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    Training Report On BSP

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    This training report summarizes Kunal Singh's visit to Bhilai Steel Plant from May 26th to June 7th, 2014 as part of his studies at the National Institute of Technology in Raipur. It provides a brief history and overview of Bhilai Steel Plant, including its founding, expansion over time, and current production capacity of over 7.5 million tons of steel annually. It also describes the major production facilities and processes at the plant from raw material intake to finished products.

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    Training Report On BSP

    Uploaded by

    sanchay3090
    2K views14 pages
    This training report summarizes Kunal Singh's visit to Bhilai Steel Plant from May 26th to June 7th, 2014 as part of his studies at the National Institute of Technology in Raipur. It provides a brief history and overview of Bhilai Steel Plant, including its founding, expansion over time, and current production capacity of over 7.5 million tons of steel annually. It also describes the major production facilities and processes at the plant from raw material intake to finished products.

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    Training Report on Bsp

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    Training Report on Bsp

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    This training report summarizes Kunal Singh's visit to Bhilai Steel Plant from May 26th to June 7th, 2014 as part of his studies at the National Institute of Technology in Raipur. It provides a brief history and overview of Bhilai Steel Plant, including its founding, expansion over time, and current production capacity of over 7.5 million tons of steel annually. It also describes the major production facilities and processes at the plant from raw material intake to finished products.

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    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    2K views14 pages

    Training Report On BSP

    Uploaded by

    sanchay3090
    This training report summarizes Kunal Singh's visit to Bhilai Steel Plant from May 26th to June 7th, 2014 as part of his studies at the National Institute of Technology in Raipur. It provides a brief history and overview of Bhilai Steel Plant, including its founding, expansion over time, and current production capacity of over 7.5 million tons of steel annually. It also describes the major production facilities and processes at the plant from raw material intake to finished products.

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    © All Rights Reserved
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    Download as docx, pdf, or txt
    of 14

    TRAINING REPORT ON

    BHILAI STEEL PLANT


    DURATION 26.05.2014 - 07.06.2014

    REPORT SUBMITTED BY: -

    KUNAL SINGH (12119037)

    INSTITUTION:- NATIONAL INSTITUTE OF TECHNOLOGY RAIPUR

    DEPARTMENT OF MECHANICAL ENGINEERING

    A Brief Introduction To Bhilai Steel Plant


    Bhilai Steel Plant, a unit of Steel Authority of India Ltd. is a
    public sector undertaking and was conceived under Indo-USSR
    Treaty in the 2nd Five year plan. This was in accordance with
    erstwhile government policy for strengthening economy and self
    reliance through development of core sector. The plant is located
    at the central position of India, which is one of the major iron belt
    of India, and it is about 40 kilometer from Raipur, capital of
    Chattisgarh. The captive mines of the plant located at DalliRajahara supplies iron ore and lime stone used to be available
    from Nandini captive mines. At present lime stone is procured
    from outside. The other major raw material, coal is purchased
    from outside either through import or from indigenous market.

    Bhilai Steel Plant, an integrated steel works, was commissioned


    in 1959 with production capacity of 1.0 million tonne of steel. In
    successive phases, capacity was enhanced to 2.5 and 4.0 million
    tonne in the year 1962 and 1984 respectively. Figure depicts
    facilities available with Bhilai Steel Plant for 4.0 mt production.
    As of now this is the largest steel plant in India with present
    capacity utilisation more than 100% for three consecutive years.

    Bhilai Steel Plant, an integrated steel works, was commissioned


    in 1959 with production capacity of 1.0 million tonne of steel. In
    successive phases, capacity was enhanced to 2.5 and 4.0 million
    tonne in the year 1962 and 1984 respectively. Figure depicts
    facilities available with Bhilai Steel Plant for 4.0 mt production.
    As of now this is the largest steel plant in India with present
    capacity utilisation more than 100% for three consecutive years.

    Bhilai Steel Plant - Major Landmarks


    Signing of Agreement for setting up of the plant

    Feb. 02, 1955

    Commencement of work at site

    May 06, 1956

    Commissioning of Coke Oven Battery # 1

    Jan. 31, 1959

    Commissioning of Blast Furnace # 1

    Feb. 04, 1959

    Commissioning of Power & Blowing Station

    Jun. 04, 1959

    Commissioning of Steel Melting Shop O.H. Fce # 1

    Oct. 11, 1959

    Commissioning of Blooming Mill 1150 stand

    Nov. 12, 1959

    Commissioning of Billet Mill

    Dec. 24, 1959

    Commissioning of Rail & Structural Mill

    Oct.27, 1960

    Commissioning of Sintering Plant # 1

    Jul. 03, 1961

    Commissioning of Merchant Mill

    Feb. 02, 1961

    Commissioning of Wire Rod Mill

    Sep. 01, 1967

    Commissioning of Sintering Plant #2

    Aug. 01, 1979

    Commissioning of Plate Mill

    Mar. 31, 1983

    Commissioning of Converter #1

    Jul. 29, 1984

    Commissioning of Continuous Casting Shop M/C #1

    Mar. 15, 1986

    Commissioning of First Twin Hearth (at SMS-1)

    Sep. 12, 1986

    Commissioning of Blast Furnace #7

    Aug. 30, 1987

    Commissioning of Coke Oven Battery

    Mar. 31, 1988

    Commissioning of Second Twin Hearth

    Jan. 01, 1990

    Commissioning of VAD unit at SMS-2

    Jan. 17, 1991

    Commissioning of Third Twin Hearth

    Jun 29, 1992

    Commissioning of Fourth Twin Hearth

    Jan 21, 1998

    Commissioning of Ladle Furnace at SMS-2

    Dec 23, 1999

    Commissioning of RH Degasser Unit at SMS-2

    Mar. 30, 2000

    Commissioning of Sintering Plant # 3

    Dec. 12, 2001

    Only Steel Plant in India to cross 5 MT

    Mar 31, 2006

    Curde Steel Production in the financial year.


    Bhilai's expansion & modernisation to 7.5 MT

    Feb. 09, 2008

    capacity inaugurated
    Bhilai repeats 5 MT + performance

    Mar. 31, 2008

    BSP FLOW PROCESS

    PLANT OVERVIEW
    S.No.

    Department

    Unit

    Capacity

    Coke Oven

    8 Batteries of 65 ovens and 4.3


    M high
    2 Batteries of 67 ovens and 7.0 M
    high

    3.3 million ton


    of BF Coke

    BLAST
    FURNACE

    3 Furnaces of 1033 Cum


    3 Furnaces of 1719 Cum
    1 Furnace of 2000 Cum

    4.71 mt of hot
    metal

    SMS-1

    4 Twin Hearth Furnaces

    2.5 mt of steel

    SMS-2

    3 BOF of 100/130 T capacity

    1.425 mt of steel

    CONCAST

    1000/700/500 mm Cont. Billet


    Mill

    1.425 mt of steel

    BBM

    3 BOF of 100/130 T capacity


    1000/700/500 mm Cont. Billet
    Mill

    2.15 mt of bloom

    RAIL AND
    STRUCTURAL
    MILL

    950/800 2 high reverseing Mill

    .75 mt of product

    WIRE ROD
    MILL

    4 strand continious Mill

    .4 mt of product

    MERCHANT
    MILL

    350 mm Cross Country Mill

    .5 mt of product

    10

    SINTERED
    PLANT

    1) 4 Machine of 50 Sq M hearth
    area
    2) 3 machine of 75 Sq M and 1
    Machine and 1 Machine of 80 Sq
    M hearth area
    3) 1 Machine of 320 Sq M hearth
    area

    8.3 mt of sinter

    BLAST FURNACES
    What is a Blast Furnace? BF is a counter current heat and mass
    exchanger, inwhich solid raw materials are charged from the
    top of the furnace and hot blast is sent through the bottom via
    tuyeres. The heat is transferred from the gas to theburden and
    oxygen from the burden to the gas. Gas ascends up the furnace
    while burden and coke descend down through the furnace. The
    counter current nature of the reactions makes the overall
    process an extremely efficient one.
    In the blast furnace process iron ore and reducing
    agents (coke, coal) are transformed to hot metal, and slag is
    formed from the gangue of the ore burden and the ash of coke
    and coal. Hot metal and liquid slag do not mix and remain
    separate from each other with the slag floating on top of the
    denser iron. The iron can then be separated from the slag in the
    cast house. The other product from the Blast Furnace is dust
    laden blast furnace gas, which is further cleaned in the gas
    cleaning plant and is used as a fuel all over the plant.

    Blast Furnace constructional features:


    A blast furnace has a typical conical shape. The sections from top down are:
    > Throat, where the burden surface is.
    > The shaft or stack, where the ores are heated and reduction starts.
    > The bosh parallel or belly and
    > The bosh, where the reduction is completed and the ores are melted down. The
    hearth, where the molten material is collected and is cast via the tap hole

    MACHINING ASSEMBLY & RE-ENGINEERING SERVICES-1


    ( MARS-1).
    MARS-1 has a vital role to play in maintaining the plant equipment so
    for as it supplies the bulk of spare parts required by the various units. It
    acquires an added significance by virtue of the finishing line of
    manufacturing activities of engineering shop . The product mix so
    arranged so as to meet the demand of both heavy and small spares. The
    shop is housed in three machining bays, 21 meters x182 meters each
    with an assembly bay of 24 meters x 96 meters .A total of 196 machine
    tools are engaged in direct production of spares, where- as the
    remaining contribute indi- rectly towards shop production. Apart from
    these, there are 12 Heat Treatment / Heating furnaces 22 material
    handling equipment (cranes,jib cranes transfer cars). The Annual
    production plan for MARS-1 during 2007-2008 is 6,40,000 credit
    hours.
    MAIN ACTIVITIES:Function wise MARS-1 carries out the following activities:
    1. Manufacture of spares, changables, tools, tackles etc. Required for
    maintenance and operation of various departments.
    2. Overhauling and repair of equipment sub - assemblies to the extent
    of those that can be transported to MARS-1.
    3. Reclamation of worn-out spares .
    4. Repair of certain equipment at site-especially where machining at
    site is required.
    5. Manufacturing and modification of equipment / spares for
    development work from the point of view of import substitution,cost
    reduction ,etc.

    BLOOMING & BILLET MILL


    Blooming & Billet Mill popularly known as "Mother Mill", is a
    primary mill designed to roll 2.5 MT/ Annum of ingots into semies in
    the form of blooms & billets. A two high reversing blooming mill and
    12 stands continuous billet mill are part of this department. The
    1150mm two high reversing Blooming Mill is designed to roll steel
    ingots into blooms for Continuous Billet Mill and Rail & Structural
    Mill. Average weight of steel ingots which are used for rolling is 8 to 9
    Ton.
    BLOOMING MILL
    The heated ingot are placed on the ingot buggy (two ingots at a time)
    by means of tongs crane which delivers it on to the receiving roller
    table of Blooming Mill.The Blooming Mill is a 2-High horizontal
    stand, equipped with individually driven rolls. Each roll of the
    Blooming Mill is driven by 930 V, 8000 KW, 0-20-80 rpm motor.
    Length of Roll - 2800 mm
    Dia. of Roll - 1150 mm (Min.1100mm & Max.1180mm)
    The Mill can roll square and rectangular blooms and also narrow width
    slab. Common Sizes of Blooms and Narrow Width Slabs
    i) 320 x 320 mm
    ii) 265 x 340 mm
    iii) 260 x 300 mm
    iv) Shaped blooms for Beam-450mm & Beam-600mm
    v) Narrow Width Slab 200 x 320 mm
    vi) Narrow Width Slab 200 x 420 mm

    BILLET MILL
    The Billet Mill has been designed to roll billets from blooms of cross
    section 325x325 sq.mm in 6 to 12 passes depending on cross section of
    billets to be produced in the Mill. The capacity of the Mill was
    designed to roll 15,01,000 Tonns/Year. But with modified output size
    of billets the mill is now capable of rolling to million tones per year.
    The Mill consists of 12 working stands arranged in three groups.
    a. The First group contains Two 2-High Horizontal stands with a 90
    deg. tilter in between. These stands are equipped with rolls of diameter
    1000mm and length 1200mm.
    b. The Second group called the roughing group contains 4 stand - 2
    each of Horizontal and Vertical stands arranged alternately. These
    stands are equipped with rolls of diameter 700mm.
    c. The Third group called the finishing group located after the transfer
    table contains 6 stands - 3 horizontal and 3 vertical stands arranged
    alternately. These stands are equipped with rolls of diameter 500mm.
    SECTION OF BILLETS ROLLED ARE
    1. 150 x 150 mm

    2. 110 x 110 mm

    3. 105 x 105 mm

    4. 100 x 100 mm

    5. 90 x 90 mm

    WIRE ROD MILL


    The 4 strand 250mm continuous Wire Rod Mill, commissioned on
    September 1 1967, was designed to roll 6, 7, 8, 10mm diameter wire
    rods from square billets of 80mm x 80mm cross section (of length 11
    to 11.8 meters) with rated capacity of 4,00,000 T per annum. The billet
    size was further enhanced to 85 mm2, 90 mm2, 100 mm2, 105 mm2 to
    improve in coil weight from 540 Kgs. to 930 Kgs. After the revamping
    of Right Side, sections 5.5 - 12 mm dia. wire rods are rolled in B ,
    C&D strands, whereas 8mm & 10mm are rolled on left side (A strand).
    BRIEF DESCRIPTION OF THE MILL
    Inspected billets are fed on the charging grate of the furnace by
    magnetic finger cranes. The billets are fed one by one to the furnace,
    through roll table and draw-in- roller mechanism. Billets are moved
    into the furnace by means of pushers at the charging end. Soaked
    billets are ejected out by means of Ejector Ram from the discharging
    end.
    The reheating furnace of the size 18Mx 12M is having 28
    burners, which includes 14 in the heating zone and 14 in the soaking
    zone. Mixed (Coke Oven & Blast Furnace) gas with calorific value of
    1800 K Cal/Cum is used in the furnace as fuel. Capacity of the furnace
    is 120T/Hr. Gas and air is preheated to 250c and 450c in metallic and
    ceramic recuperators respectively.
    The roughing group consists of nine horizontal stands in
    which combined drive is provided for stands 2-3 and 4-5; whereas
    stands 1, 6, 7, 8 and 9 are individually driven. All the drives are
    controlled by thyristor converter.
    Flying Shear is provided after stand no. 9 for front-end cutting
    & cobble cutting. First intermediate group has 6 horizontal stands, out
    of which stand No. 12 & 13 are not being used. Stand No. 10 & 11/14
    & 15 are used for rolling on all the strands. After stand No. 15, the Mill
    is divided in four strands, old line (A) and Modernised line (B,C&D).

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