic detention time of apprx. 23 hours. For this 8 nos. of 30 hp aerators have been provided.
Aeration involves the exchange of gases between the water and atmosphere. This treatment method is
basically for the transfer of oxygen to water for the expulsion of CO2, H2S and other volatile substances.
It is very important in the effluent /wastewater treatment applications to include the precipitation of
impurities like iron, manganese in certain forms, and reducing COD and BOD. Pseudomonas bacteria
are cultured as a feed for phenol removal. Turbulence level is sufficient to ensure effective distribution of
oxygen throughout the reactor. The aeration tank no. 1 contents flow into the clarifier no.1 where solids-
liquids separation takes place. The activated sludge from the clarifier is pumped back into the aeration
tank to maintain the Mixed Liquor Suspended Solids (MLSS). When MLSS is attained to a desired level
(approx. 2000-4500 mg/l), the excess activated sludge is wasted to the sludge drying beds via sludge
thickener.
In 2
nd
stage, the clarified effluent form clarifier no.1 flows into aeration tank no.2. Similar
biological activity takes place. Hydraulic detention time provided is approx. 28hrs. In this stage, removal
of requisite quantities of ammonia, cyanide & organic BOD has been envisaged. Nirtosomonas bacteria
20

are cultured as a feed for ammonia removal. The 3
rd
stage of treatment is a biological process envisaged
through a biological filter (TRICKLING FILTER). The settled effluent from clarifier no. 2 is pumped into
the inlet chamber of trickling filter. Here bacterial growth takes place on the surface of the stone media
filled up in the filter. In this stage, cyanides, thiocyanates and remaining BOD is removed so that the final
effluent parameters are maintained at desired levels. Pseudomonas and klebsiella family of bacteria feed
on cyanides. The effluent (liquor) from trickling filter flows into the sump from where it is pumped to a
distribution chamber, partly to be recycled back into the trickling filter and other part to be gravitated to
clarifier no. 3. The settled sludge in this clarifier is pumped to a gravity thickener. The thickened sludge is
sent to the sludge drying beds.
The finally treated effluent from clarifier no.3 flows into a sump from where it is pumped
partly back into the system for dilution at the inlet of aeration tank no.1 and the balance part is sent back
for coke quenching. Sludge can be used as a biofertilizer and has a very high calorific value. The whole
process can be summarized by fig. 4

With the strict operational control, the existing BOD plants in Indian Integrated Steel Plants, could meet
the design norms with respect to oil & grease, phenol, ammonia, thiocyanate. Moreover, treated water in
BOD plant in BSL is also used for plantation as it has nutrients and microorganisms required for the
growth of plants. Though cyanide concentration pertaining to the CPCB norms is 0.2 after treatment,
min. 0.6 to 0.8 is attainable. Here in BSL, cyanide is reduced to 1.2 mg/l after the biological treatment.
Chemical treatment of cyanide should be avoided because of the formation of carcinogenic cyanide
compounds. Biological treatment is preferred over chemical treatment because of its ecofriendly-ness.
Products of chemical treatment may or may not be harmful and their further removal will again pose a
challenge while products of biological treatment are carbon-dioxide and water which are harmless to us.
Also chemical treatment requires continuous investment while biological treatment requires only the
initial investment and hence cheaper in long terms.








21







SINTER PLANT

Introduction:-
Sintering is the process where heat is produced by combustion of solid fuels within moving beds of
loosely packed particles, so as to agglomerate the loosely packed particles i.e. the iron ore and other
fines into a compact porous mass, called sinter. This sinter is used in blast furnace as iron bearing
change material, which would otherwise, had to be disposed in the form of iron ore fines. Thus sintering
plant not only supplies a suitable charge but also eliminates other intricate problems.
The sintering plant at Bokaro has a very high sintering area per machine, with a provision of partially
cooling the sinter on machine itself.
The ignition furnace is of double hearth and extended hearth and provision is there for adding extra coke
on the top layer of charge.
A Sinter Plant typically comprise the following sub-units as shown below.
22



Sections:-
It consists majorly of 5 sections viz. 1) Stock bins and proportioning section 2) waste bins section 3) raw
materials section 4) machine building section 5) slime thickening section
1. Stock Bins and Proportioning section: - It receives prepared raw materials from RMP i.e.
limestone, dolomite, coke fines, flue dust, mill scale, lime dust etc. Secondly, it proportions
different raw materials in required amount. Finally it mixes these materials in primary mixing drum
and sends it to the Machine Building section. All material transport occurs through conveyors
except in case of lime tankers.

2. Waste Bin section:- It has a threefold function:-
a) Receives waste material generated within the plant in ground bins, which is flue dust from
blast furnace or mill scales.
b) All the raw materials are proportioned by disc feeders.
c) Carries the waste materials to stock bin section via conveyor belt.

3. Raw Materials Section: - It consists of 5 units viz. Hammer crushers, Flux screens, Emergency
bunkers, Fuel storage building and Stock bins.

a) In Hammer crusher building, lump limestone and dolomite received from RMP is crushed and
sent to the flux screen. From the flux screen, the oversized particles (+3mm) are sent back to the
hammer crushers and the remaining goes to the Stock Bins section.

b) The coke received in sintering plant is from blast furnace as screen return and from coke oven
as coke breeze. If received in Fuel storage building, then it is transferred in 3 no. bunkers that
send it to coke crushers.

c) In case FSB is full of coke, then coke comes to Emergency bunker via dumper loading and the
dumper in turns dumps the coke in the coke yard.

d) In Coke Crusher building fuel received from FSB is crushed to -3mm size and then transferred
to stock bins. For coke there's no further screening unlike limestone and dolomite.

4. Machine Building Section: - After the raw materials are prepared, proportioned and mixed,
they're sent to MBS where sinter is made, cooled and screened before being sent to the Blast
furnace.
The raw materials are distributed in two bunkers and received onto 2 parallel conveyors. One is
added with extra coke and then they are sent to baiing drums along with water addition. This
charge is received in hoppers via shuttle conveyors.
23

Sinter of size 8-12mm is also received via another source.

The sinter machine is an endless moving grate. As the machine moves and hopper gates are
opened, bed materials and sinter charge falls on it. The lowermost layer is of bed material,
intermediate of sinter charge with less coke, and topmost is the sinter charge with extra coke.

This passes through ignition furnaces with primary hearth at 1200
0
C, using the mixed gas and
secondary at 1000
0
C, using the coke oven gas.

As the charge is ignited from the top it is simultaneously under the action of suction below sinter
machine through the 26 vacuum chambers connected to exhausters, throughout the working
length. As the charge enters the hearth there's suction from below, continuing up to the end of
machine.

From this the ignited zone slowly moves the top surface towards the bed material layer. The
continuous movement and feeding of charge and bed material facilitates continuous sinter
production with the raw material becoming a part of the final sinter mass. The sinter is partially
cooled and crushed to smaller size. -150 mm sinter is allowed to pass, which is further cooled
separately in drum coolers (-6mm) and straight line coolers, consisting of pallets in series
(+6mm). From the SLC's, sinter is passed to cold screen, containing two screens of 6mm and 12
mm. from the first screen -6mm are sent to Stock bins in form of 'cold sinter return' and +6mm are
passed through the 12 mm screen. From this, the sinter in range (+6mm -12mm), called fines is
termed bed material and sent to bed material bunker. The oversize sinter (+12mm) is sent to
Blast Furnace and stored in sinter bunkers.
Technical Data:-
1. Stock Bins and Proportioning section:-
No. of rows-3
No. of bins in a row-23
Ore fines 1-6 Flux 7-13
Coke 14-17 Flue dust/mill scales 18
Cold and hot sinter return 19-21 Burnt lime 22-23


Average charge mix ore fines-51% Lime and dolo fines-15 to 16%
Coke fines-4% Sinter return-21%
Water-6 to 8%

2. Hammer Crusher:-
No. of hammer crushers-5 (reversible type) No. of coke crushers-8
Capacity-250T/hr Capacity-16T/hr
Product size 0-3mm Feed size -10mm
No. of Flux screens-14 Product size 0 to 3mm
Capacity-150 to 200 T/hr

3. Fuel Storage:-
No. of Coke piles-2 Handling capacity-10000 cubic meter
Waste bins no.-10 Capacity of each bin-90 cubic meter

4. Machine building:-
Production of sinter-6.2MT/hr Production of sinter per day-18000T
Capacity-300 to 450 T/hr Total sinter area-252sq.m
No. of pallets/machine-130 Max. Depth of sinter bed-450mm
Vacuum chambers-26 (3 for partial cooling)
24


Activities to reduce Work Zone emissions:-
1. Improvement in sintering process by modernization leading to reduced dust emissions-2
2. Installation of High Capacity fans in Hammer crusher-2
3. Installation of high capacity fan motor-5
4. Ventury Scrubbers-12
5. Revamping of defunct dusting units-14

Activities to reduce Stack Emissions:-
1. Battery cyclone element changing
2. Roof changing for B/C-1, 2, 3, 4
3. Intensive cleaning of gas main and B/C element
4. Plugging leakage in B/C hoppers
5. Modification of Water sprayers
6. Replacement of damaged ducts, scrubbers and ventury scrubbers.
Advantages of using sinter in Blast Furnaces:-
1. Use of iron ore fines, coke breeze, metallurgical wastes, lime, dolomite for hot metal production
2. Better reducibility and other high temperature properties
3. Increased BF productivity
4. Improved quality of hot metal
5. Reduction in coke rate in blast furnaces



BLAST FURNACE
Introduction:-
The aim of blast furnace is to produce pig iron from ore and sinter, i.e. iron bearing materials. The Iron
oxide of ore and sinter is reduced to iron with the help of CO, produced by the action of coke and air.
Coke serves another purpose of supplying heat for the reactions and melting iron inside the furnace. Part
of the heat is provided by the blast heated upto 1000 C, before introducing the materials in it. The
gangue materials like silica and alumina, sinter and coke ash are removed as slag with the help of flux
provided by limestone and sinter. Other additives like quartzite and Mn-ore are also charged as
corrective materials for the proper furnace working and control of analysis. Except air blast fed from the
lower part of furnace, all the other materials are charged from top. The products of furnace are pig iron
(hot metal) and slag, from the lower part and flue dust and BF gas from the top.
In Bokaro SAIL plant, 5 Balt furnaces of 2460T/day capacity are functional with a working volume of
1758 cubic metres.

Sections:-
25

1. Charging section:-
This section consists of 14 bins with the following distribution:- sinter (4), lump ore (4), additives (Mn ore,
quartzite and limestone)-4 and coke (2).
The bins receive materials from reversing conveyors. Sinter from bins over the skip pit is fed by the
means of 100 cu m/hr, vibrator screens, directly into sinter weighing hopper. When the specified weight
is attained, the screen stops vibrating and scheduled weighed portion is transferred to skip. Coke from
bins is fed by 400 cu.m/hr vibrator, into coke funnel scales. Upon weighing the coke loaded into a skip,
under 25 mm coke breeze and under 5 mm sinter fines are directed by conveyors to sintering plant.
Lump ore and additives are fed with the aid of electrical vibration feeders. Weighed portions of ore and
additives are transferred from 600 cu.m/hr. belt, to a skip.

2. Furnace Proper:-
For hoisting raw materials to the top of furnace there are two skips car in each BF. Then there are
receiving hoppers and revolving distributors (bells) that dump the material into furnace and then close
the seal to prevent the gas from escaping. The cylindrical upper portion of the furnace is called throat,
and then a conical portion called stack. Then again a cylindrical portion called belly and then an inverted
conical portion called bosh. The lower cylindrical portion where the metal and slag collect is called hearth
The metal is removed from the furnace through iron notch into metal ladles. Slag is removed from slag or
cinder notch into slag pots. Hot metal is transferred to Pig casting machines or to steel melting shops.
Slag is sent to Dump yard and slag granulation plant that can be used for cement making.
At a time 2 ladles of hot metal and 3-4 ladles of slag are tapped out of BF.
The blast furnace gas leaves the top through 4 uptakes joining together to give two down comers,
bringing the gas to dust catcher and then to a gas cleaning plant. Cleaned gas is burnt in stoves to
preheat the incoming blast air that is conducted by hot blast line to bustle pipe circling the furnace. Aire
enters furnace water cooled lining called tuyers located just below the top of hearth. The air supplied by
these tuyers is used with coke for various reactions inside the furnace.




Design data:-

1. Skip
no. of skips- 2
capacity of each skip- 13.5 cu.m
hoisting speed - 3.5 m/s

2. Charging system:-
Big Bell-Diameter-4400mm ; weight 34.7T; Drop of big bell-750mm
Small Bell-dia-2000mm; weight-13.4T; Drop-900mm

3. Furnace:-
Hearth Diameter-9750mm
Hearth height-3800mm
Volume hearth-280 cu.m
Bosh volume-250 cu.m
belly volume-159.5 cu.m

26

The cooling and refractory lining for bottom is provided with air cooling from below and water cooling on
periphery. To improve cooling efficiency lower part of bottom is graphitized carbon block and upper
central with alumina blocks and carbon blocks on periphery.
The belly and stack have high density fireclay brick lining. The bottom hearth, tuyere zone, bosh and
belly are cooled by stave coolers. The tuyeres are cooled by circulating water along its whole surface.
There are 512 stave coolers which are double walled with water circulation. Average water requirement
for each furnace is 2560 cu.m/hr for a temp. rise of 4-5
0
C.
Each furnace has two casthouses equipped with:-
Mudgun:- For closing the tap hole made up of cast steel. Anhydrous tar bonded with clay is used, that is
forced into the tap hole via a mudgun.
Drilling machine:- For opening the tap hole, drilling machine is used.
Castable runners are provided for taking the metal from furnace to ladles.

Operating conditions for the furnace is given by following parameters:-
1. Burning Intensity- 940 Kg dry coke per cu.m of furnace/24hr
2. Blast temperature- 1100 degC
3. BF gas temp.- 250-280 deg c
4. BF Gas pressure- 1.5 atm
5. Alumina content in pig iron - 24-25%
6. Silica content- 1.2-2%
7. Hot metal temperature- 1450
0
C

3. Stoves:-
The purpose of stoves is to heat the air blast to a temperature of about 1110 degC, before it's introduced
in the furnace. Each furnace has 4 stoves, which work on regenerative principle i.e. first the gas is burnt
inside the stove for about 3 hrs. and then as the high alumina brick work gets heated up, burning is
stopped and air blast is passed through stove. The blast takes out the heat and attains the required
temperature. This cycle is called the "on-blast" cycle, lasting for 1.30 hrs. For proper working of stoves
the gas/air ratio is very important. It has been observed that 10-12% of air excess gives the right flame
appearance i.e. of violet colour. The air/gas ratio comes generally to 1:0.75.


Design data:-
1. Full height- 45,200mm
2. External dia- 9000mm
3. Wall thickness- 605mm
4. Insulation layer thickness- 260mm

Working Data:-
1. Cold blast temperature- 140-180
0
C
2. Dome temperature- 1350
0
C
3. Flue gas temperature- 400
0
C
4. Gas volume- 60,000 cu.m/hr.

Auxiliaries:-
1. Pig Casting Machines:- Here the metal is poured in moulds that are continuously moving by
motor. During movement, they're cooled by water sprays. After being cooled, on the strands
(strand length is determined, such that metal gets cooled at the end of strand), they're collected
27

in wagons. The moulds are coated with lime milk produced in lime preparation unit, to prevent
them from sticking to the moulds. There are 4 two strand pig casting machines with a capacity of
1,700T/day for producing pigs from hot metal.
2. Ladle repair and other maintenance shops
3. Slag Dump Yard

Environmental management:-

1. Blast furnace slag granulation: - Granulation of Blast Furnace slag is a very attractive option
since it turns the Blast Furnace slag into a valuable byproduct that can be sold to the cement
industry. Blast Furnaces normally generate 200 to 400 kg of liquid slag for every ton of hot metal
produced. During the initial years, Blast Furnace slag was considered a waste product and was
being dumped at a convenient place away from the Blast Furnace. The use of granulated Blast
Furnace slag replacing clinker for cement production is now accepted worldwide with the end
result being a high quality cement, comparable to that of conventional Portland cement, at an
attractive cost. The dumping and accumulation of large amounts of Blast Furnace lump slag can
so be avoided which reduces the intensity of use and maintenance of the dry slag pits and the
associated environmental issues. Since the unit volume of Portland cement is reduced, this
concrete is less vulnerable to alkali-silica and sulfate attack.

An additional benefit when using Blast Furnace slag for cement production is the reduction in
CO
2
emission. For every ton of clinker that is replaced by granulated Blast Furnace slag there is
one ton less CO
2
emission. Bokaro steel plant is currently working in association with JP Cement,
to utilize its blast furnace slag.





STEEL MELTING SHOP
Introduction:-
The SMS-I complex of BSL has 5 LD converters, each of 100/130 T capacity. Out of these 5, 3 are in
continuously running condition while other 2 are under repair.
In these converters technically pure oxygen (99.5% pure) is blown from the top through a water cooled
lance so as to remove the impurities of hot metal by oxidation. By this process hot metal is converted to
steel. All the 3 type of steel viz Killed, Rimming and Semi-killed is produced at SMS-1. The capacity of
the shop is 2.5MT of ingot steel.

The SMS II complex of BSL has two LD Converters each of 300 hundred Ton Capacity. SMS II differs
with SMS-I mainly because of blowing process and gas recovery system. Unlike SMS-I, SMS-II have got
suppressed combustion system, where atmospheric air is not allowed to enter in the hood area and the
28

combustion of converter gas is suppressed. Capacity of SMS-II is 2.25 MT of liquid Steel. At present,
mainly Killed steels are produced in the shop.
Gas Cleaning Plant widely known as GCP is meant for treating the cases generated from the Converter.
It consists of hood, skirt, stack and down take, all fabricated of steel tubes. The gases are cooled &
cleaned while they pass through this system. This gas is used by reheating furnaces and Soaking Pits.
Sections:-
The major sections of SMS are:-
1. Mixer
2. Bulk Material & Ferro Alloy storage & Magnetic Yard
3. Converter
4. Slag Yard
5. Pit Side
6. Stripping yard, hydro cooling & cleaning section, graphite coating yard & mould preparation
section.

A. MIXER:-
The mixer covers 3 purposes:-
1. It acts as a hot metal reservoir. Hot metal from mixer is supplied to converter as per demand.
2. It homogenises the composition of hot metal received from different furnaces and casts.
3. It maintains required temperature of the hot metal through burners.
There are two mixers in the shop each of 1300T capacity. A mixer is a refractory lined cylindrical drum
with charging door at the top and pouring spout at one side of cylindrical surface. The temperature of the
hot metal is maintained at 1310+-10
0
C with the help of three CO mixed burners, two horizontal at two
ends and one vertical near the pouring spout.
The hot metal comes to the mixer from Blast Furnace in hot metal ladles. These ladles are then lifted to
the mixed floor and then hot metal is charged in the mixer with the help of crane. A minimum of 640T is
always kept in the mixer. A special feature of the mixer is its self- returning mechanism i.e. in case of
power failure when it is pouring hot metal it will automatically return back to its original position. The hot
metal transfer from the mixer zone to the converter zone is done in mixer ladle which is dragged by a
locomotive.


B. Bulk Material & Ferro Alloy storage & Magnetic Yard:-

1. Bulk Material Storage
The function of the section is to receive the bulk material like Mn ore, Bauxite, Limestone & Lime
and then supply them to the converter building.

Materials brought in wagons Materials from trenches piled Materials transferred to hoppers
& unloaded in pits (6.4m high) of drying drum

Materials transferred to From bins, materials loaded in Materials reach Service Bunkers
Receiving Bins (3m deep) stationary hoppers through conveyors
2. Ferro Alloy Storage

Ferro alloys unloaded in Ferro alloys crushed and screened Alloys fed to SDC (Self
Trenches (3m) Discharging Containers)

SDC transferred to Bunkers and unloaded
29


3. Magnetic Yard

Iron & Steel scrap from SSD and Rolling mills Materials unloaded by magnetic crane in
received in wagons magnetic yards

C. Converter:-
In converter, the hot metal received from Blast Furnace is converted to steel by removing carbon and
other elements present through the Bessemer process.
Hot Metal from blast furnace contains
C : 4.5%
Si : 0.6 to 1.2%
Mn : 0.6 to 1.1%
S : 0.05% (max)
P : 0.25%
The change of hot metal to steel is brought by blowing 99.5% pure oxygen in converter. The principle
involved is that of oxidation of the impurities in the iron by the oxygen of air that is blown through the
molten iron; the heat of oxidation raises the temperature of the mass and keeps it molten during
operation. The process is carried on in a large container called the Bessemer converter, which is made
of steel and has a lining of silica and clay or of dolomite. The capacity is from 8 to 30 tons of molten iron;
the usual charge is 15 or 18 tons.
Before starting the blowing, the converter is properly charged. First, 2-3T lime is charged in the bottom.
Then scrap addition is done by a charging crane. The reactions in converter during the blowing process
are highly exothermic. At this time scrap acts as a coolant. Finally, hot metal is charged and oxygen
blowing is done by lowering the lance and opening the oxygen shut-off valve. The lime and other
additions are done during the blowing process. Lime is added as a flux and to maintain the basicity of
bath. Basicity is the ratio of CaO and SiO
2
and is kept between 3 and 3.5.

Blowing involves 3 periods:-
1. Slag formation: - It involves oxidation of Fe, Si & Mn. Si oxidizes more than other elements.
Lime is continuously added for assimilation of Fe, Si & Mn oxides in slag. Lance is kept at 2-3m
for 2-3 mins and then brought to 1.5-1 m.
2. Carbon Oxidation Period: - Here the brightness of the flame increases due to the burning of CO
and CO
2
at the mouth of converter. The lance is brought down to 1.2-1m during the last period.
3. End of Blow: - It is judged by dropping down of flame. Blowing takes approx 25-28 mins.

After stopping the blowing, the converter is tilted which runs off the slag. Temperature of the metal is
then measured with a thermocouple and samples are collected for chemical analysis. Then tapping is
done during which required amount of deoxidizers (FeMn, FeSi etc) are added to the teeming ladle
depending on the quality to be made (Reeming or Killed or Semi-Killed). After tapping, converter is tilted
to remove the slag in slag pots which are sent to the slag yard. The teeming ladle is transferred to the
teeming bay.

D. Slag Yard:-
The function of the slag yard is to receive, cool, crush and then to dispatch the slag.
The molten slag is received in lime coated slag pots, cooled by means of water spray and then crushed
into pieces by dropping a heavy weight (an ingot) on the solid slag mass by magnetic cranes. The
dumper dispatches the slag mass to rubbish yard.

30

E. Pit Side:-
The pit side work can be divided into 2 main parts:-
1. Teeming
2. Ladle Preparation
Teeming: - After tapping, the ladle is transferred to the teeming bay by cranes. In between tapping
and teeming the ladle is held for about 10 mins to allow deoxidation products to float up.
In teeming ladle nozzle at the bottom is kept plugged with a wooden wedge. The wedge is first
removed and then slide gate is operated and teeming starts.
After teeming the ingot mould train is held for about 15mins in the platform and one and a half hour in
holding and then sent to Stripping Yard, from where it is sent to the Slabbing Mill.
Ladle Preparation:- Immediately after teeming, the ladle is detached and is laid in the pit. Then
oxygen lancing is done to clean the nozzle of any metal. The machine is then opened and both the
top and bottom plates (refractory) are removed. Used springs are removed and nozzle condition is
checked.
The top layer is placed with the mastic (inflow mass) and the bottom layer is placed inside the
machine. The gap between heat sliding plate and bottom plate is filled with plastic clay. The ladle is
lifted vertically, taken to platform and from the top of the platform well mix to the tune of 12Kg is
added in a polythene bag to fill the nozzle with the mix.

F. Mould Yard & Stripping Yard sections:-
Mould Preparation Section: - The main function of this section is to prepare and supply mould trains as
per requirements of pit sides.
Hydro-cooling and cleaning section: - Here the moulds are cooled by spraying water and in cleaning
section, moulds are cleaned by 100Kg/cm
2
water jets.
The graphite coating of moulds is done to avoid sticking tendency between moulds and ingots.
Stripper Yard: - In stripper yard the ingots are stripped of moulds and stickers released and free ingots
are sent to Slabbing Mill for charging in soaking pits.



Gas Management Systems Installed:-
a. Waste Heat Boiler:-
It is an important auxiliary equipment in the converter. Its function is to cool the converter gas and
generate steam.
The waste heat boiler consists of feed water pumps which send desalted and deaerated water to
the boiler pump. The water is circulated with the help of circulating pump through filter and then
through the tubes of the boiler arranged in the path of converter gas. As a result steam is
generated and collected in the water drum which is separated from water by means of cyclone.
The steam is stored in the accumulator and supplied to the steam line.

b. Gas Cleaning System:-
Gas Cleaning Plant is meant for treating the gases generated from converter. The gases are
cooled as they pass through the system. On the way they are cleaned and sucked by ID fan into
chimney or to Gas Storage Holder. On an average, 20,000-25,000 m
3
of converter gas is stored
in every heat. This gas is used by reheating furnaces and soaking pits.

31











ENVIRONMENTAL POLLUTION AND
MANAGEMENT
Introduction:-
Environment is the sum total of all physical, chemical, biological, social and economic factors which
constitute the surroundings of man, who is both creator and molder of his environment. With increasing
scientific knowledge and industrial activities, various transformations have been introduced in the
environment leading to a crisis known as Environmental Pollution.
Following major acts have been introduced by the Govt. and are being abided by the industries:-
1. The Water (Protection and control of pollution) Act, 1974
2. The Water (Cess) Act, 1977
3. The Air (prevention and control of pollution) Act, 1981
4. The Environment (protection) Act, 1986
5. The Public Liability Insurance Act, 1991 and
6. The National Environmental Tribunal Act, 1995
32


Environment Control Department of BSP:-
Environment Control Department (ECD) is regularly engaged in Air, Water and Noise Monitoring work.
The Laboratory forms the heart of the elaborate monitoring system established for the purpose of
generating the relevant Environmental data which is being sent to internal agencies for taking correcting
action and also to the external agencies like CPCB, JSPCB and other governmental organizations for
meeting statutory obligations.
Any discrepancies in meeting the norms related to any particular section of the plant are first sent to the
concerned department and then put forward in a meeting of all BSP departments.

Industry and the Government:-
1. For any industry to be set up, it needs a clearance from the Ministry of Environment & Forest. For
this it needs to put forward a plan regarding their plant along with an assurance and proposal that
the industry will meet the prescribed Environmental norms to the fullest. For that purpose, an
Environmental Impact Assessment (EIA) needs to be conducted by an authorized agency and an
EIA/EMP report is to be submitted to MOEF underlining all pre and post environmental impacts of
setting up the industry.
2. Also before its set up, industry needs to provide a detailed plan of its efforts towards social and
community development within 5 km radius of it boundary.
3. Once the industry has been set up, it needs to submit a Compliance report to the Ministry of
Environment & Forest once in every 6 months mentioning the details of each and every plant
along with the data of various pollutants released by the plants in water, air as well as on land.
This has to be accompanied by measures being taken to control the pollution and certain future
proposals to be met in case of deviations from the prescribed norms. Any failure to submit the
report will result in the issuing of a Shut Down Notice by the Govt.
4. Moreover, the industry needs to gain Consent to Operate once in every year from the State
Pollution Control Board.
5. No Objection Certificate also needs to be gained by the industry from the SPCB.

Sections of Monitoring:-
Monitoring done by the Environment Control Dept can be broadly classified in four sections:-
1. Air Emissions
2. Water Effluents
3. Noise Levels
4. Solid Waste
The basic concept involved in any monitoring system is the 3Rs concept i.e.
Reduce
Recycle
Reuse

AIR EMISSIONS:-
For the monitoring of air Stack Emissions, Work Zone Air Quality and Ambient Air Quality are measured.
Stack Emission and Work Zone air quality monitoring:-
Monitoring of the Mill Zone is done once in every 3 months while that of Iron and Steel zones is done
monthly.
Ambient air quality monitoring:-
Ambient air quality monitoring involves assessing the air quality of the Township area. To achieve this 7
sections have been developed on the periphery of the plant where monitoring is done on a regular basis.
Standard Stack Emissions:-
33

1. Coke oven - 50 mg/Nm
3

2. SMS (during Blowing) - 800 mg/Nm
3

3. Blast Furnace Stove - 50 mg/Nm
3

Other Stack - 100 mg/Nm
3

4. Rest Emissions - 150 mg/Nm
3

Work Zone air quality:-
Max. permissible particulate matter- 10,000 ug/Nm
3

Important Measures Taken:-
1. A Gas Cleaning System has been installed in the blast furnace which separates flue dust from
the gas. This gas, being of high calorific value, is used as a fuel while the flue dust is sent to the
RM-MHP where it is blended with the iron ore fines and used in the sinter plant for steel
manufacturing. It involves installation of wet scrubbers and venture tubes.
2. ESPs have been installed in the Sinter and other Plants to reduce Fine dust particle emissions.
3. At some units, Bag Filters and Battery Cyclones have been installed to reduce air pollution.

WATER EFFLUENTS:-
Water from Telughat Dam is the source of all the water used in the BPL arena. Continuous Sampling,
Analysis and Monitoring of the effluent water from various plants is done on a regular basis. Effluent
water from different plants is treated before being dumped, through the Outfalls, in Damodar River. The
major amount of water used in steel plant is for cooling purpose, which are recycled as show in the figure
shown below:












There are 3 outfalls:-
1. Outfall 1 receives water from CO & BPP, SP, RMP and Power Plant
2. Outfall 2 receives water from CCS, SMS- 1 & 2, HSM, CRM and Slabbing Mill section
3. Outfall 3 receives water from Auxiliary Shops, Operation Garage and Bokaro General Hospital
In the process of operation, water is used and discharged after use, which is collected into outlets and
outfalls. To monitor the potential load of pollutants, the effluent/ waste water are monitored at the
following locations:
1. Outfall no. 1
2. Outfall no. 2
3. Outfall no.3
4. TPP Outlet
5. BF clarifier outlet
6. CO & BPP
7. RMP & BF Outlet
8. Sinter plant outlet
9. CRM outlet
10. SMS outlet




Integrate
d Steel
Plant
97%
1.5 % Losses
1.5 %
Outflow
Make Up
34


Standard Parameters:-
1. pH - 5.5 to 8.5
2. Oil -10 mg/l
3. Phenol - 1 mg/l
4. Cyanide - 0.2 mg/l
5. Ammonical Nitrogen - 50 mg/l
6. COD - 250 mg/l
7. BOD - 30 mg/l

Important Measures Taken:-
1. A Biological Oxidation and Dephenolisation (BOD) plant has been installed to treat the water from
Coke Oven & By Product Plant. This water after being treated is reused in the Coke oven
campus. Very small amount of it is being dumped in the Damodar River.
2. Retention Ponds have been provided for removing the Suspended Solids in the effluent water
from various plants before dumping it into the river.
3. Moreover, 5 oxidation plants have been provided in the Township area. The water treated from
these ponds can be used up in the plant. This is an initiative to cut the dependency on fresh
water from the dam for plant use.

NOISE LEVELS:-
As per the prescribed norms the noise levels in the work zone area should not be more than 90 db.
In those regions where noise levels cant be controlled, then presently Ear Plugs have been provided to
the workers in order to avoid any harm being caused to their hearing abilities.



SOLID WASTE MANAGEMENT:-
Important Measures Taken:-
1. In order to reduce Ash Generation, 70% of coal is being imported which has low ash content.
This coal is blended with 30% of indigenous coal and then utilized. This way ash generation is
being reduced.
2. LD Slag, a by-product of the steel making process, was previously dumped at separate locations
resulting in the formation of large heaps which trap solar heat, making it difficult (although not
impossible) for vegetation to take root; this encourages erosion and creates dangerous, unstable
slopes. To prevent this, nowadays, LD Slag is blended with the Iron Ore fines since they contain
residual Limestone and Dolomite. This way not only waste is being managed but its hazardous
impacts are also taken care of.
3. Continuous Cast House Slag Granulation plant have been installed in Blast Furnace 4 & 5 which
convert the Slag into granules which are used as a Raw Material in the Cement Industry that has
been set up by the collaboration of Jaypee Cements & SAIL.
4. The scale generated on the walls of mills contains Iron Oxide and therefore it is reutilized in the
manufacturing process. The scale is removed from the walls through water jets and then
35

transported to the RM-MHP, where it is blended with the Iron Ore fines and is thus further
utilized.
5. BF Slag, the limestone and iron ore impurities collected at the top of the molten iron, make up the
largest portion of ironmaking by-products. Sulfur dioxide and hydrogen sulfide are volatized and
captured in air emissions control equipment and the residual slag is sold to the construction
industry. While this is not a pollution prevention technique, the solid waste does not reach
landfills.
6. Slag is a major component of the waste produced in Basic Oxygen Furnaces. Because of its
composition, this slag, unlike that from the blast furnace, is best used as an additive in the
sintering process. As its metallic content is lower, it does not make a good raw material for the
construction industry.























WATER POLLUTION MANAGEMENT

The total world annual production of steel is 715.4 million tonnes of which India contributes 14.5 million
tonnes. On an average each tonne of steel production consumes 25 to 60 cubic meters of water and 4 to
5 tonnes of other raw materials. It may be noted that in developed countries the water consumption for
each tonne of steel production varies from 3 to 6 cubic meters, i.e., 8 to 10 times less than that of water
consumption in India. In recent years, due to increasing water scarcity, stringent regulation and public
awareness, the industry is in the process of upgrading or installing new wastewater treatment plants for
proper treatment of wastewater. The major water polluting units are the coke-ovens and by-product
plants from which highly contaminated toxic wastewater containing phenol and cyanide is generated.
Other effluents contain high amounts of oil, grease and BOD. Among the wastes from all the operational
units, spent liquor from ammonia stills, is the most polluting one.

Available data on plant wise water use is shown in Table 1.

Table 1: Water consumed (cum) per tonne of steel produced
Steel Plant Water consumed (m3) per tonne of steel produced
Rourkela (SAIL) 68
36

Bhilai (SAIL) 32
Bokaro (SAIL) 57
Durgapur (SAIL) 47
IISCO, Burnpur (SAIL) 42
TISCO Jamshedpur (TISCO) 25
Vizag Steel (Rastriya Plant Ispat
Nigam)
28

The water required in various processes in the steel plant may be used once and discharged or reused
or recycled. In the reuse system, the water used in one process unit is used again in other production
process without any treatment. After the second use, water is further used or discharged. In the recycling
system, all the water used in the process production is recycled after necessary treatment. Recycling
may be a closed loop system for individual process production or central closed circuit system for the
whole plant. The best way of preventing any negative effect on water resources is to have a completely
closed water recycling system. In the closed recycling system, due to the presence of salts in the water
whose concentration goes on increasing with each cycle, a certain amount of water has to be bled to
avoid scaling and corrosion in the water supply system.
Water use taken as a whole, considering all unit processes for the production of one tonne of finished
steel, may vary from 200-400 cum. Two thirds of this water is used for indirect cooling where heat is the
only contaminant. This water is segregated, cooled and recycled. Part of the balance of the one third
water carrying suspended solids only can be settled and recycled in the closed loop system. Rest of the
water gets contaminated with chemicals and other pollutants, like effluents from coke oven and
byproducts; plant, acid pickling, effluents from cold rolling mill and water treatment plant of boiler feed
waters, etc. Management of wastewater needs attention and care because this wastewater needs
special and rigorous treatment. The plants at Bhilai and Bokaro are having central cooling ponds and
water is being recycled. The plants at Durgapur and Rourkela are having recycling system for individual
processes. In the water balance schemes as originally framed, provision is there for making up for loss
of water due to evaporation and seepages only.






Impact of steel industry effluents on water bodies:
The major pollutional effects of the untreated wastewaters of steel industry if discharged into the
receiving water bodies are: toxicity to aquatic life, reduction of D.O., silting due to suspended solids,
taste and odor problems, temperature rise affecting the dissolved oxygen and aquatic life and formation
of oil slicks due to floating oil. Toxicity to aquatic life due to ammonia, phenols (monohydric, Polyhydric
and derivatives of phenols) and cyanide is well known. With the rise of pH value, the concentration of
free ammonia increases. Hence, ammonia toxicity is particularly severe at high pH. Due to discharge of
biodegradable organic substances from CO and BP plant into the water bodies, the soil and water
bacteria utilize the organic matter as source of carbon and dissolved oxygen (DO) in the water for the
respirational requirement.

Considerable quantities of suspended and colloidal matter in the discharge reduces the penetration of
sunlight. In the water bodies, resulting in reduction of Photosynthetic activity, an essential feature of self
purification of polluted water bodies. Suspended and colloidal matter can also smother bottom dwelling
aquatic organisms affecting the life of water bodies/streams and may lead to heavy siltation which affects
the flow.
Untrapped oil and grease from the effluent lead to formation of ugly oil slicks and iridescent, colour which
cause poor aesthetics. Oil slicks also reduce the diffusion of oxygen from the atmosphere to water
affecting self purification. Where steel plants are located on the coasts, wave action invariably brings
back oil and grease to the shore and spoils the beaches.
37


Coal-tar from coke oven and byproduct creates maximum physical problems. Light tar floats on water
and attaches itself to anything on its way giving an ugly appearance and heavy matter settles down
choking the pipes and cavities in waste treatment units. Phenolic substances in coke oven wastewater
are known to create taste and odor problems even at 0.002 mg/l level when chlorinated. Fish living in
water containing non-toxic level of phenol are found to be affected. Soluble iron and manganese are
known to give rise to bad taste in drinking water even at 0.1 mg/l.
Hot uncontaminated effluents in steel plants can reduce DO level and decrease the solubility of oxygen.
Nearly 2/3 of water consumed in steel plants is used for heat exchange only and requires' no treatment
except cooling. This water should be segregated, cooled and recirculated.














































Transport & Storage
Crushing
Limestone Coal Ore
Lime Burning
Coking
Sintering or
Pelletizing
Particulates
SOx, NOx
SS,BOD,
NH3 ,CN,
Phenol
Hydrocarbons,
Steam,
Particulates, CO,
SO2, NO2, H2S
Hydrocarbons,
Particulates, CO,
SOx, NO3, HF,
Noise
Lime Coke Sinter
Crushing or
Screening
Particulates
Steam
38


































Figure: Schematic flow diagram linking pollution and principal operations


OUTLINE OF EFFLUENT TREATMENT PLANTS:
The purpose of waste water treatment is to obtain clean effluent by removing the pollutants from the
waste water, or decomposing the pollutants in the water to make them lose their properties as pollutants.
When planning to construct a waste treatment plant, the following conditions must be considered during
preliminary studies.
i) Exact and detailed analyses about raw materials and production processes used in the factory.
ii) Studies on the qualities and quantities of waste water and their changes with time.
iii) Studies on the environmental conditions of the factory or plant concerned such as its geographic
location and the condition of the water area into which waste water is to be discharged.
Thus, the construction plan of a waste water treatment plant must be promoted by taking into
account the results of such preliminary studies.



Iron making
Pretreatment
Steel Making
Ladle treatment
Ingot or
Continous casting
Reheating
Scarfing
Hot & Cold
Rolling
Steel
Particulates, CO, SOx, NO3, ZnO
SS,BOD, NH3 ,CN, Cl, sulphates
Particulates
Particulates, CO, SOx, NO3, ZnO
SS,BOD,CN
Steam
SS, Oils
Particulates, SO2, NOx
Particulates, Noise
Noise
SS, BOD, chromates
Slag
Slag
Slag
Sludge
Sludge, Mill
scale, Oily
waste
Cooling or
Granulation
Crushing
Crushing
Particulates
Particulates
BOD
Blast
Furnace
Steel Furnace
Air Pollutant
Water Pollutant
Solid Wastes
Integrated Iron&SteelPlant
Contaminated
Effluents
TREATMENT
Clarifiers/Thick
eners

Sludge Settling
HEATED
WATER

COOLING
39







The figure shown above depicts the treatment system employed in a steel plant.
CO & BPP:
The total water usage at a coke plant is a function of the plant size, the extent of by-product recovery,
the design of specific units, and the degree of water recycling. Total demand, as reported by the US
Environmental Protection Agency(EPA) varies from 1150 m
3
h
-1
to 10225 m
3
h
-1
. Of this total, 70-95% is
normally used for indirect cooling and for condensing steam and the only adverse change is the
temperature increase. The main sources of contaminated liquid wastes from a by-product coke plant are
excess ammonia liquor, final cooling water overflow and light oil recovery (benzol plant) wastes. Minor
wastewater sources include coke wharf drainage, quench water overflow and coal pile runoff. Critical
contaminants include ammonia, cyanide, phenol, sulfide and their compounds, BOD, oil and suspended
solids.
The method of disposal can cause serious manufacturing and environmental problems. Examples:-
1. Air pollution can be created by the contaminants in wastewater which, instead of being
destroyed, are simply volatilized and discharged to the atmosphere.
2. Some of the contaminants in the quenching wastewater are entrained in the coke and are carried
over to the blast furnace. As an example, the high chloride content of wastewater then causes
deterioration of the structural components of the blast furnace.
3. Quenching mist can cause extensive corrosion to neighboring areas due to deposition of salts
and oxides of sulfur.
At plants where the coal has low chlorides and sulphate content, these problems are less severe.
Table 2: Sources of Process Wastewater from Coke Oven Byproducts Plants
Sr. No. Unit operation Pollutants
i. Coke quenching Coke breeze, sulphurous acid (also ammonia, phenol, cyanides and
hydrogen sulphide when spent ammoniacal liquor is used for coke
quenching).
ii. Cooling, scrubbing and refining
a) Flushing liquor Tar free ammonia
b) Condensate pits Tar, crude ammoniacal liquor, some benzol
c) Machine house Tar, crude ammoniacal liquor, some benzol
d) Dephenolation plant Tar, crude ammoniacal liquor, some benzol
e) Potash plant Sodium carbonate and bicarbonate, sodium ferrocyanide, thiocyanate
and hyorosulphide.
iii. Fainal coolers Ammonia solution, wash oil (220 to 315C fraction of tar)
iv. Ammonia stills Ammoniacal liquor
v. Benzol plant Wash oil benzol
vi. Tar distillation plant Tar, light oils, tar oils
40


vii. Carbolic acid unit Phenols, benzol, sodium sulphate cum-suIphuric acid solution
a) Composite effluent pH value 8.5 to 9.5
b) Thiocyanate 50 to 100 mg/l
c) Thiosulphate 110 to 220
d) Total ammonia 800 to 1400
e) Sulphide 10 to 20 mg/l
f) Cyanide 10 to 50
g) Phenol 500 to 1000
h) Chloride 4000 to 4200

Wastewater management in COBP involves, firstly, reduction in pollutants load in process wastewater
and, secondly, proper operation and maintenance of the BOD plant to obtain the desired performance.
Treatment of COBP wastewater is achieved by giving physico-chemical (primary treatment), followed by
biochemical treatment. The primary treatment consists of equalisation and physico-chemical separation
of suspended, dissolved or emulsified oils and tar. Biochemical treatment is given in Activated Sludge
Process (ASP) or Trickling filters. The biological treatment is achieved in multiple stages to meet the
prescribed norms. These wastes can be treated in admixture 50-50 with raw sewage with a view to bring
the toxicity of phenol to acceptable levels. It can also be treated biologically without addition of sewage
but it is advisable to dilute it with water or some non-toxic wastes so as to keep the phenol level less
than 200 mg/l and preferably below 100 mg/l. For biological treatment, wastewater is to be cooled if it is
hot. It should be ensured that nutrients required by the micro-organism are available. The CO & BP
wastewaters are rich in nitrogen but not so in phosphorous which is required to the extent of 1% of/the
BOD.

The performance of BOD plants depend on proper design, inlet concentrations of pollutants, type of
treatment units, operation and maintenance, availability of trained manpower, etc

Carbon Treatment Method
Trace concentration of phenol from wastewater from CO & BP can be removed by adsorption on
granulated carbon. This process can be directly applied to undiluted effluents from the ammonia still,
final cooler blowdown, light oil decanter liquor and fractional ion condensate without previous biological
treatment. In addition, all the streams which have been bio-treated and diluted can further be carbon
treated. Therefore, carbon treatment is either an alternative or an adjunct to biological treatment.
Efficiency of carbon treatment in comparison to bio-treatment is furnished in Table 5.

Table 3: Efficiency of Carbon Treatment to bio-treatment
Parameters % Efficiency of Untreated stream Removal biotreated stream
BOD 80 72
Phenols 90 81
Cyanide 90 81
Ammonia 0 0
Suspended
solids
90 81
Sulphide 100 90
Oil 90 81

The secondary residuals from this treatment process are particulate and sulphur dioxide from carbon
regeneration in the reactivation of carbon by burning off the adsorbed residuals. However, this method is
costlier than bio-treatment.

Sintering:
Sinter plants require relatively small quantities of water for sinter mix preparation, air and exhaust gas
cleaning and for indirect cooling of sintering equipment. Most wastewater is discharged directly from the
41

air and gas cleaning operations with the balance evaporated. Dry gas cleaning operations are used
which virtually eliminate contaminated water discharges. However if mill scale is used as a part of sinter
mix, difficulty can be experienced with the use of bag filters and ESPs since volatilized oils clog the filter
cloth or cause explosions. For this reason, high energy water scrubbers are often used at these
installations. Wastewater from the air scrubbers is treated, either alone or in combination with blast
furnace gas cleaning wastes, for suspended solids removal and either discharged directly or partly
recycled. The settled solids are dewatered for re-use in the sintering process.

Contact water applications for air cleaning have been reported by US EPA to be from 434 to 14201 T
-1
of
sinter produced with associated wastewater suspended solids concentrations from 4340 to 19500 mg/l
and oil and grease concentrations from 504 to 457 mg/l.

Blast Furnace:
Water is used in the blast furnace area for non-contact cooling of furnace walls and hearth and stove
walls and for contact cooling and cleaning of blast furnace gases. Lesser amts are used for cooling slag,
production of steam for turboblowers and steam condensation. Additional water enters the area as a
result of runoff from raw material storage piles.
Non-contact cooling water quantities of approximately 21000 T
-1
of iron produced is reported by USEPA.
Blast furnace gases are cleaned first by dry dust catchers, followed by wet washers, disintegrators and
ESPs. Depending upon the gas produced, water application for cleaning as reported by USEPA can
range from 6300 to 17000 T
-1
of iron produced. The wastewater is characterized by a high suspended
solids concentration, the major portion of which is removed by settling in thickeners before the
wastewater is recycled or finally discharged. The settled sludge is dewatered and either disposed of at
landfills or recycled to the sinter plant. Additional contaminants in water include phenol, cyanide, fluoride
and their compounds.
Significant quantities of contaminated wastewater occur as runoff from precipitation, especially from the
areas of material storage. Runoff from limestone storage areas would contain suspended solids, have a
high pH and be extremely hard due to dissolved calcium; ore storage runoff would contain high amounts
of iron.


Steel making processes:
Basic oxygen furnace:- Water used in steel making processes is generally for indirect cooling of
furnaces and equipment, gas cooling and cleaning, for the cooling of seals and at barometric
condensers. Where vacuum degassing is installed, steam condensing water is required. Cooling of gas
in basic oxygen furnace is done by waste heat boilers and quenching sprays. The spray water may
evaporate completely or produce a residual effluent which is added to scrubber recirculating system.
Gas cleaning is accompanied by dry, semi-wet and wet methods. The dry method does not require
contact method and semi-wet method should operate on an exact water balance with no direct water
discharge from the system due to complete evaporation of the spray water. The wet method utilizes high
energy scrubbers for solids removal. The cleaned gases may be discharged, flared or stored for use as a
fuel. Water use for gas cooling and cleaning at BOF installations, according to USEPA, ranges widely
from 209 to 3700T
-1
of steel produced. Contact water use at vacuum degassing facilities ranges from
1300 to 2900T
-1
of steel degassed. All of the above contact waters contain suspended solids, iron oxide,
some trace metals(e.g. Zn,Cd) and fluorides. The wastewaters from scrubbers flow to thickeners where
the major portion of entrained solids settles and supernatant water overflows for recycle or discharge.
Additional contact water may be used in slag cooling and in the ingot casting areas. The slag is usually
air cooled and any water used is evaporated on site.
42

Electric arc furnaces:- Water is used at electric arc furnaces for 3 purposes- indirect cooling of the
furnace and associated equipment, gas conditioning and gas cleaning. Gas conditioning requires large
volumes of water which is applied to lower the temperature of gas for subsequent solids removal in
either wet or dry systems similar to those used in basic oxygen furnace systems. The wastewaters from
the contact is also similar to the BOF system. In the electric arc furnace process, the collected gases are
ducted to Bag house / wet scrubber/ ESP. Water is used for cooling the furnace and certain components
of the electric gear. This water leaves the furnace at a higher temperature. Suspended solids in the
water are in the range of 1000-5000 mg/l. Where wet scrubbers are used, process water is piped to
thickeners where suspended solids settle down and clean water is recycled.

Vacuum degassing:
Vacuum degassing is a process of removing gases from molten steel. The molten metal is placed under
a vacuum generated by a multiple-stage steam jet ejectors. In order to create the vacuum required, the
steam must be condensed with barometric condensers. This water is contaminated by gases removed
from the molten metal and and with certain elements which were volatilized in the degassing process.
This water is usually recirculated and combined with other water systems.

Pig Casting:
While casting pig iron, heavy lime solution is sprayed on the moulds of the pig casting machine to
prevent sticking of pig iron in the moulds and to ensure release of it after the metal has solidified and the
moulds are inverted. Water is sprayed on the moulds and pigs for cooling. This cooling water contains
solid particles (scale and sand with high settling velocity). The wastewater from the casting machine is
led to the settling pits for removal of solids and effluents with high pH (around 10) are either- recycled
after-correction of pH or discharged.

Other processes:
In Continuous Casting process, the wastewater is produced in the apron spray zone and machinery
cooling is normally contaminated with mill scale and oil leakages from the machinery. This water is
treated in scale pits where scale and oil is removed.

In hot and cold rolling operation, the primary rolling mill effluent containing scale and debris (10 to 20
mesh size) at 100 .- 200 mg per liter and oil at. 10 - 25 mg per liter drop into the flumes below the
stands. Some oil also sticks to the scale. Otherwise, it is non-emulsified. The wastewater from
Secondary Mills is very similar to that of primary mills which contains mostly scale from the rolling
operations and some oil as leakage from the machinery. The wastewater from pickling operations
contains strong spent solution, rinse water and water used in fume scrubbers. Water used in fume
scrubber is generally encountered when acid other than sulphuric or phosphoric is used as an industrial
cleaning hygiene measure. In the Coating process, the wastewater originating varies considerably
depending on the plating material used. The spent solution and rinse water are the main sources of
wastewater.

Corrective measures:
Consumption of large quantities of water in Indian steel plants, despite being designed for total recycling,
warrants taking up corrective measures. Following are some of the measures which are used in steel
plants in India:.

Water Consumption and Pollution Reduction

Adopting improved technology in unit processes, especially in blast furnace rolling mills and pickling.
Adopting evaporation cooling system in the areas, like shell, cooling of blast furnace, door cooling in
SMS areas, etc., where indirect cooling is involved.
43

Adopting dry scrubbers, instead of wet scrubbers, for cleaning emissions.
Cooling of roller in rolling mills may be done with spray cooling system instead of using perforated
pipes. Twenty five percent reduction in water consumption by adopting this method coupled with efficient
cooling was reported from the erstwhile USSR.
Adopting cascade method of washing metal which require only 25% of water presently used. In this
method, washing channel is divided into
3-4 sections and the fresh circulating water is fed into the last section along the route of the metal. Water
is then pumped out to the next section to meet the advancing metal.
Adopting the recent developed technology to remove scale from the rolled metal without the use of
acid, resulting in elimination of pickling acidic effluents.

Effluent Treatment

Proper operations and maintenance in COBP process units should be ensured to the maximum
possible extent to minimize spillage, leakages of
condensate, blow-down, etc., as these increase the quantity of combined wastewater. Quantity of
effluent from COBP units should be kept more or less constant.
Ammonia and cyanide concentrations influent should be reduced with proper operations and
maintenance of ammonia stills.
Regular maintenance of hydraulic mains and proper operations of tar decanters will helps in minimising
hydraulic shock loads to BOD plants.
100% utilisation of COBP effluent from BOD plant should be achieved by quenching of hot coke and
granulation of slag.
High cyanides bearing streams, such as seal pot effluent, gas condensate, etc., can be segregated and
reduced back to the hydraulic main. This stream can also be treated separately by injecting CO
2
gas in a
free leg type reactor to form HCN before mixing with the combined influent to BOD plant. This will help in
reducing the concentration of cyanide in the combined wastewater and subsequent load to BOD plant.
Non polluting streams, such as cooling tower, blow-down, the benzol plant, saturates and other units,
may be segregated from the combined effluent to the BOD plant. This will help in reducing the hydraulic
load to BOD plant.
Sludge generated from the BOD plant should be reused as fuel after mixing with coal..
Discontinue the use of NaOH for pH control in the BOD plant, Alternatively,use Na
2
CO
3
solution, which
can be a source of inorganic carbon for nitrifying the organisms. It is necessary to maintain pH in the
range of 7.5-8.5 in the second stage in the aeration tank.
Increase Mean Cell Residence Time in the second stage aeration tank with continuous recirculation of
sludge.
Every BOD plant should have separate bacterial tanks for individual biological treatment units to
maintain stock of the acclimatised biomass to the supplemented in case of death or loss of biomass in
the system during breakdown.
Concentration should be properly maintained and if required addition of micro nutrients, like iron,
manganese, zink, cobalt, etc., to be considered.
To reduce consumptions of chemicals for pH control, attempts should be made to replace dilution water
with alkaline process wastewater from other process units.
Energy meters should be installed at BOD plants.
An approach should be made to attain zero discharge from COBP plant by using the treated
wastewater of BOD plant in quenching operations.
Ammonia at the inlet of the BOD plant is converted into nitrate in biological treatment. Therefore, the
quantity of ammonia at the inlet be reduced and should be as far as possible from the source. Similarly,
44

cyanide also interferes in biological treatment. Hence lowering of cyanide levels is also required at the
inlet of the BOD plants.
OXIDATION PONDS:
Oxidation Ponds are also known as stabilization ponds or lagoons. They are used for simple secondary
treatment of sewage effluents. It contains partially treated wastewater which is then left to allow the
growth of algae and bacteria which decompose the rest of the waste and analysed for selected 9 Physio-
Chemical parameter for 3 times. It was found that TSS and BOD were exceeded the norms for all
oxidation pond but other parameter were found to be within the norms.
There are five oxidation pond in Bokaro.
1. oxidation pond Sector xii
2. oxidation pond Sector vi
3. oxidation pond Dhandabra
4. oxidation pond Camp II
5. oxidation pond BGH
Typically oxidation ponds need to be less than 10 feet deep in order to support the algal growth. In
addition, the use of oxidation ponds is largely restricted to warmer climate regions because they are
strongly influenced by seasonal temperature changes. Overall, oxidation ponds tend to be inefficient and
require large holding capacities and long retention times. The degradation is relatively slow and the
effluents containing the oxidized products need to be periodically removed from the ponds.
RETENTION POND:
Retention ponds are used to catch storm-water runoff from landscaping and roadways. The water is held
in the basin so dirt and pollutants have a chance to settle to the bottom. Many times, a retention pond is
simply a large depression surrounded by a fence. However, retention ponds are more attractive and
functional if populated with native aquatic and bog-loving plants that help filter runoff and attract wildlife.
There is one retention pond in Bokaro steel city.


OIL CATCH PIT:
There is one oil catch pit situated at the outfall 2.

Energy Conservation:
Energy conservation is a high priority area at Bokaro. Optimisation of energy consumption is a
continuous process. The Coal Dust Injection system, better quality Coke and Oxygen enrichment have
significantly reduced the coke rate in Blast Furnace. Efficient power distribution and load management
45

also help in saving energy. The Continuous Casting Shop and the Walking Beam Reheating Furnace at
Hot Strip Mill are examples of the adoption of energy efficient technology.

An overview of water consumption in april 2012
(Unit 1000CuM)
Water received from tenughat 11526
Water received per hour 16.008
Water received by rainfall 0
Cooling pond 1(area 3.25 sqkm)
Level in month beginning(m) 217.78
Level in month end(m) 217.57
Drop in level(mm) 210
Water drawn(1000 CuM)(X) 683
Cooling pond 2(area 2.25 sqkm)
Level in month beginning(m) 217.78
Level in month end(m) 217.59
Drop in level(mm) 190
Water drawn(1000 CuM)(Y) 427
Sludge compartments(area 0.5 sqkm)
Level in month beginning(m) 223.20
Level in month end(m) 223.20
Drop in level(mm) 0
Water drawn(1000 CuM)(Z) 0
Water drawn from reservoir use(X+Y+Z=D) 1110
Drinking water consumption(E) 6548
Water losses by evaporation(F) 1397
Water used by power plant(G) 1750
Seepage losses in CPs & SCs(H) 1530
Water consumed in plant(J=A+B+D-E-F-G-H) 1411
Crude steel production(tonne)(K) 307876
Water consumption/T of crude steel (J/K) 4.58
Water distribution for the same month
Water pumped
PH1/VERT 45300 PH1/HOR 13393
PH1/WCTP 648 PH2/VERT 53280
PH3/GCP 6840 PH4A 4320
PH4B 1294 CPH 3315
TOTAL 128390

Water recirculated
Turbo generators 13680 Turbo blowers 21600
46

Turbo compressors 11564 Captive powerplant(make up only) 1800
Blast furnaces 11000 Pig casting machines 1052
BF/Gas cleaning plants 4800 Sinter plant 3210
Coke oven & BPP 143 Central compressor plant 4168
Oxygen plant 3724 Steel melting shop-I 3188
Steel melting shop-II 1462 C.C.D 4406
Steel foundry 400 Ingot mould foundry 315
Iron & copper foundry 204 Mechanical shops 140
Refractory material plant 358 RM&MHP 214
Gas booster 322 Slabbing mill 3221
Hot strip mill 16300 H.R.C.F 143
Cold rolling mill 12004 Sulphuric acid plant 284
TOTAL 119702
Water not-recirculated
W.C.T.P 648 Coke oven & BPP 1800
Continous casting M/c 504 Township/WTR treatment plant/ADM bldg 3900
Works/Water treatment plant 1728 Slag granulation plant 108
TOTAL 8688
Water not pumped
Township/WTR treatment plant/sec-9 920
TOTAL WATER NOT RECIRCULATED 9608

Freshwater received from tenughat 11526
CIRCULATION LOSSES 1918
STANDARD CERTIFICATIONS
Quality Assurance:
The Bokaro Steel Plant for continous improvement and maintaining standards has gone for following
certifications:
ISO 9001:2000 QMS Certification
The ISO 9001 family of standards are related to quality management systems and designed to help
organizations ensure that they meet the needs of customers and other stakeholders. ISO 9001 deals
with the requirements that organizations wishing to meet the standard have to fulfil. ISO 9001:2000
specifies requirements for a quality management system where an organization
1. needs to demonstrate its ability to consistently provide product that meets customer and
applicable regulatory requirements, and
2. aims to enhance customer satisfaction through the effective application of the system, including
processes for continual improvement of the system and the assurance of conformity to customer
and applicable regulatory requirements.
All requirements of this International Standard are generic and are intended to be applicable to all
organizations, regardless of type, size and product provided.
47

Although, ISO 9001 family had many versions but the 2000 version sought to make a radical change
in thinking by actually placing the concept of process management front and center ("Process
management" was the monitoring and optimisation of a company's tasks and activities, instead of
just inspection of the final product). The 2000 version also demanded involvement by upper
executives in order to integrate quality into the business system and avoid delegation of quality
functions to junior administrators. Another goal was to improve effectiveness via process
performance metrics: numerical measurement of the effectiveness of tasks and activities.
Expectations of continual process improvement and tracking customer satisfaction were made
explicit.
Thus, in its pursuit of excellence and enhanced customer satisfaction, Bokaro has gone for ISO
9001:2000single certification for all units form Coke Ovens to Cold Rolling Mill complex. Bokaro products
are well-received in both developed and developing countries. The CR products are packaged using
HDPE cloth/polythene sheet, metal sheets and edge protectors to maintain brightness and for protection
against corrosion and edge damage during transit. Similarly the HR coils are strapped to prevent
damage.
ISO 14001:2004 EMS Certification
For Environmental measure and control Bokaro steel plant has been certified by ISO 14001:2004 EMS.
The ISO 14001:2004 Environmental Management Systems (EMS) certification enables an organization
to demonstrate its commitment to the environment. The standard provides guidance on how to manage
the environmental aspects of your business activities more effectively, while taking into
consideration environmental protection, pollution prevention and socio-economic needs.
ISO has many other standards dealing with specific environmental issues. The intention of ISO
14001:2004 is to provide a framework for a holistic, strategic approach to the organization's
environmental policy, plans and actions. It also assists you to ensure compliance with environmental
legislation and reduces the risk of penalties and possible litigation. Demonstrating commitment to the
environment can transform corporate cultures externally by opening up new business opportunities with
environmentally aware customers or clients. Internally, it can improve employee ethics and the
workplace. ISO 14001:2004 compliance can also provide a company with a better use of energy and
resources, and reduce costs over time. Thus ISO 14001:2004 is a tool to:
Demonstrate that the internal environmental objectives have been achieved
Provide assurance to management that it is in control of the organizational processes and
activities that impact environment
Assure employees that they are working for an environmentally responsible organization
Provide assurance on environmental issues to external stakeholders such as customers, the
community and regulatory agencies
Comply with environmental regulations
Support the organization's claims and communication about its own environmental policies, plans
and actions
Provide a framework for demonstrating conformity via suppliers' declarations of conformity,
assessment of conformity by an external stakeholder - such as a business client - and for
certification of conformity by an independent certification body
OHSAS 18001:2007 Certification
For necessary Safety Measures & proper training of personnel, Bokaro steel plant has been certified by
BS OHSAS 18001:2007. Managing health and safety (OH&S) issues in the workplace represents an
enormous challenge due to varying human nature, skills set, process complexity & local culture and have
implications for everyone at the workplace. Effectively managing these issues means taking account not
48

only of legal requirements, but also the well-being of any personnel in the organization. Achieving OHS
performance with improved well being is the need to assure the regulatory bodies, customers and other
stack holders due to high premium cost for any incident.
Certification to OHSAS 18001 show the commitment to the health and safety of employees,
demonstrates your ability to manage risk & hazards associated with the activities and provide assurance
to all concerned including customers and management that legal compliance is effectively managed.
Implementation of OHSAS 18001 policies gives systematic approach to minimizing health and safety
risks and provide a framework for an organization to manage its legal compliance and improve
occupational health and safety performance, including risk and opportunity identification, analysis, target
setting, and measurement.
OHSAS 18001 is basic and globally recognized standard for occupational health and safety
management systems and is applicable to any organization in any business sector. Effective
Management of Health and Safety risks will help:
Demonstrate your commitment to the protection of employee, property and plant.
Minimize the number of accidents and production time loss due to better control over hazards at
the workplace
Focus on employee safety results in a satisfied, motivated and highly productive work team.
Increase control and reduction of hazards through the setting of objectives, targets and evolved
responsibility.
Maximize the well-being and productivity of all people working for the organization.
Encourage better relationships with contractors and more effective contracted activities.
Reduction in insurance premiums & workers compensation
Demonstrates an innovative and forward thinking approach
Ensuring legal compliance
Improve safety culture & your reputation in the eyes of customers, competitors, suppliers, other
stakeholders and the wider community.

A BRIEF LOOK OVER INDUSTRYS
ENERGY REQUIREMENTS
Table 4: Energy Balance Summary Sheet for period Apr2012
S.No. SHOP/UNIT GCAL/T
of
Product
PRODUCTION RATIO
Actual Balanced
GCAL/T Consumed
Actual Balanced
1
2
3
4
5
6
Coke Oven
Sint. Plant
Bl. Furnace
S.M.S-I
S.M.S-II
Con.Cast
1.634
0.578
3.303
0.346
0.209
0.099
0.615 0.569
1.066 0.931
1.137 1.001
0.322 0.322
0.678 0.678
0.678 0.678
1.006 0.930
0.616 0.530
3.764 3.357
0.111 0.111
0.142 0.142
0.067 0.067
49

7
8
9
10
a)
b)
c)
d)


Slab. Mill
HSM&HRCF
CRM&CRCF
Aux&Losses
RMP
Oxy. Plant
Minors
Losses

0.864
0.705
1.332

1.603
2.561
0.204
0.098


0.223 0.236
0.897 0.857
0.164 0.167

0.101 0.101
0.270 0.065
1.000 1.000
1.000 1.000

Total:
0.193 0.204
0.633 0.604
0.216 0.249

0.161 0.161
0.166 0.166
0.204 0.204
0.069 0.068

7.348 6.253

Table 5: Energy Balance Summary Sheet for period Apr2012
S.No. ITEM UNIT QTY. ENERGY
VALUE
GCAL/UNIT
TOTAL
ENERGY
MGCAL
1.0 Input Energy
1.1 Coking Coal
1.1a Ind
1.1b Imported

Tonne
Tonne

64354
191708

6.501
6.501

0.418
1.246
1.2 CDI Coal Tonne 12033 6.501 0.078
1.3 Purchased Coke Breeze Tonne 0 6.236 0.000
1.4 Purchased B.F. Coke Tonne 44023 6.236 0.275
1.5 Purchased Power
1.5a BPSCL
1.5b DVC

MWH
MWH

88173
95805

2.400
2.400

0.212
0.230
1.6 Process Steam Tonne 450119 0.661 0.296
1.7 Diesel KL 667 10.000 0.007
1.8 Fce Oil KL 110 8.875 0.001
1.9 LSHS KL 0 8.875 0.000
1;10 Purchased Nut Coke Tonne 800 6.236 0.005
1.11 Liquid Oxygen Tonne 0 1.127 0.000
1.12 Oxygen from BOD Plant 1000nm
3
21755 1.610 0.035
1.13 Propane gas Tonne 147 10.985 0.002
1.14 CBM gas 1000nm
3
193 7.961 0.002
1.15 Total Energy Input 2.807
2.0 ENERGY CONSUMED OUTSIDE
WORKS

2.1 Power to T/ship MWH 25843 2.400 0.062
2.2 Power to BOD Plant MWH 18115 2.400 0.043
2.3 Output subtotal #1 0.105
3.0 ENERGY SOLD & STOCK
3.1 B.F.Coke Tonne 0 6.236 0.000
3.2 Coke Breeze Tonne 0 6.236 0.000
3.3 Tar Product Tonne 138 8.500 0.001
3.4 Benzol Product Tonne 0 8.500 0.000
3.5 Granulated Slag Tonne 49742 1.070 0.053
3.6 Liquid Oxygen Tonne 1367 1.127 0.002
3.7 B.F. Gas to BPSCL TCM 130116 0.863 0.112
50

3.8 C.O. Gas to BPSCL TCM 3973 4.002 0.016
3.9 Output subtotal #2 0.184
4.0 ENERGY INPUT IN WORKS
(1.15-2.3-3.9)
2.518
5.0 ENERGY CONSUMED IN STEEL
WORKS

5.1 Actual energy used Mgcal 307676 7.370 2.269
5.2 Energy for saleable pig & skull
- Saleable pig & skull Production
- Energy consumed per t of pig
- Energy for saleable pig & skull

Tonne
Gcal/t
Mgcal

13420
4.776



0.064
5.3 Energy used exc. Saleable Pig & skull Mgcal 2.205
5.4 Energy for balanced steel production Mgcal 307676 6.783 2.068
6.0 OVERALL BALANCE
6.1 UNACCOUNTED LOSS
(4.0-5.1)
0.248













INDUSTRIES DEPENDENT ON STEEL
INDUSTRY
The Indian steel sector, being a core sector, enjoys overall major consumption by sectors like automobile
industry, consumer durables, and infrastructure (or construction, housing) industry. India is currently the
fifth largest steel-producing nation in the world with production of over 65.6 million tonnes (MT).
However, it has a very low per capita consumption of steel of around 51.7 kgs as against an average of
203 kgs of the world. This wide gap in relative steel consumption indicates that the potential ahead for
India to raise its steel consumption is high. Other sectors dependent on steel include electronic industry,
steel re-rolling mills, furnace units, mining sectors, rail-road industry and a wide variety of industries
share some kind of dependent or reciprocal relationship with the steel industry.
Since steel is ubiquitous in its use for construction and other purposes, the health of the industry can be
an indicator of overall global economic progress. If the steelindustry is healthy and there is a high
demand for its products, then that can be seen as a positive sign for the global economy.During the
period from 1997-98 to 2000-01, steel production witnessed a marginal CAGR growth of 3%. However
during 2001-02 to 2010-11, owing to boom in the infrastructure and automobile sectors, the industry
51

witnessed a sharp turnaround and registered a steep hike of 8.6% CAGR. Its fortune is dependent on
the growth of these user industries.
Some key points concerning growth of Indian Steel Industry are:
Supply With trade barriers having been lowered over the years, imports play an important
role in the domestic markets. Currently India is net importer of steel.
Demand The demand is derived from sectors that include infrastructure, consumer
durables and automobiles.
Barriers to entry High capital costs, technology, economies of scale, government policy.
Bargaining power of
suppliers
Low for fully integrated players who have their own mines for raw materials. High,
for non integrated players who have to depend on outside suppliers for sourcing
raw materials.
Bargaining power of
customers
High, presence of a large number of suppliers and access to global markets.
Competition High, presence of a large number of players in the unorganized sector.








REFERENCES
http://www.sail.co.in/pnu.php?tag=bokaro

http://www.sail.co.in/learning_cemter.php?tag=learning_center_coke_ovens

http://www.sail.co.in/pnu.php?tag=bokaro_facility

The Coke Oven By-Product Plant
Contributed by Mick Platts, ThyssenKrupp EnCoke USA

Training Module, Technical Library, Bokaro Steel Plant

Wastewater Treatment Technologies Commonly Practised in Major Steel Industries in India
By Dr. AHMED Sirajuddin , RATHI R. K and CHANDRA Umesh

http://www.istc.illinois.edu/info/library_docs/manuals/primmetals/chapter2.htm
52


Advances in Biological waste water treatment; V. Jegatheesan, C. Visanathan and R. Benaim;
School of Engineering James Cook University, Townsville, QLD 4811, Australia.
Nutrient requirement in biological industrial waste water treatment. Bashaar Y. Ammary, water
and environmental Engineering Dept., BalqaApplide University, Huson College. Huson.
The treatment of Wastewaters from Steel Plants
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Kohlmann Ruggiero Engineers, New York, USA

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Book-Treatment of Industrial Effluents by A G Callely, C F Forster and D A Stafford, published by
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http://www.ustudy.in/node/3148

http://www.equitymaster.com/research-it/sector-info/steel/Steel-Sector-Analysis-Report.asp

http://www.aster.in/iso14001-2004.html

http://www.dqsindia.com/iso-certifications/ohsas-18001-health-and-safety-management-
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www.sciencedirect.com

EMD & ECD Department, Bokaro Steel Plant

http://www.rpi.edu/dept/chem-eng/Biotech-Environ/FUNDAMNT/streem/methods.htm