Enhancing The

World Of Steel

Induction Report

Submitted by
POLY GERA
BSP0584
MANAGEMENT TRAINEE (BSL)

ACKNOWLEDGEMENT
I feel extremely indebted to our own organization Bhushan steel
limited for providing me a platform focused on development and
learning which will play a pivotal role in my journey of professionalism.
This induction program gave me exposure of all the departments in the
organization adding finesse to the technical acumen.
Firstly I wish to express my deep sense of gratitude to our managing
director Mr. NEERAJ SINGHAL for providing us this pool of
opportunity of learning.
My sincere thanks to our Human Resource manager Mr. ALOK
PANDEY for organizing this informative induction process. I would
also like to thank all the department heads of various departments for
providing such learning and illuminating environment and allowing me
to start my career in the best possible way, I could have ever imagined.

INDEX

Awareness of quality management system

Environment management
Raw material handling system & RMPP
Direct reduced iron
Sinter plant 1, 2, 3
Blast furnaces 1, 2
Coke ovens 1, 2
Oxygen plant
Lime plant
Steel making shop (BOF)
Hot strip mill
Cold rolling mill
Power plant

QUALITY MANAGEMENT SYSTEM

Definition of quality in industrial sector

It is ability of the material to perform satisfactorily in an application
for which it is intended by user.
Abilities to judge the quality of product

Suitability
Durability
Dependability
Safe workability
Affordability
Appeal ability

Eight quality management principle;

Customer focus
Leadership
Involvement of people
Process approach
System approach to management
Continual improvement
Factual approach to decision making
Mutually beneficial supplier leadership

What is meant by ISO?

ISO means international organization for standardization.
ISO is a worldwide federation of standard writing agencies from
over 180 countries now.

 It was formed after Second World War.

It develops product and organizational standards for industries.
All the standards are developed through consensus process.
Objective of ISO implementation
To create a commitment among employees for zero customer
complaint & for ensuring the product quality
To develop competency among employees
To create a confidence in customer Internal/external) that
organization is capable of delivering quality product
Some of the ISO designations are stated as follows:
ISO 9000
ISO 9001
ISO 9002
ISO 9003
ISO 9004

Fundamentals
Design
Manufacturing
Service
Guidelines

FIRE SAFETY TRAINING

FIRE IS CHEMICAL REACTION IN WHICH SUBSTANCE (FUEL) COMBINES WITH
OXYGEN MAKING AN EXOTHERMIC REACTION WITH THE EMISSION OF LIGHT,
HEAT & SMOKE

METHOD OF EXTINGUISHING
COOLING: Removal of heat (Best cooling media is water)
SMOTHERING: Reducing % of oxygen, cutting off the supply of oxygen.
(Blanketing, Use foam)
STARVATION: Removable of fuel and removable of combustible material.

FIRE CLASSIFICATION
CLASS A: - SOLID COMBUSTIBLE SUBUSTANCE. E.g. Wood, Paper, Plastic,
Coal.
CLASS B: - LIQUID COMBUSTIBLE SUBUSTANCE. E.g. Petrol, Diesel, HFO,
Wax, Paint.
CLASS C: - FLAMMABLE GASES. E.g. LPG, Hydrogen, Oxygen.
CLASS D: - REACTIVE METAL FIRE. E.g. Sodium, Magnesium, Aluminium.

FIRE EXTINGUISHERS
WATER TYPE EXTINGUISHER
It is best suited for combating fires involving Solid Organic Carbonaceous
materials like wood, paper, coal, plastic, cloth and rubber. Water knocks down
fire rapidly by striking, instantly Cooling and penetrating the most deep seated A
class fire.

FOAM TYPE EXTINGUISHER

It is powerful flame knockout agent for spill fires involving Flammable and
volatile liquids like petrol, paints and other solvents. Foam extinguishers form a
thick blanket of foam over the burning surface, effectively cutting off the oxygen
supply there by Smothering the fire and prevent re-ignition. Foam extinguishers
are effective against A & B class of fire.

DRY CHEMICAL POWDER

Dry Chemical Powder Extinguishers are versatile and highly effective against B &
C class fires, specially for combating three dimensional or running fires involving
inflammable liquids like petrol, paints and gases. They can also be used on
Energized Electrical Equipments.

CARBON-DI-OXIDE
Carbon dioxide fire extinguishing media is highly effective against B & C class of
fire. They can also be used on Energized Electrical Equipments.

RAW MATERIAL HANDELING SYSTEM (RMHS)

WAGON TIPPLERS
Tippler is used for emptying the loaded wagons by tipping it. Tippler retains
wagon from top as well as from side by using clamping devices provided on it.
Apart from that track stops, wheel grippers and different type of limit switches are
provided as features of wagon tippler.

Figure: Wagon tippler in action

For the expansion of Bhushan Steels steel plant at Meramandali, india, Larsen and
Toubro carried out the design, engineering, supply, erection, testing and
commissioning of the raw material handling system that included 43 kilometres of
belt conveyors.
Bhushan Steel Ltd. (BSL) is a globally renowned company and one of the
prominent players in the steel Industry. It is one of Indias largest manufacturers of
auto-grade steel and has transformed itself as the third largest producer of cold
rolled steel in the country.
Bhushan Steels Phase III expansion of its integrated steel plant at Meramandali,
Orissa from 3 to 6 million tonnes per year comprised of facilities such as blast
furnace, Direct Reduced Iron (DRI) kilns, sinter plant, basic oxygen furnace, coke
oven, steel melting shop, matching lime and dolomite plant including auxiliary
facilities such as coal/ore crushing, captive power plant, coal washery etc. Here it
is noteworthy to mention that Larsen and Toubro (L&T) was entrusted with the
responsibility for the complete Raw Material Handling System (RMHS) for
Bhushan Steels Phase III Expansion which is the largest executed by L&T till
date.
The Flow of Raw Materials
The production of steel requires various raw materials such as coal, coke, iron ore,
flux, mill scale, sinter etc. and they undergo processes like unloading, stacking,
reclaiming, blending, crushing, grinding and screening and are finally conveyed to
the sinter plant, coke oven battery and blast furnace. The RMHS in a steel plant is
designed to cater to these materials and is critical to achieve the desired production
capacity. The course of the material in this system is shown in Fig. 2.
Coal, limestone, dolomite and iron ore are unloaded by wagon tipplers, track
hoppers and truck unloading systems (BSL scope) and stacked in the stock yard by
yard machines and reclaimed.
Coking coal is fed to the coke oven battery after blending, crushing and mixing.
The quenched coke after segregation as per separation size is fed to blast furnace
stock house or base blending system.
Iron ore fines, limestone, dolomite from the stock yard, mill scale from trucks, nut
coke/coke fines from coke oven, sinter fines from stock house are fed to base
blending system for production of base mix. The sinter produced from base mix is

fed to blast furnace and emergency storage is available to ensure continuous feed
to blast furnace.
Iron ore fines from blast furnace stock house is fed to stock yard for feeding to
DRI plant and nut coke from blast furnace stock house is fed into base blending
system.
Non-coking coal is fed to coal washery and the washed coal (5 to 22 mm) is sent to
DRI plant for further processing. Iron ore lump from stock yard through Raw
Material Processing Plant (RMPP) and dolomite from trucks/ground hoppers is
also fed to DRI plant for processing. The output DRI is then fed to the steel
melting shop.
Blast furnace once ignited need to operate continuously, hence to ensure
continuous feed of material, all the raw materials such as blast furnace coke, sinter,
iron ore, additives, pellets are stored in the stock house and proportionately fed to
the blast furnace via charging conveyors.
The slag generated from the blast furnace is conveyed to the wagon loading area
for transportation outside the plant.
Non-coking coal (-6 mm) from the stock yard through coal crushing and screening
system is fed to a captive power plant
Operational Scheme
Based on the flow of material, the complete RMHS at Bhushan Steel is packaged
into various systems such as base blending system for sinter plant, coal and coke
handling system for coke oven, blast furnace stock house and charging conveyors,
yard machines, wagon unloading equipment and associated conveying system and
slag handling system. In addition to these systems, RMHS work for Bhushans
captive power plant and coal washery was also carried out by L&T. The major
scope (see Fig. 3) and working of each system is covered in the following sections

Wagon Unloading System

Run-of-Mine (ROM) coal, imported coal, limestone, dolomite and iron ore are
unloaded by five Rotaside wagon tipplers (three by others) and the truck unloading
system and are sent to stock yard through series of belt conveyors. In hauling of
loaded wagons, placement and out hauling of empty wagons is done by rack and
pinion type side arm charger (one for each tippler). The raw materials unloaded
from each wagon tippler are drawn by two nos. Apron feeders installed below the
hoppers and fed on to the conveyors below.
ROM coal is also unloaded at two track hopper complexes (twin type, 210 m long)
with four traveling type paddle feeders in each complex, see Fig. 4. The track
hopper unloads material from bottom discharge type wagon by opening gates
pneumatically/manually and the same is fed onto four underground belt conveyors
at the bottom of track hopper complexes
The material received from both the track hopper and wagon tippler stream will be
fed onto conveyors for transportation to stockyard via junction towers.
Stockyard and Yard Machines
Stockyard and the yard machines are designed to cater the raw material needs for
the 6 million tonnes per year stage. The stock yard is serviced by eight
stacker/reclaimers and three bucket wheel reclaimers (see Figs. 5 and 6). Out of the
total eleven yard machines, ten machines have been supplied and erected by L&T
including one stacker/reclaimer which comes within a covered storage area. The
brief specifications of the yard machines are furnished in Fig. 7.
Sinter Base Blending System
This circuit comprises of the raw material preparation and handling system for
feeding raw materials from stock yards to sinter plants SP2 and SP3, conveying
product sinter to the blast furnace stock house, coke and lump ore to blast furnace
stock house and handling coke/sinter fines generated in stock house.
The primary reason of adding sinter in the blast furnace is to increase its efficiency.
Sinter is produced using base mix in the base blending system and the course of
raw materials is given in the following sections.
Iron ore fines reclaimed from the yard will be discharged on to eight bins in the
base bin building through reversible shuttle conveyor and charging hatches.

Limestone and Dolomite Circuit

The limestone and dolomite reclaimed from the stock yard is fed on to the surge
bins in the flux crushing and screening building. The flux (+25 to 50 mm) is
crushed to predominantly (-3 mm) with the help of three reversible hammer mill
crushers (2W+1S) and the oversize material (+3 mm), screened using flip flop
screens, is crushed with the help of three secondary reversible hammer mill
crushers (2W+1S). The flip flop screens ensure recirculation of (+3 mm) size to the
secondary crushers. Thus (-3 mm) flux produced during closed loop crushing and
screening system is transported to the four bins in the base bin building through
four high angle conveyors (vertical conveying system) due to space constraint and
reversible shuttle conveyor. Vibro feeders are used to regulate the feed to crushers
and screens.
Coke Circuit
Coke fines arising from the existing plants and purchased coke unloaded in the
ground hopper are conveyed to six bins in the coke fines bunker building through a
series of conveyors. Coke from the coke fines bunker building is fed to the coke
crushing building through high angle conveyors. The coke is screened for 3 mm
separation using flip flop screens and the oversize material (+3 mm) is discharged
into four surge bins with the help of a reversible shuttle conveyor. Coke stored is
crushed with the help of rod mills (2W+2S) installed below respective surge bins.
Crushed coke (-3 mm) and screened out (-3 mm) is conveyed to the four bins in the
base bin building.
Base Mix and Product Sinter
The base blending building is the heart of the base blending system and it
comprises of 20 bins each of capacity 360 m3 to store iron ore, flux (crushed
limestone and dolomite), coke, mill scale and sinter fines. The bins are provided
with bin level indicators and air blaster system. The raw materials stored in the
base blending building are reclaimed at required proportion with the help of belt
weigh feeders to form the base mix. The base mix produced is stacked in either of
the stock yards by the twin boom stacker machine and the barrel reclaimer is used
to retrieve base mix across the full width. The barrel reclaimer machine will be
transferred to either of the beds by transfer car. One bed will have the formation of
the base mix while the other will be under reclamation. The reclaimed base mix is
conveyed to the sinter plant after necessary trimming, addition of coke fines and

lime fines. There is also a provision of transportation of base mix directly to the
sinter plant without stacking and reclaiming
Product sinter received from the sinter plant is either conveyed to an emergency
sinter storage building or directly to the blast furnace stock house. The emergency
sinter storage building consists of 16 bins each having a volume of 485 m3 to store
sinter as emergency stock.
Coal and Coke Handling
This system comprises of the coal circuit which carries coking coal from the yard
to the coal tower and the coke circuit that conveys the product coke to the blast
furnace and base blending system. The details of the system are given in the
following section.
The coal handling system is designed for a nominal capacity of 750 tph and caters
to the total coal requirement of two coke oven batteries and the plant will operate
365 days per year (two shifts per day). Its major sub systems are coal reclaiming
from yard, coal blending, coal crushing and mixing and coal tower feeding.
Coking coal stored in the yard is reclaimed by a stacker/reclaimer machine and fed
to one of 12 storage bins in the coal blending building. The bins are designed for a
total storage capacity of 8800 t (735 t each) corresponding to 20 hours storage
availability and Nitrogen inertising system is provided in each of the bins to avoid
any risks. To achieve the desired blend, coal stored in the bins is reclaimed at the
required proportion with the help of belt weigh feeders installed below each of the
bins.
The blended coal is fed to the rotating conveyor in the coal crushing building
which can feed to any of the four surge hoppers (one in future). Vibro feeders
installed below the surge hoppers feed the coal to four reversible hammer mill
crushers (2W+2S). The feed (0 to 50 mm) is ground to predominantly (-3 mm).
After crushing, the coal is transported to the mixing station using high angle
conveyors. A distribution system consisting of reversible belt feeders and diverter
gates feeds the material to three 750 t/h mixers (BSL scope). Subsequently after
crushing and mixing the blended coal is fed to the coal tower through a series of
conveyors. A coal sampler station is also installed in one of the conveyors to
collect samples to check the quality of blending.

The 500 t/h coke handling system is designed to operate continuously on three
shifts per day, 365 days a year. The quenched coke is dumped on the wharf and fed
to the wharf conveyor by means of 400 t/h plough feeders (BSL Scope). A cooling
water system is installed in both the wharf conveyors to avoid damage of belt
conveyors due to hot pieces (if any).
The material is then fed to the two vibrating grizzly screens (separation -80 mm)
inside the coke treatment building. The oversize material is fed onto two smooth
double roll crushers (BSL scope) to reduce the grain size. Subsequently the
screened out and crushed material (-80 mm) is screened by three double deck
screens (BSL scope) to segregate coke fines (0 to 15 mm), nut coke (15 to 25 mm)
and coke for blast furnace (15 to 80 mm).

DIRECTLY REDUCED IRON

A solid porous metallic mass
Appear like a honey comb structure with minute holes all over the surface
Produced through solid state reduction of iron ore
Escape of gaseous products
DRI Advantage
More Volumetric Weight :
Considerably higher (10-100%) than other types of scraps.
Consistent Chemical Analysis :
Avoids product quality deviations, residual element free.
Continuous Charging :
Eliminates scrap recharging; consistent power loading during melting.
Reduced Flicker & Noise Level :
Significant reduction in noise and flicker than that of scrap.
Reduced Nitrogen content :
Lower nitrogen level (~20 ppm) for 100% DRI.
Better Bath Stirring :
Highly effective bath stirring due to CO boiling.
Foamy Slag :
Easy Generation of foamy slag.

SL/RN Sponge Iron Plant

Rotary Kiln

ROTARY KILN

IMPORTANCE OF SIZE OF RAW MATERIAL IN DR PROCESS

5mm to 18mm size of Iron Ore mostly preferred for DRI production.
5mm to 20mm size of Feed Coal & Coarse Coal preferred.
0mm to 5mm size of Fines Coal preferred.
0 mm to 8 mm size of Dolomite preferred.

General Discussion about Iron Ore

The iron ore of 62 - 65 % Fe (T) can give Fe (M) 81 - 83 % for 90 %
Metallization on reduction.
So iron ore of 65 % to 68 % Fe ( Total) is suitable for sponge iron making

IRON ORE TESTS

TUMBLER INDEX: It is a relative measure of resistance of material to
breakage on impact. It should be > 88 %.
SHATTER INDEX : Dropping a certain amount of material from a standard
height for a certain number of drops. Range 0.7 % - 1.0 %.
ABRASION INDEX : It is the relative measure of the degradation of
material by abrasion. It should always be < 2%.
DECRIPITATION INDEX : When iron ore is suddenly exposed to the kiln
through feed tube breakdown may occur due to thermal shock. This is
known as Decripitation. It is measured by dropping a certain amount of
material in a previously heated furnace to a temperature of 400-6000 C under
normal atmosphere, inert atmosphere or under mildly reducing conditions.
After the charge attains the desired temperature, it is removed, cooled and
screened to measure the % age of breakdown.
Decripitation Index = 1.5 - 2.8% (% of -1mm in reduced product)
REDUCIBILITY DEGRADATION INDEX : 500 gms of dry sample in the
size range of 10-15mm is charged in a vessel (700mm x 75mm). The vessel
is pushed in an electric muffle furnace maintained at 550 deg C. then mixed
with gas of N2 & CO in the ratio 70:30 is passed for 30 min at 15 ltr / min.
subsequently the sample is cooled down to room temperature by passing N2
gas @ 5 Ltr / min. Reacted sample is rotated in a small tumbling drum
(200mm x 130 mm) at 30 rpm for 30 min. Resultant sample is screened on

6mm and 3mm screens. % age of 3 mm fraction is reported as R.D.I. of iron

ore.
THERMAL DEGRADATION INDEX : It is defined as the fragmentation
and breaking up points showing generation of fines when the material is
subject to heating in an Oxidizing or Reducing Atmosphere. The iron ore
solid is susceptible to thermal degradation when heated to a temperature
more than 4000C. The reduction degradation is the chemical phenomenon
which occurs while conversion of Hematite to Magnetite in the initial stage
of reduction.
REDUCIBILITY TEST (dr/dt) : This test aims at measuring the rate of
reduction of iron ore under rotary kiln conditions. The use of reduction
temperature in the range of 900 1050 deg C and an atmosphere of reducing
gases (CO or CO & H2). The sample of a known weight & of fixed size is
placed in the furnace in the form of static bed. dr / dt should be 0.5-0.6 %
per min.
COAL (COMPOSITION):
Coal Size = ( 5 - 20 mm )

B grade

F grade

WASH grade

Moisture

5-10 %

5-10%

15-18%

Fixed Carbon

40-45%

25-28%

35-38%

Volatile Matter

28-32%

20-24%

28-32%

Ash

25-30%

45-50%

32-37%

Direct Reduced Iron

Cross section of partially reduced sponge iron:

METALLIZATION :
Fe (Metallic) / Fe (Total) = Metallization in Sponge Iron.
Metallization checked by chemical process in our Laboratory.
Instant Metallization can be checked by the machine called
SATTMAGAN.
SATTMAGAN Result is the Ratio of gravitational weight & magnetic
weight.
In normal process Metallization is observed physically by our process
engineers every hour by breaking the sample and analyzing the % age of
reduction for best process control.

Quality Of The Product:

The important constituents determining the quality of sponge iron are the Fe total,
Fe metallic , sulphur, phosphorous, carbon and gangue content.
Fe total:
The Fe total content in sponge iron purely depends on Fe con tent in iron ore and
the degree of reduction achieved in the process. Fe total content of 90%min is
required for steel making requirement.
Fe metallic:
Fe metallic content in sponge iron depends on the effective control of process
parameters
Like temperature profile, retention time , mean particle size of iron ore/coal. Fe
metallic content of 78-82% is desirable for steel making. Fe metallic content of
grain size fractions of 4-12mm, +12-16mm, +16mm should also be determined
once in a week for control of consistency in product quality.
Carbon content:
The carbon content in sponge iron produced by coal based rotary kiln processes are
generally low and is in the range of 0.08% to 0.20%.The carbon content in gas
based processes can be controlled to a level of 1.5% to 2.0% based on requirement
for steel making.
Sulphur content:
The sulphur content in sponge iron is controlled by adding 1-6mm of
limestone/dolomite along with feed materials which picks up sulphur from the coal
preventing the sulphur pick up in sponge iron. The sulphur content in sponge iron
can be controlled in the range 0.012 to 0.025%
Phosphorous content:
The phosphorous present in the iron ore is retained as P2O5 in sponge iron with out
any change. The phosphorous content in sponge iron is generally varies from
0.06% to 0.09%.

SINTER PLANT
In Bhushan Steels Limited for the preparation of input material for the blast
furnace that is called sinter the company has three Sinter plants.

Technology Used

Sintering area (m2)

SINTER PLANT 1

Chinese

177

SINTER PLANT 2&3

German

204

SINTER MAKING:
Due to increased mechanization in the mines, lot of fines are generated which
cannot be charged into the Blast Furnaces directly. In order to conserve these,
otherwise waste material, they are compacted together and made into lumps by a
process known as sintering. Sintering is
defined as the agglomeration of the fine mineral particles into a compact lumpy
mass by incipient fusion caused by the heat produced during the combustion of the
solid fuel within the moving bed of loosely particles.
ADVANTAGES OF SINTER:
Helps in the conservation of raw materials.
Enhances the productivity of Blast Furnace.
Decreases coke rate in BF.
Decreases the flux rate in BF.
Improves the permeability of BF.
Helps in the smooth running of the BF.

SALIENT FEATUES AND SPECIFICATIONS OF SINTER

PLANT 2 & 3
Technology Supplier: Outotec ltd.
Production Start Date: (SP2) 23rd OCT 2012 & (SP3)24th MAY 2013

Particulars

Details

Plant capacity (rated) (Net)

Plant capacity (rated) (Gross)
Sintering Area
Product size range
Annual working days
Suction at grate bar
Depth of Sinter bed
Pellet Width
Sinter machine length
No. of Wind box
No. of Pellets
Mixing Drum size
Mixing Drum capacity
Cooler type
Waste gas fan(max pressure)
Motor Power
ESP Volumetric flow rate
Electro Static Precipitator (ESP)

:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:

Stack outlet gas dust content

Mean size
Tumbler Index(TI) +6.3 mm
RDI (-3.0 mm)
Reducibility Index(RI)
Productivity
Electrical energy

:
:
:
:
:
:
:

2.00mtpa
2.30mtpa (Net fines @ 15%)
204 m2
5-40 mm
330 days/year
1600-1700 mm WC(max)
700 mm
3m
77 m
17
164
4m*15m (Diameter*length)
424tph
Circular, dip rail
1702 mbar
8.4MW
170m3/s NTP (WG ESP)
92m3/s NTP (PD ESP)
WG ESP(95kV,1700mA) - 5 field
PD ESP(110kV,1100mA) - 3 field
<50 mg/Nm3
18-20 mm
75 %
30% max
65% min; (dr/dt) : 1.1% min
1.42 t/h/m
3638 KWh/ton sinter

INPUT MATERIAL:
1. Iron ore fines
2. Lime stone fines
3. Dolomite fines
4. Coke Breeze
5. Return fines
6. Mill Scale
7. LD Slag
Input in the form of Base Mix (a homogeneous mixture of Iron ore fines, Flux,
Coke Breeze, and Plant Returns) is supplied from RMHS.

PROCESS OF SINTERING:
The Sinter Plant-II & III has a rated capacity of 2.0 million tones of sinter per year.
There are two sinter machines supplied by Outotec private limited with 204 sq.
meter working area. The raw materials as specified above are brought, stored,
crushed and sent to proportionating bins. The different materials are drawn from
these bins in a fixed ratio on to a common belt conveyor leading to the primary
mixing drum. Here water and return fines are added. The raw mix is stored in two
intermediate bins from where it is fed into the two pelletizing drums. Here further
water is added to facilitate balling which increases the permeability of the raw mix.
This is carried to the charging hopper over the sinter machine 2 & 3. The material
is fed over the sinter machine pallets and the height of the bed is maintained 650700 mm depending upon quality of raw material used and sinter to be made. The
sinter machine is provided with 17 wind boxes at the bottom to suck the air
through the bed. As the bed travels through the Ignition Furnace, the top layer is
ignited. This combustion zone proceeds downwards till the pallets reaches the
discharge end. The temperature in the last wind box is maintained at around
C.
The hot sinter coming out from the machine is broken by the sinter breaker and
then screened. The -6 mm fraction is sent to the Return fines bin. The sinter is then
cooled in the cooling strand by blowing air through it and finally it is sent to the
double deck cold screen. Here it is separated into 3 fractions. The +25 mm is either
stored in the sinter storage bunker (1200 T capacity) or is directly sent to the Blast
furnaces. The -25 mm and +15 mm fraction is used as a bedding hearth layer on
the sinter machine in order to:
1. Increase the permeability of the bed.
2. To protect the grate bars from the direct contact with the hot sinter. -15 mm
fraction is again screened with 6mm screen. +6 mm fraction is sent to the

Blast furnace along with +25 mm fraction. -6 mm fraction is sent to return

fines bin.
Two space dedusting fans with Electro Static Precipitators are installed for
dedusting from various transfer points. Two waste gas fans with Electrostatic
Precipitators are installed for creating suction in the sinter bed from bottom.

SINTERING BED

BLAST FURNACE
Blast Furnace is a counter current heat & mass exchanger, in which the burden
(solid raw materials like Iron ore, Sinter, Coke & additives / fluxes) is charged
from top of the furnace & hot blast is sent through the bottom via tuyeres. The
heats transferred through the ascending Hot Blast to the descending burden &
oxygen from the burden to the gases. In the counter current process, the iron ore &
reducing agents (Coke, Coal) are transformed to hot metal & slag, formed from the
gangue of the iron ore, sinter & the ash of coke. The liquid hot metal & slag do no
mix and remain separated from each other with the slag floating on top of the
denser iron. The liquid iron & slag are separated in the cast house during casting.
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. The
raw materials require 6 to 8 hours to descend at the hearth of the furnace where
they become the final product of liquid metal and slag. These liquid products are
drained from the furnace at regular intervals through tap hole. The gases generated
into the furnace ascend to the top in 6 to 8 seconds after going through numerous
chemical reactions.
These 2 Blast Furnaces in BSL were commissioned with the technical and
financial assistance Of Paul Wurth.
The raw materials required for production of hot metal are Iron ore, Sinter, coke,
LD Slag, Quartzite & Manganese ore (as per requirement of SMS). Apart from
these solid raw materials, it also requires air and oxygen for burning of coke, water
for cooling various parts & equipment of furnaces. Iron ore supplied from OBBP,
Sinter from Sintering Plant (I & II), Coke from Coke Oven, LD Slag and scrap
from SSD.
The main sections supporting the furnaces are:
1. High line Stock House & charging section
2. Furnace proper and cast house
3. Hot Blast Stoves
4. Gas Cleaning plant
5. Slag Granulation plant
6. Pig Casting machine
7. Fleet of Hot metal ladles
Raw Material Sources for Blast Furnace
Iron Ore:

Sinter: Sinter Plant I & II

Coke: Coke Ovens (Coals from.. & imported coal)
Mn Ore: Purchased
Quartzite: Purchased
LD Slag: SMS through SSD
Nut Coke: Coke Ovens through Sinter
Pig Iron Chips: PCM through SSD

RAW MATERIAL USED IN BLAST FURNACE AND THEIR

SPECIFICATION
Material
Iron Ore

Sinter

Coke

Lime Stone

Dolomite

Quartz

Chemical Specification
Fe
:
63-64 %
SiO2 :
2-3%
Al2O3 :
2-3%
Fe
:
54-55%
SiO2 :
4.5-5%
CaO :
9.5-10%
MgO :
2-2.5%
Al2O3 :
2.5-3%
Carbon:
87%
Ash :
12%
S
:
0.6%
CaO :
45-50%
MgO :
2.5-3%
SiO2 :
5-5.5%
Al2O3 :
1.5-2%
CaO :
MgO :
SiO2 :
Al2O3 :
SiO2 :

28-30%
19-20%
3-4%
0.5-1%
98%

BLAST FURNACE 1(BF 1)

Stoves
Dust Catcher
Scrubber
Slag Granulation Plant tons/min)
Pig Casting Machine
Pulverized Coal Injection Stock House
Iron Ore
:
Sinter
:
Coke
:
Fluxes
Charging System
Waste heat recovery system

3 nos, (Max temp. 1250 deg C)

(Inlet load 50g/Nm3, Outlet load 5 g/Nm3)
1 no, (Inlet load 5 g/Nm3, Outlet load 5 mg/Nm3)
1 unit, (Capacity 2.75 to 5.5 t/min, Max 8
2 units, (Capacity 2100 t/day/Unit)
1 unit, (Capacity 150 kg/thm, Max 250 kg/thm)
2 Bunkers
6 Bunkers
8Bunkers
:
6 Bunkers (One each)
Paul wurth Bell less top charging system.
To utilize the heat of stove flue gases

Technical Specification
Total Volume
Working Volume
Throat Diameter
Belly Diameter
Hearth Diameter
Stack angle
Bosh angle
Throat volume
Stack volume
Belly volume
Bosh volume
Hearth volume

1681 m3
1462 m3
6.73 m
10.0 m
8.40 m
85.20
81.00
89 m3
901 m3
172 m3
210 m3
219 m3

Production data
Production

Rated 3625 t/day

Productivity

2.48 t/m3/day

Coke Rate

400 kg/thm

PCI Rate

150 kg/thm

Fuel Rate

550 kg/thm

Carbon Rate

455 kg/thm

Ore / Coke

4.0

Fe / C

2.0

Operational Data
Blast Volume

2600 2800 Nm3/min

Blast Pressure

2.4 2.8 bar

Hot Blast temp

1100 1200 C

Top Pressure

1 1.5 bar

Top Temp

80 100 C

O2 Enrichment

4%

Steam Injection

20 35 g/Nm3

Pulverized Coal Injection

6 30 t/hr

BLAST FURNACE 02
Main Constructive Characteristics:Number of notches
Number of tuyeres
Top hoppers effective volume
Charging system
Top closing system
Hearth
Number and type of probes for stockline
control
Tuyer belt

4
34
65
With the help of conveyor belt
Parallel bell less top(BLT), paul Wurth
Cast iron staves
1 mechanical and 2 radar
Cast iron staves from middle stack to
throat

Pressure equalizing system:

semi-clean gas + nitrogen
Cooling system
Under-hearth:
water pipes
Hearth:
cast-iron staves
from Bosh to lower Stack:
copper staves (approx. 11,500 mm)
Tuyere belt: cast iron stavesfrom middle Stack to Throat: cast iron staves
Number and type of probes for stockline control: 1 mechanical, 2 radar
Technical Specification
Throat Diameter

9.500 m

Belly Diameter
Hearth Diameter

14.700 m
13.000 m

Throat height
Belly height
Bosh height
Working height
Inner height
Total height
Tap hole inclination

1.600 m
2.100 m
3.950 m
25.900 m
30.300 m
33.100 m
10

Hearth volume

584 m3

Working Volume

3,230 m3

Inner volume
Total Volume

3,814 m3
4,186 m3

Production Data: Annual hot metal production: 2,500,000 tHM

Working days per year: 350 d/y
Daily hot metal production (average): 7,150 tHM
Peak daily hot metal production: 7,850 tHM
Reactions in the Blast Furnace
Upper Stack Zone

Reduction of oxides
3 Fe2O3 + CO = 2 Fe2O3 + CO2
Fe3O4 + CO = 2 FeO + CO2
FeO + CO = Fe + CO2
Decomposition of Hydrates
CO + H2O = CO2 + H2
Decomposition of Carbonates
Middle Stack Zone
Direct / Indirect reduction
FeO + CO = Fe + CO2
CO2 + C = 2 CO
FeO + C = Fe + CO
Lower Stack Zone
Calcination of lime
Reduction of reduced iron
Reduction of Silica / MnO2
Formation / melting of slag
Combustion Zone
Burning & combustion of coke & complete reduction of iron
oxide.
C + CO2 = CO2 + 94450 Cal (Direct Reduction)
CO2 + C = 2CO 41000 Cal (Solution loss reaction)
Race way
Coke & Hydrocarbons are oxidized
Large evolution of heat.

Top Charging System

In Bell Less Top (BLT), these are no bells as the nomenclature states. The skips
dump the materials to a receiving hopper, which is separated from the BLT by
upper material gate and upper gas seal valve. After opening of upper material gate
& upper seal valve, material is discharged into BLT material bin placed over the
lower material gate & lower gas seal valve. Then the UMG (Upper Material Gate)
& USV (Upper Seal Valve) are closed to seal the furnace from the atmosphere &
the receiving hopper is ready to receive material from the skips. To dump the
material into the furnace, the lower seal valve opens and then the lower material
gate is opened. The material is dumped through a rotating chute, which can dump
material at any position of the furnace and can complete the dumping in variable
number of rotation so that desired burden distribution is achieved. The whole BLT
system is hydraulically operated & PLC controlled. Besides achieving perfect
burden distribution, BLT ensures very good gas sealing at the furnace top so that
furnace can be operated at a high top pressure.
Hot Blast Stoves & Associated System
The function of Hot Blast Stoves is to pre heat the air blast before its admission
into furnace through tuyeres. Each furnace is provided with 3 hot blast stoves
which are tall cylindrical shell with dome shaped top. Each stove consists of two
parts namely combustion chamber & checker brick work. The combustion chamber
is lined with fire clay brick & checker bricks are Alumina bricks. BF gas is burnt in
combustion chamber and the sensible heat of the flue gases heat up the checker
bricks while passing through them from top towards bottom. The period of heating
is called On Gas & normally a stove remains on gas for 1 hour
minutes at a
stretch. After heating, cold blast, supplied from turbo blowers of CPPI is passed
through the checker works from bottom and the air got heated up by taking
sensible heat from checkers. The period of blast heating is called On Blast
condition of stove. The blast period is usually for 1 hour.
The hot blast stoves are provided with several attachments such as burners to burn
the premixed air and BF gas in the combustion chamber. Different valves are
provided for controlling the BF gas, combustion air, waste gas, cold blast and hot
blast to or from the stoves. The hot blast from stoves passes through insulating
refractory bricks lined pipes (hot blast main, bustle main & tuyeres stocks) and
then injected through tuyeres into the furnaces. The entire operation & control of
stoves & hot blast is made from a control room adjacent to stove.

Cast House
The Cast House is the most important section of Blast Furnace. The function of
cast house is to tap the liquid metal & slag from the hearth of furnace on schedule,
separate the metal & slag in troughs and flow them through runners to metal ladles
and slag pots respectively. Production of Blast Furnace is greatly influenced by
effective tapings which depend on a good cast house practice.
Hydro pneumatic drill machines are used to drill the tap hole up to 2 m into the
hearth to tap the metal & slag. Oxygen lancing through mild steel pipes is resorted
to, if taping is not possible by drilling alone. Hydraulic powered mud guns are used
to close the tap hole after casting is over with anhydrous tap hole mass which get
quickly hardened inside the tap hole. The main components of cast house is the tap
hole, troughs, iron runners, slag runners, iron & slag spouts, mud gun and drill
machine.
Cast House Slag Granulation Plant.
BF 1 and 2 both have Cast House Slag Granulation Plant (CHSGP) where the slag
after beingseparated from iron in troughs, is diverted to the granulation plant.
Major units of CHSGP arehot runner, old runner, Blowing box, Receiving hopper,
Dewatering drum & disposal belts.As the Hot slag flows down from the Hot
runner, several water jets from the blowing box, breakthe slag stream into droplets
&carried them into a receiving hopper as a slurry. The slurryfalls on wire nets and
paddles of a rotating drum, wherein water passes through and goes to thehot water
tank whereas the granulated slag is captured by the paddles, which move along
withthe drum rotation. When the paddles come over a belt running at the center of
the drum, thegranulated slag falls into the conveyor and is carried away to the
disposal yard. The yield ofgranulated slag of CHSGP is around 90%. It has been
designed by M/s Paul Wurth. Granulated slag is a major raw material for Portland
slagcement. Therefore by granulating slag not only is the waste material used
economically, it alsoavoids environmental problem that is associated with liquid
slag dumping.
Gas Cleaning Plant (GCP)
BF1 and 2 both have dedicated GCP to clean the BF Gas coming from furnace.
The BF gasleaving from top of BF is having about 20 25 g / Nm3 dust. BF gas is
subjected tosuccessive cleaning in dust catcher (by changing the direction of the
flow of the gas), ventury scrubber (washing with water sprays) and Electrostatic
precipitator (by ionizing the dust particle byapplying high potential to electrodes),
where by dust content is reduced to the extent of 4 to 6g/Nm3.

COKE OVEN PLANT

Coal carbonization is used for processing of coal to produce coke using
metallurgical grade coal.
Coal carbonization involves heating of coal in the absence of air. Coke making
process is multistep complex process and variety of solid liquids and gaseous
products are produced which contain many valuable products. Various products
from coal carbonization in addition to coke are coke oven gases, coal tar, light oil,
and aqueous solution of ammonia and ammonia salt.
Coke oven gases are about 310-340 cubic meter per tone of dry coal which
contains gaseous products coal tar,vapors, light oil and water. With the
development of steel Industry there has been continuous development in coke oven
plant since latter half of nineteenth Century to improve the process conditions,
recovery of chemicals and environmental pollution control strategies and energy
consumption measures.
Carbonization can be carried out at low temperature or high temperature. Low
temperature carbonization is used to produce liquid fuels while high temperature
carbonization is used to produce gaseous products.
Low temperature carbonization (450-750 degree C): In low temperature
carbonization quantity of gaseous product is less while liquid products are large.
High temperature carbonization (above 900degree C): In high temperature
carbonization, the yield of gaseous product is more than liquid products with
production of tar relatively low.

In any integrated steel plant, Coke Oven Department is the first production unit.
Coke is
required in Blast Furnace for reducing iron ore (Fe2O3) to molten iron, which is
also termed as
Hot Metal. The major advantages of using coke in Blast Furnace are:
It is strong & hard and can withstand the abrasive action inside the blast
furnace and remains in solid form till it reaches the tuyere zone.
Because of its strength, it can take the load of the burden above it.
It is porous which allows good contact between the carbon (present in coke)
& oxygen in air.
It is uniform in size for better distribution inside the furnace.
It is having a high heating value.

The Coke
Coke is made from coal. Normally two varieties of coals are available in the earth's
crust.
Non-coking coal
Coking coal
India has vast reserve of Non-coking coal, which is generally used for power
generation by Thermal Power Plants . Coking coal is scarce, and is used form
metallurgical purpose only.
When coking coal is heated in the absence of air, pyrolytic cracking of coal
occurs with the evolution of number of volatile products like Ammonia, Tar,
Benzol and Coke Oven gas. The solid carbonaceous residue is called coke which is
hard dense & porous. The residue of non-coking coal does not agglomerate
butremains in powder form.
Coal Blending:
Coking coal is sub-divided into two categories depending upon its coking
characteristics.
(i) Prime Coking Coal (PCC)
(ii) Medium Coking Coal (MCC)
In India, the availability of PCC coal is scarce and hence its usage is also restricted.
Further due to inherent high ash content, the coke made from above coal also has
high ash rendering it unsuitable for use in Blast Furnace. In order to lower the ash
in Indian coals, it has to be suitably blended with low ash imported coking coals.
Two varieties of coals are usually imported primarily from Australia, USA & New
Zealand.
Blast furnace requires coke of uniform size, high mechanical strength, and porosity
with minimum volatile matter and minimum ash. Coking coal may be diveded on
the basis of their coking properties: prime coking coal, medium coking coal, semi
coking coal. The prime coking coal produce strong metallurgical coke while coals
of other groups yield hard coke only the concentration of moisture ash, sulphur and
sometime phosphorous and ash fusion temperature are important in determining
the grade of coking coal since they influence the quality of coke produced. Low
moisture, ash, sulphur and phosphorous content in the coal are desirable for

production of good quality coke. The desired analysis of typical coal charge to
coke oven is.
Ash content
Moisture
Volatile matter
Fixed Carbon
Sulphur
Phosphorus

16%0.5%
6% - 7%
22%-25%
58%-60%
0.56%
0.009%

Some of the other factors affecting quality of coke are rank of coal, particle size,
bulk density, weathering of coal, coking temperature and coking rate, soaking time,
quenching practice.

Coal Preparation
Coal as it comes from the mine ranges in size from large lumps to dust and is
known as "Run of Mine". This coal contains a lot of impurities which are to be
removed before it can be used. "Run of Mine" coal is sent to washery for
cleaning. After removal of gangue material the coal is sent to steel plants in box
wagons. Imported coking coal is brought through sea route, and is unloaded in
ports from where it is loaded in box wagons & dispatched to all steel plants.

The Coking Process

The carbonization of coal is carried out at high temperature in long, narrow silicabrick chambers called ovens in which coal is coked by the combustion of fuel gas
in flues built in the refractory brick walls which separate the ovens.Numbers of
ovens are placed side by side and together it is called a Battery.The walls of the
ovens are maintained at a temperature of >1000C by burners which are located
inside the walls. Here CO gas, BF gas or mixed gas are used as fuel for
maintaining the wall temperature. The annular spaces between the walls are filled
with coal taken from coal towers. The coal is indirectly heated for a period 20 to 23
Hrs. All volatile
matters present in coal escape. The residue coke is pushed out from the oven,
quenched with water to prevent combustion of coke and dumped into a wharf.The
empty oven is again refilled with coal & the process continues. The by-products of
carbonization namely Ammonia, Benzol, Tar & Coke Oven gas generated during
the process are sent to By-Product division for removing impurities. The gas after
cleaning is used as fuel throughout the steel plant.

BY PRODUCT DIVISION

The By Product Division Plant at Bhushan Steel serves two purposes:

(i) To recover the primary products like ammonia, crude tar to clean and cool the
Coke Oven gas, so that it can be conveniently used for heating purpose.
(ii) To further process and refine the crude tar to yield a number of marketable
Products .

Ammonium Sulphate Plant

The gases from exhaust goes to ESP where tar is separated and the tar free gases
goes bubbled through dil. solution of sulphuric acid in saturators. Ammonia is
absorbed by sulphuric acid and ammonium sulphate is formed. One tonne of coal
yields about 0.3 tonne tar and 5-8 gm ammonia per m3 of gas.

Benzoyl Recovery Section

The gases from saturator goes to series of coolers and then to benzoyl scrubbers
where benzoyl is scrubbed with wash oil. Benzoyl crude oil goes to benzoyl
recovery section where benzoyl is removed and the wash oil after treatment is sent
to the scrubbers. Crude Benzoyl thus recovered goes to benzoyl rectification plant.
Light crude benzoyl contains low boiling sulphur compound, BTX, solvents, still
bottom residue. Benzoyl after washing and neutralization with caustic soda is
send to benzoyl column for fractionating into different fraction.

Coal Tar Distillation

Coal tar is produced as result of high temperature carbonization and is a viscous
dark brown product with characteristic odour and consists of about 300 different
products. some of the major constituents are the aromatics and heterocyclic
compounds; benzene, toluene, xylene, phenol cresol, naphthalene, anthracene,
phenanthrene, pyridine, carbazole, coumarone etc..

OXYGEN PLANT
Oxygen Plant is used to produce liquefied Oxygen, Nitrogen and Argon at
Cryogenic Temperature as well as gaseous Nitrogen and Oxygen too. It uses
atmospheric air as its raw material. Atmospheric air is converted into liquid
Oxygen, Nitrogen and Argon with the help of Adiabatic Compression, the
principle which is used in Cooling System.

USES OF PRODUCTS OF OXYGEN PLANT

1. Oxygen- Used for ignition at high pressure in SMS (Steel Melting Shop), BF
(Blast Furnace), CO (Coke Oven) etc.
2. Nitrogen- Used for purging in SMS, for cooling purpose in BF, BOF, CRM,
HSM as well as a carrier for various materials in different shops.(eg. used as a
carrier in PCI (Pulverized Coal Injection).
3.Argon- Used in BOF, SMS only.

VARIOUS COMPONENTS OF BOP

1. AIR SEPERATOR- In Air Separator CO2, moisture, and hydrocarbons are

separated with the help of various processes. CO2 is removed by freezing at a
temperature of -150 degree Celsius, moisture is removed with the help of use of
absorbent and Molecular Sieve method is used of the removal of hydrocarbons.

2. BOOSTER/COMPRESSOR- features50 gauge pressure

Maximum refrigeration occurs here.

3.MAIN HEAT EXCHANGER- featuresCounter current type

Air and liquid O2 and N2 is passed for heat
exchange.
4.TURBINE-

featuresCooling effect
Constant Speed
Iso-entropy
-110degree Celsius inlet temperature
-170degree Celsius outlet temperature.

LIME PLANT
Basically limestone is used as a slag former. Dolomite is used as a slag former,
slag modifier and as a refractory material.
The process of iron making is the reduction of iron ore to produce iron. Iron ore
normally contain gangue materials such as silica (SiO2), Alumina (Al2O3) along
with sulphur (S) and Phosphorus (P). Removal of these impurities is done by
combining the gangue materials with CaO and/or MgO to form slag which consists
of low melting point complex compounds such as calcium silicate, calcium
aluminate etc. CaO and MgO is charged along with other raw materials in the form
of lime stone and dolomite or it is charged through sinter where again fines of
limestone and dolomite is used. This limestone or dolomite is first decomposed
into CaO or CaO+MgO which then combine with gangue to form slag. Further
lime from limestone reacts with sulphur present in the raw materials to form CaS
which goes into slag.

During pretreatment of hot metal in desulphurization plant lime is an essential

component of the desulphurizing compound. During steel making high basicity of
the steel making slag is being maintained with the help of lime. Lime is also used
in secondary steel making. In steel melting shop, fettling of the lining as well as
patching is done with dolomite based compounds. Calcined dolomite is also used
in converters to maintained MgO levels in the steel making slags. It also acts as a
slag modifier in case of slag splashing. Burnt dolomite is also used for making
refractory bricks for the purpose of lining in steel melting shop.
There are three types of kilns used in Lime Plant :
1. Single Shaft Kiln
2. Rotary Kiln
3. Twin Shaft kiln
Twin Shaft Kiln has been further specified into 4 types1.Circular
2.Rectangular

3.Stretch O [Used in BSL]

4.D-type

QUANTITY OF LIME AND DOLO REQUIRED IN BSL ANGUL-

1) 60 kg of Lime per ton of steel.

2) 40kg of Dololime per ton of steel.

USES OF LIME
1) SMS (Calcined) Lime-10 to 80mm.
2) Sinter Plant-0 to 10mm.

SOURCES OF RAW MATERIAL (LIMESTONE)1)Katni (MP)

SiO2 content is 3.5% (required 1%) hence it is not suitable.
2)Rajasthan
Present in less quantity as well as high cost make it unsuitable.
3)Dubai
Used in Bhushan Steel Plant.

BASIC OXYGEN STEEL-MAKING

Basic oxygen steelmaking (BOS, BOP,BOF, and OSM), also known as LinzDonawitz-Verfahren.
steelmaking or the oxygen converter process is a method of
primary steelmaking in which carbon-rich molten pig iron is made into steel.
Blowing oxygen through molten pig iron lowers the carbon content of thealloy and
changes it into low-carbon steel. The process is known
as basic because fluxes of burnt lime ordolomite, which are chemical bases, are
added to promote the removal of impurities and protect the lining of the converter.
The process was developed in 1948 by Robert Durrer and commercialized in
19521953 by Austrian VOEST and AMG. The LD converter, named after
the Austrian towns Linz and Donawitz (a district of Leoben) is a refined version of
the Bessemer converter where blowing of air is replaced with blowing oxygen. It
reduced capital cost of the plants, time of smelting, and increased labor
productivity.

At SMS 3 in BSL there are 2 top blown oxygen converter called as LD Converter
(L&D stands for Linz and Donawitz) or Basic Oxygen Furnace (BOF)/converter is
having capacity 220MT.
Basic oxygen steelmaking is a primary steelmaking process for converting the
molten pig iron into steel by blowing oxygen through a lance over the molten pig
iron inside the converter. Exothermic heat is generated by the oxidation reactions
during blowing.

The basic oxygen steel-making process is as follows:

1. Molten pig iron (sometimes referred to as "hot metal") from a blast
furnace is poured into a large refractory-lined container called a ladle;
2. The metal in the ladle is sent directly for basic oxygen steelmaking or to a
pretreatment stage. High purity oxygen at a pressure of 100-150 psi (pounds
per inch square) is introduced at supersonic speed onto the surface of the
iron bath through a water-cooled lance, which is suspended in the vessel and
kept at few feet above the bath. Pretreatment of the blast furnace hot metal is
done externally to reducesulphur,silicon, and phosphorus before charging
the hot metal into the converter. In external desulphurising pretreatment,
a lance is lowered into the molten iron in the ladle and several hundred
kilograms of powdered magnesium are added and the sulphur impurities are
reduced to magnesium sulphide in a violent exothermic reaction. The sulfide
is then raked off. Similar pretreatments are possible for external
desiliconisation and external dephosphorisation using mill scale (iron oxide)

and lime as fluxes. The decision to pretreat depends on the quality of the hot
metal and the required final quality of the steel.
3. Filling the furnace with the ingredients is called charging. The BOS process
is autogenous, i.e. the required thermal energy is produced during the
oxidation process. Maintaining the proper charge balance, the ratio of hot
metal, from melt, to cold scrap, is therefore very important. BOS vessel can
be tilted up to 360 and is tilted towards the deslagging side for charging
scrap and hot metal. The BOS vessel is charged with steel or iron scrap
(25%-30%) if required. Molten iron from the ladle is added as required for
the charge balance. A typical chemistry of hotmetal charged into the BOS
vessel is: 4% C, 0.20.8% Si, 0.08%0.18% P, and 0.010.04% S all of
which can be oxidised by the supplied oxygen except sulphur (requires
reducing condition).
4. The vessel is then set upright and a water-cooled, copper tipped lance with
3-7 nozzles is lowered down into it and high purity oxygen is delivered at
supersonic speeds. The lance "blows" 99% pure oxygen over the hot metal,
igniting the carbon dissolved in the steel, to form carbon
monoxide and carbon dioxide, and causing the temperature to rise to about
1700C. This melts the scrap, lowers the carboncontent of the molten iron
and helps remove unwanted chemical elements. It is this use of pure oxygen
instead of air that improves upon the Bessemer process, as the nitrogen (a
particularly undesirable element) and other gases in air do not react with the
charge.
5. Fluxes (burnt lime or dolomite) are fed into the vessel to form slag, to
maintain basicity more than 3 and absorbs impurities during the steelmaking
process. During "blowing," churning of metal and fluxes in the vessel forms
an emulsion that facilitates the refining process. Near the end of the blowing
cycle, which takes about 20 minutes, the temperature is measured and
samples are taken. A typical chemistry of the blown metal is 0.30.9% C,
0.050.1% Mn, 0.0010.003% Si, 0.010.03% S and 0.005-0.03% P.

HOT STRIP MILL (HSM)

Hot Strip Mill (HSM) is a fully continuous millcomprising of 2 Reheating Furnace
of capacity 600 T/Hr. 1 Roughing Mill i.e. 4 highReversing Mill, Coil Box, Six
Stand continuous 4 High Finishing Mill in tandem and 2 Hydraulic down coiler.
Coil box, Quick Work Roll, Change Roll in Finishing Mill, High Speed Descaler,
Reheating Furnace were installed under modernisation for rolling heavier and
longer slabs to coils. The HSM was originally designed and commissioned on
turnkey basis by SMS SIEMAG, West Germany and mill driven by SIEMENS.
It is designed to roll the slabs of thickness 180 250 mm to finished strip gauge of
1.6 to 5mm in 800 1680 mm width. The annual production capacity of the mill is
5.2 Million Tons of slab weight.
The HSM being an integrated unit of BSL supplies Hot Rolled Coils as input
materials to its downstream customers such as Cold Rolling Mills and also to
Dividing Line. It also caters to the requirements of external customers.

Sections:
1.
2.
3.
4.
5.
6.
7.
8.
9.

Slab Yard
Reheating Furnace
Roughing Mill
Coil Box
Finishing Mill
Down Coiler
Coil Yard
Roll Shop
Utility

Slab Yard
All the slabs are produced are stored in six slab yards. If required slabs are further
cut to required length before being dispatched. There are two types of slabs hot
slab and cold slabs both type of slabs are proceed to reheating furnace via shifting
car.

Reheating Furnace
Two Walking Beam Reheating Furnaces of 600 T/Hr. capacities were
commissioned during modernization of HSM. Each Furnace is having 9 zones
(Preheating zone top & bottom, heating zone top & bottom and Soaking zone top
& bottom). Preheating and heating zones are having dual firing system with mixed
gas and furnace oil, where as Soaking zones are having only mixed gas firing.
Slabs are put on charging side roller table from depiler with the help of depiler
crane with tong / EOT crane with magnet. Each slab is weighed on Charging
Roller Table Weigh Bridge. Spotting of slab is done with laser beam and after
spotting, the slab is pushed inside the furnace with the help of pusher. Movement
of slabs inside the furnace takesplace by the movement of walking beams called
movable skid pipes (4 nos.), which move in lift,forward, lower and reverse
direction in one complete cycle.
There are also 4 nos. of fixed skid pipes inside furnace on which the slabs rest
while in stationary state. Tracking and heating of slabs to required temperature is
done by computerized thermal model. Once the slab reaches the discharge end, it is
detected in the discharge pulpit by the Gamma ray system provided at the
discharge side. After slab detection and getting clearance from cabin, slab is
extracted from furnace by extractor and is placed on the discharge roller table and
sent to through primary descaler for rolling.
TYPE- WALKING BEAM FURNACE:
No. of Fce: TWO (FURNACE No. 1 & 2)
FUEL: MIXED GAS (COG & BOF)
CAPACITY: 600 TONS / HOUR (SLAB Wt.)

Primary Descaler
To remove the scale formed on the surface of slabs during its heating inside
furnaces, water jet at high pressure of 145-160 Bar is applied on top and bottom
surface of slabs.

Roughing Mill
Roughing stand is reversing type 4 High Mill with full automation. It has twin
drives with AC motors (with Cyclo-Converters) of 3000 kW each.
Heated slabs are given 7 passes maximum and reduced to desired thickness and
sent to isvertical edger for width control by squeezing slab width up to 230 mm.
Slabs after rolling at are called Intermediate Transfer Bars.

Coil Box
The Intermediate Transfer Bar after Roughing Mill travels through the Delay Table
to Coil Box, where it is coiled in hot condition and subsequently uncoiled to feed
tail end of transfer bar into the Finishing Mills. In general coils with finish gauge
less than 35 mm are taken through coil boxwhere as for finish gauge more than 35
mm are taken directly to Finishing Mills in Pass Through Mode (PTM). The head
end of the transfer bar/ Coiled transfer bar is cropped at Crop Shear and after
descaling at scale washer pinch roll, the transfer bar enters the Finishing Mill for
rolling to the required gauge.
Advantages of Coil Box Technology :
1.
2.
3.
4.
5.
6.
7.
8.

Uniform temperature of the transfer bar

Reduced power rating and lower energy consumption in the finishing train
Shorter total length of hot strip mill
Smaller number of finishing stands
Optimum rolling time adjustment between roughing train and finishing train
Extended range of dimensions
Improved strip quality
Improved thickness control

Finishing Mill
The bar enters 6 stands, 4 high continuous mills where reduction is given to the bar
in each stand. In between the stands, loopers are provided to maintain constant
tension. There are two R-30 process computers of Siemens make. One is speed
computer, for regulating the speed of all mill stands, ROT, coiler wrapper rolls and
mandrel. The other one is AGC computer for automatic gauge control to get
uniform thickness of the strip. AGC hydraulic cylinders are provided in last four
stands F3, F4, F5, F6. After rolling in finishing stands, the strip temperature is
controlled on Run OutTable (ROT) by laminar cooling by water through cooling
banks.

Down Coiler
The strip moves over ROT and gets coiled in one of the two hydraulic down
coilers. There are two Hydraulic down Coilers each having three Wrapper Rolls.
Coils are taken out from coiler and placed on Conveyor. The hot coils are
circumferentially strapped on the body by Automatic Strapping Machine and
marked for identification. Necessary samples are cut fromthe coils for its testing.
Coils are then transferred to coil yard where coils are allowed to cool toroom
temperature before they are sent for further processing in different units of BSL or
to the external customers of HR Coils. The capacity of the Coiler is 35 Tons (max.)
coil weight.
Parts of Down Coiler:
1. Top & Bottom Pinch Roll
2. Three Numbers of Wrapper Rolls.
3. One Mandrel with Two Stages of Expansion.
4. Coil Car for Taking out The Coil
5. Centering Arm for Lifting Of Coils
6. Tilter for Tilting the Coil to the Conveyor
7. Mandrel Dia: 762 740 725 MM
Hold Down Roll for Preventing Tail end Shifting

Coil Yard
Shipping Area dispatch of coils to internal as well as external customer. The HR
sheets are shipped through different areas by RailWagaon and Trucks.
Slitter Line:Hot Rolled Coils meant for converting into HR plates are uncoiled in
Uncoiler, levelled in Leveller-I and then sheared at Dividing Shear to the required
lengths as per requirement of the customer. After shearing, the plates are levelled
once again in Leveler-II and piled in Pilers. There is also provision of plate
inspection for both the sides each plate at Plate Turn overDevice (PTOD) before
Piler

Roll Shop
Roll are used for rolling purpose in rolling mill.The are made of High Speed Steel
(HSS). Rollers are subjected to very high temps and continuous colling so the
roller gets hard. To soften the outer surface and making it reusable for rolling
purpose grinding is performed. The CNC grinding machine sense the hardened
thickness are remove the material so we can reuse it again.

Utility
In the HSM the equipments and machines used are subjected to very high
temperature. In the descaler very high pressure of water is required for descaling
the slab. Water used in HSM for various purpose and treatment of water before
making it usable for next cycle comes under Utility Section. There are many tanks,
reservoir for storing the water. Many filters for water treatment and motors are
used for suppling the water and providing the required pressure in HSM.

COLD ROLLING MILL

Cold Rolling Millis one of the complex units of BHUSHAN STEEL PLANT,
producing bulk amounts of quality finished steel. Purpose of cold reduction is to
achieve the following:
1.
2.
3.
4.
5.

A reduction in the thickness of the final product.

A designed surface finish.
Desirable mechanical properties.
Close dimensional tolerance.
Producing as per customer requirements.

The input to Cold Rolling Mills is the Hot Rolled Coils (HR Coils).

PICKLING LINE
The first unit of CRM after HSM is Pickling line. During the hot rolling process, a
layer of
Scale(Iron oxides) is formed on the strip surface, which must be removed prior to
further
processing. This removal of scale is performed by physically breaking of scales by
mechanical means & then chemically treating the surface of hot rolled strip with an
acid. The process, called Pickling, removes the remaining scale by dissolving it
in acid. In CRM, BSL HR Coils are treated chemically by hot dilute Hydrochloric
acid to remove the oxide scales, so that it can be further rolled to thinner gauge.
The Acid Concentration, Salt Concentration are shown below.
Tank No.
1
2
3
4

Acid
Concentration(HCL %)
3 TO 5
5 TO 10
10 TO 15
15 TO 18

Salt
Concentration(gm/liter)
MAX 200
150
100
50

The temperature is controlled by Steam heating. The spent liquor from Tank is sent
to the Acid Regeneration plantwhere the Ferric chlorideis separated by

Crystallisation and Refrigeration Process and the acid is brought to original

concentration by adding new makeup acid.
COLD ROLLING :
The next operation is the cold reduction of the pickled coil. After pickling, the
main cold rolling
Operation, i.e. cold reduction, is performed in cold reduction mill where pickled
strip is fed
Between very hard rolls. This is done in a single reversing stand, equipped with an
uncoiler and a coiler, by making several passes in reversing directions.

COLD REVERSING MILL-1 (TOTAL 3 MILL )

This is one, 4-Hi reversing mill which makes 2-5 passes to reduce thickness. It has
a single stand with reels located on either side of the mill. Steel strip is passed back
and forth till the required thickness is obtained. On the entry side of the mill,
means are provided for the coil to be threaded through the mill to the tension reel
on the delivery side. After the first pass, the tail end of the coil coming from the
uncoiler is gripped by the second tension reel on the entry side of the mill. In each
unit, the reel serving as the pay-off unit is operated as a generator, providing back
tension to minimise the rolling friction and feeding of the coil into drive reel
motor. In the last pass, the tail end of the coil is released from the unwinding
tension reel. This is one, 4-Hi reversing mill which makes 2-5 passes to reduce
thickness. It has a single stand with reels located on either side of the mill. Steel
strip is passed back and forth till the required thickness is obtained. On the entry
side of the mill, means are provided for the coil to be threaded through the mill to
the tension reel on the delivery side. After the first pass, the tail end of the coil
coming from the uncoiler is gripped by the second tension reel on the entryside of
the mill. In each unit, the reel serving as the pay-off unit is operated as a generator,
providing back tension to minimise the rolling friction and feeding of the coil into
drive reel motor. In the last pass, the tail end of the coil is released from the
unwinding tension reel.

PRODUCTS
1. CRCA (COLD ROLLED CLOSED ANNEALED)
PARAMETERS
Thickness (mm)

TECHNICAL DETAILS/SPECIFICATIONS

Width (mm)

10 to 1700 (Max)
Up to 30 MT (7 to 18
kg/mm width)
Super Bright, Bright, Dull & Matte. (RaValue
with controlled Rmax on request).
Specifications - As per JIS/BIS/ ASTM/EN
Standards
Low Carbon CRCA Grades
Super EDD/DD/D (SPCX, SPCEN, SPCD,
SPCC) non-aging, IF-HighStrength steel(IFHSS), High Strength Low Alloy Steel (HSLA),
viz., ST -42,ST-45, ST-52, SAPH-400/41O, Steel
for Porcelein Enammeling, CorrosionResistant
Steel, viz., Tin Mill Black Plate (TMBP)
Medium & High Carbon CRCA Grades
C- 30, C-40,MC -ll,EN - 8, for spring steel
application, C-55,MC-12, EN- 9 C-62,C-60, C80,HC-14,EN-42J

Coil Weight (MT)

Surface Finish

Grades

0.10 to 4.00

ELECTRICAL Grades Elec -I, Elec-n, Elec-nI,

Semi Processed Elect. Steel
OTHER CRCA Grades
Case Hardening Steel- 15Cr3, SAE 1010, SAE
1012
Through Hardening Grades- SAE 1040, SAE
1045, 1055, 1065, 1080, 1541

H.R PICKLED/ SKIN PASSED & OILED

Thickness (mm)

0.10 t0 4.00

Width (mm)

10 to 1700 (Max)

Cut- to -Length (mm)

Max. Width for Cut Size

H.R PICKLED/ SKIN PASSED & OILED

Thickness
Up to 3.00 mm

3.00 mm - 4.00 mm

Max. Width for Cut Size

1500 mm

Width for Coil

50 mm - 1700 mm

Thickness

Width for coil

1250 mm

Above 4.00 mm
600 mm

50 mm - 1700 mm

50 mm - 1700 mm

Up to 3.00 mm
3.00 mm - 4.00 mm
Above 4.00 mm
50 mm - 1700 mm
50 mm - 1700 mm
50 mm - 1700 mm

Coil Weight (MT)

Up to 30 MT (7 to 18 kg/mm width)

Surface Finish

Super Bright, Bright, Dull & Matte. (RaValuewith controlled

Rmax on request).
Specifications - As per JIS/BIS/ ASTM/EN Standards
Low Carbon CRCA Grades
Super EDD/EDD/DD/D (SPCX, SPCEN, SPCD, SPCC) nonaging, IF-High
Strength steel (IF-HSS), High Strength Low Alloy Steel
(HSLA), viz., ST -42,
ST-45, ST-52, SAPH-400/41O, Steel for Porcelein
Enammeling, Corrosion
Resistant Steel, viz., Tin Mill Black Plate (TMBP)
Medium & High Carbon CRCA Grades
C- 30, C-40,MC -ll, EN - 8, C-55, MC-12,
EN- 9 C-62, C-60, C-80, HC-14, EN-42J
ELECTRICAL Grades Elec -I, Elec-n, Elec-nI, SemiProcessed
Elect. Steel
OTHER CRCA Grades
Case Hardening Steel- 15Cr3, SAE 1010, SAE 1012
Through Hardening Grades- SAE 1040, SAE 1045, 1055,
1065, 1080, 1541

Grades

PROCESS ROUTE OF CRCA MATERIAL

(A) ANNEALING PROCESS:

Cold rolled strip as such is not suitable for drawing and deep drawing operations
due to
lack of ductility. The loss is caused by the work hardening effects of cold
reduction. After
the cold reduction process, the internal structure of the steel is as follows:
1. The grains in the steel have been elongated in the direction of rolling.
2. Longitudinal rolling stresses have been set up in the steel and any foreign matter
present in the core zone of the rimmed steel have been rolled out into the form of
segregated bands.
3. The steel being very hard and brittle will fracture very easily in the direction
oftransverse to the rolling.
4. Myriads of stress points are found to be present in each grain.
Now these CR coils are to be annealed to remove the stresses. The various
purposes of
annealing are listed below:
1. To improve the mechanical properties.
2. To increase ductility, particularly to restore the normal conditions of steel after
cold
working.
3. To relieve the internal stresses.
4. To remove chemical non-uniformity.
5. To change the micro-structure of steel from the distorted structure of cold
worked steel
to the equi-axed structure.
(B) SKIN PASSING:
Skin passing is a cold reduction method and the steel surface or skin is hardened by
cold Working, keeping the steel core soft & ductile. In Cold Rolling Mills of BSL,
one single stand 6- high mills and one twin stand 4-high mill have been installed.

Skin Pass Mills ( SP 1 To 3)

The softened or annealed Steel is then skin passed or Temper rolled with the aim of
imparting a work hardened skin to the steel strip leaving its core soft in the
annealed condition.
Following are the main advantages of Skin Passing.
a. To impart different surface finishes to the strip required for painting, coating
enamelling etc.
b. To give a flat surface to the strip.
c. To impart the desired mechanical properties to the strip.
d. To keep the strip free from stretcher strains and luder bands that may develop
during the forming operations.
Applications:
Used for making steel furniture, refrigerator bodies, automobile bodies, railway
coach paneling, drums, barrels, deep drawing and extra deep drawing available as
per Indian Standard specifications. Besides CR coils and sheets CRM, BSL also
produces Galvanised plain and corrugated sheets.

2. GALUME
Introduction
BHUSHAN has set up the technology of manufacturing a very
new coated product called BHUSHAN GALUME being the
brand name. This alloy coating consists of 55% Aluminum and
43% Zinc and the balance contains Silicon around 1.5% to
affect excellent adhesion to the steel substrate.
Galume Production Technology
This coating is given on the cold rolled substrate processed from selective Hot
rolled coils with selective chemistry for getting the desired mechanical properties
specified by the customers. The Galume product is made by the continuous hot dip
process. The cold rolled coils are welded end to end and passes through 3 stage
degreasing section for achieving excellent cold rolled strip surface. The coating
system is 2 pot system- premelting pot and the main coating pot. The bath

chemistry is continuously controlled and monitored at the pre melting pot which
continuously feeds the main coating pot through the refractory tunnel.
Galume market:
We have produced about 3,00,000 MT as on date from the commissioning of our
Galume production. Our line is fully booked and hopes to produce continuously
about 1,30,000 MT per month.
In India, we are supplying Galume and Pre-painted Galume to reputed companies.
To mention few of them, we supply to Kirby, Tigger steels, Lloyds Insulation,
Multicolor, GSP Power, ERA Metal Bldg, Unimet Profiles, Isolloyds Eng, Color
Roofing, Hawells India Ltd, MG Industries, Ganga roofers, Metco Roof-Pondy,
Century wells and others. Our 80 % of production is exported to various counties
all over the world, USA, European Countries and Spain, South Africa, Italy and
South East Asian countries. There are no Indian standards for this product. We
have established our product in international market against ASTM / EURO and
AS standards. It is imperative to mention to you that now our product or brand is
preferred over Arcelor and Blue scope. Some of our Global direct customers are
Defer co-USA, NOVO Steel USA, Toyota Tshuho, America Nialco SA Belgium,
Savogni Italy, Gibbs Steel, South Africa, Arcelor BarbaDOS, Global RoofingDurban and others.

3. GALAVANISED
Hot-dip galvanization is a form of galvanization. It is the process of
coating iron and steel with a layer of zinc by immersing themetal in a bath of
molten zinc at a temperature of around 840 F (449 C). When exposed to the
atmosphere, the pure zinc (Zn) reacts with oxygen (O2) to form zinc oxide (ZnO),
which further reacts with carbon dioxide (CO2) to form zinc carbonate (ZnCO3), a
usually dull grey, fairly strong material that stops further corrosion in many
circumstances, protecting the steel below from the elements. Galvanized steel is
widely used in applications where corrosion resistance is needed without the cost
of stainless steel, and can be identified by the crystallization patterning on the
surface (often called a "spangle").
Galvanized steel can be welded; however, one must exercise caution around the
resulting toxic zinc fumes. Galvanized steel is suitable for high-temperature

applications of up to 392 F (200 C). The use of galvanized steel at temperatures

above this will result in peeling of the zinc at the inter metallic layer. Electro
galvanized sheet steel is often used in automotive manufacturing to enhance the
corrosion performance of exterior body panels; this is, however, a completely
different process which tends to achieve lower coating thicknesses of zinc.
Like all other corrosion protection systems, galvanizing protects steel by acting as
a barrier between steel and the atmosphere. However zinc is a more electronegative
metal in comparison to steel, this is a unique characteristic for galvanizing which
means that when a galvanized coating is damaged and steel is exposed to the
atmosphere, zinc can continue to protect steel through galvanic corrosion (often
within an annulus of 5 mm above which electron transfer rate decreases).
Application:
Galvanizing Sheet is used extensively for roofing, paneling, industrial sheeting, air
conditioning ducts and structural applications.
Shipping Section:
All Cold Rolled products like CR Coils/Sheets are packed, weighed and dispatched
through Road or Rail Wagons. ETP & GP/GCpackets are packed in the line itself.
Weighment and loading is done in Shipping Section.

POWER PLANT
Introductory overview
In a coal based power plant coal is transported from coal mines to the power
plant by railway in wagons or in a merry-go-round system.Coal is unloaded
from the wagons to a moving underground conveyor belt. It is taken to the
Crusher house and crushed to a size of 20mm . Raw coal from the raw coal
bunker is supplied to the Coal Mills by a Raw Coal Feeder.coal air mixture is
burnt in the boiler in the combustion zone.The boiler is a water tube boiler .
Water is converted to steam in the boiler and steam is separated from water in
the boiler Drum. The saturated steam from the boiler drum is taken to the Low
Temperature Superheater, Platen Superheater and Final Superheater
respectively for superheating. The superheated steam from the final
superheater is taken to the High Pressure Steam Turbine (HPT). In the HPT the
steam pressure is utilized to rotate the turbine and the resultant is rotational
energy.The outlet of the Turbine is sent to the condenser for condensing back
to water by a cooling water system.This condensed water is collected in the
Hotwell and is again sent to the boiler in a closed cycle. The rotational energy
imparted to the turbine by high pressure steam is converted to electrical energy
in the Generator.

Principle
Coal based thermal power plant works on the principal of Modified Rankine Cycle.

Typical diagram of a coal-fired thermal power station

1. Cooling tower
2. Cooling water pump

10. Steam Control valve

11. High pressure steam
turbine
line (3- 12. Deaerator

3. Transmission
phase)
4. Step-up transformer (3phase)
5. Electrical generator (3phase)
6. Low pressure steam
turbine
7. Condensate pump
8. Surface condenser

13. Feedwater heater

14. Coal conveyor

22. Combustion air

intake
23. Economiser

15. Coal hopper

24. Air preheater

16. Coal pulverizer

17. Boiler steam drum

25. Precipitator
26. Induced draught
(draft) fan
27. Flue-gas stack

9.
Intermediate 18. Bottom ash hopper
pressure steam turbine
Boiler

19. Superheater
20.
Forced
draught
(draft) fan
21. Reheater

A boiler is a closed vessel in which water or other fluid is heated. The fluid does
not necessarily boil. The heated or vaporized fluid exits the boiler for use in
various processes or heating applications, including water heating, central
heating, boiler-based power generation and cooking.
The lower part of the boiler has air nozzles below the sand bed and so the name
comes fluidized bed , from which air is supplied for the combustion of coal. The
bed is covered with sand due to its excellent property of heat absorption and to
maintain the heat for coal being injected. The walls of the furnace also contain air
supply for complete combustion of coal. The coal is supplied from the holes
provided on the walls of furnace. Just above the furnace walls are made of tubes
through which water flows and gets the heat from the flue gases generated by
burning coal.
Economizers
Economisers , are mechanical devices intended to reduce energy consumption, or
to perform useful function such as preheating a fluid. The term economizer is used

for other purposes as well. Boiler, power plant, heating, ventilating, and air
conditioning (HVAC) uses are discussed in this article. In simple terms, an
economizer is a heat exchanger. Economiser uses hot flue gases generated by
burning coal to pre heat water. It is a tube type heat exchanger. The main purpose
of using the economizer is to use the heat of flue gases to the maximum extent for
better efficiency.
Air preheater
An air preheater (APH) is a general term used to describe any device designed to
heat air before another process (for example, combustion in a boiler) with the
primary objective of increasing the thermal efficiency of the process. The purpose
of the air preheater is to recover the heat from the boiler flue gas which increases
the thermal efficiency of the boiler by reducing the useful heat lost in the flue gas.
As a consequence, the flue gases are also conveyed to the flue gas
stack (or chimney) at a lower temperature, allowing simplified design of the
conveyance system and the flue gas stack. It also allows control over the
temperature of gases leaving the stack.
Steam turbine
A steam
turbine is
a
device
that
extracts thermal
energy from
pressurized steam and uses it to do mechanical work on a rotating output shaft. A
turbine is a turbomachine with at least one moving part called a rotor assembly,
which is a shaft or drum with blades attached. Moving fluid acts on the blades so
that they move and impart rotational energy to the rotor.
High pressure steam is generated in the boliler which after getting superheated is
sent to turbine , which apply force on the blades to rotate it. The shaft rotates at
around 3000 rpm . This mechanical energy is used to generate electricity by
generator.

Condenser
In systems involving heat transfer, a condenser is a device or unit used
to condense a substance from its gaseous to its liquid state, by cooling it. In so
doing, the latent heat is given up by the substance, and will transfer to the
condenser coolant. Condensers are typically heat exchangers which have various

designs and come in many sizes ranging from rather small (hand-held) to very
large industrial-scale units used in plant processes. A surface condenser is a
commonly used term for a water-cooled shell and tube heat exchanger installed on
the
exhaust steam from
a
steam
turbine in thermal
power
stations. These condensers are heat exchangers which convert steam from its
gaseous to its liquid state at a pressure below atmospheric pressure.

Deaerator
A deaerator is a device that is widely used for the removal of oxygen and other
dissolved gases from the feedwater to steam-generatingboilers. In particular,
dissolved oxygen in boiler feedwaters will cause serious corrosion damage in
steam systems by attaching to the walls of metal piping and other metallic
equipment and forming oxides (rust). Dissolved carbon dioxide combines with
water to form carbonic acid that causes further corrosion.
Generator
In electricity generation, a generator is a device that converts mechanical
energy to electrical energy for use in an external circuit. The source of mechanical
energy may vary widely from a hand crank to an internal combustion engine.
Generators provide nearly all of the power for electric power grids.In any power
plant the generator used is synchronous generation which is coupled through the
turbine such that the turbine acts as a prime mover for the synchronous generator
.For the excitation of the synchronous generator in the power plant an exciter is
used. Here in this power plant Brushless DC excitation is used.
Boiler feed pump(BFP)
It is Installed in between deaerator and boiler.Takes water from deaerator and
supply to Boiler
Condenser Extraction Pump
Installed in between condenser hot well and deaerator .Takes water from condenser
hot well and supply to deaerator.

Low pressure(LP) and High pressure(HP) Heaters

Low pressure heater is placed between condenser and deaerator . Steam from
turbine is extracted and fed to LP heater to pre heat the water supplied from
condenser to deaerator .
High pressure heaters are placed between deaerator and Boiler. Steam from turbine
is extracted and fed to LP heaters to pre heat the water supplied from deaerator to
Boiler.
This used steam from LP and HP heater is sent back to hot well.
Dumping system
It is a by pass system used to send steam to condenser directly due to following
reasons
1. more steam is supplied then sent some directly to condenser.
2. Also during start up water is bypassed untill the required temperature is
attained.
If
ESP(Electrostatic Precipitator)
An electrostatic precipitator (ESP) is a filtration device that removes fine
particles, like dust and smoke, from a flowing gas using the force of an
induced electrostatic charge minimally impeding the flow of gases through the
unit.
Stripper Cooler
When the bed of boiler is over filled with bed ash, a side gallery is opened from
where bed ash is removed to reach to the desired height . It has 3 coolers in
sequence. In first cooler hot bed ash comes in which cold water is sprayed to
lower the temperature of ash then in second and third cooler ash is cooled by heat
exchange with cold water flowing in pipes . This processed bed ash is sent to silos
and finally dumped in land or used in other applications.