VOCATIONAL TRAINING REPORT

INDUSTRIAL TRAINING AT :-
STEEL AUTHOURITY OF INDIA LIMITED (SAIL)
BOKARO STEEL PLANT,
BOKARO STEEL CITY , JHARKHAND

Submitted In Practical fulfillment of the requirements of the degree of

DIPLOMA IN
METALLURGICAL ENGINEERING
BY
RAVI KUMAR
3RD YEAR (5TH SEMESTER)

17103130009

CENTRE FOR BIOINFORMATICS, TUPUDANA,

RANCHI
DATED :- 12TH October , 2019 1
CERTIFICATE

2
 ACKNOWLEDGEMENT

I would like to express my sincere gratefulness and profound gratitude to STEEL

AUTHORITY OF INDIA LIMITED for providing an opportunity to undergo
Vocational Training of 04 weeks in “ BOKARO STEEL PLANT, BOKARO STEEL CITY,
JHARKHAND “.

I bear immense pleasure in expressing my gratitude and thanks to all the Employees
of respective shops for their honest teaching, practical demonstration, guidance and
suggestion in respective shops.

Furthermore, I would like to acknowledge with much appreciation the crucial role of
the staff, who gave the permission to use all the required equipments and the
necessary material during our training period.

This training wasn’t possible if HOD of METALLURIGICAL DEPARTMENT MR.

. OF CENTER FOR BIOINFORMTICS , TUPUDANA, RANCHI . wouldn’t have allowed
us in the first place, so thanks to him as well.

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 Content

1. Introduction
2. Process Flow Of Steel Productin
3. Shop Description
 COKE OVEN & BY PRODUCT PLANT (CO & BPP)
 SINTER PLANT (SP)
 STEEL MELTING SHOP & CONTINOUS CASTING SHOP (SMS&CCS)
 SMS-I
 SMS-II
 CCS
 BLAST FURNACE (BF)
 CONCLUSION

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 INTRODUCTION

STEEL AUTHORITY OF INDIA LIMITED IS India’s largest steel production company and ranks 18th in the
World. It was founded in 19th January 1954. With headquarter at NE an annual turnover of Rs.49350 Crore,
the company is among the seven Maharatans of the country’s Central Public Sector Enterprises.

SAIL. manufactures and sells a broad range of steel. products. including hot and cold rolled sheets
and coils, galvanized sheets, electrical sheets, structural. railway products, plates, bars and rods,
stainless steel and other alloy steaks. It has been possible through 5 integrated plats and 3
special steel plants which employs over a lakh of employees and produces 13.5 million metric
ton of steel annually. Along with this there are various subsidiary and pint venture plant set up
with SAIL

SAIL. has its own Research and Development Centre at Ranch' to examine and improve the quality
of steel production and update the technologies to be in par with rest of the world, Besides,
SAIL. has its own in. house Centre for Engineering and Technology {CET}, Management
Training Institute( MTI) and Safety Organization ad Ranchi. For promoting and selling variouus
long and flat products produced in domestic market and abroad_ SAW. has its own Central
Mark.sting Organization with branches spread all across the India and world. SAIL's International
Trade Division (IDT) in New Delhi- an ISO 9001:2000 accredited unit of CMO, undertakes exports
of Mild Steel products and Pig Iron from SAIL's five integrated steel plants.

SAIL INTEGRATED PLANTS

 Raurkela Steel Plant
 Bhilai Steel Plant
 Durgapur Steel Plant
 Bokaro Steel Plant
 IISCO Steel Plant

SPECIAL STEEL PLANT

 Alloy Special Steel Plant , Durgapur, West Bengal

 Salen Steel Plant, Tamil Nadu
 Visvesvaraya iron and Steel Plant, Karnataka.

SUBSIDIARY
 Maharashtra Elactrosmelt Limited (MEL) in Maharashtra

JOINT VENTURE

 NTPC SAIL Power Company PVT.LTD (NSPCL)

A 50-50 joint venture between Steel Authority Of India LTD . (SAIL) And National Thermal Power
Corporation LTD (NTPC LTD. ) manages the captive power plant at Rourkela, Durgapur and Bhilai with
a combined capacity of 314 mega watts(MW) . it has installed additional capacity by implementation of
500MW power plant at Bhilai . The commercial generation of 1st unit has commenced in April 2009 and

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2nd unit is likely to start commercial generation by july 2009.
  BOKARO POWER SUPPLY COMPANY PVT.LTD (BPSCL)
The 50-50 joint venture SAIL at the Damodar Valley Corporation formed in January 2002 is managing
the 302 MW power generation station and 600tons /hr. steam generation facilities at Bokaro Steel Plant.
BPSCL has porposed to extend its capacity by installing 2*250 MW coal based thermal unit at bokaro. In
addition, construction activities are underways for installation of 9th Boiler (300t/hr.) & 36 MW back
Pressure Turbo Generator (BPTG) project at Bokaro.

LIST OF SAIL CUSTOMER

INDUSTRIES TYPES OF STEEL USED
Railways Wheel, axel, rails, plates, sheets

Shipbuilding & Bulding Engineering

Sector. Heavy Plates, Sheets.
Construction Works , Bridges
Air Conditioning ducts, roofing, TMT bar, Rods, Structural Steets.
pancling
Consumer Durables Galavanizes Steel.
Transport of oil, Gas, Water.
Ultra Thin Cold Rolled Sheets
Industrial &Consumer use

Defense Steel Pipes,.

Stainless Steel.

Special Grade Steel (Armour grade steel, warship, bullet

proof Steel &Many more defense grade steel.

 SPECIAL PRODUCT
Rockets Launcher, Agni Missile, INS VIKRANT, Arjun Main Battle Tank, Armoued Vechicals.

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 MAJOR UNITES OF SAIL

Some major products of SAIL are being marketed under the following brand names: SAIL Boiler, SAIL TMT,
SAIL NOX, SAIL Marine, SAIL TOR. SAIL Superform, Sail Tin, SAIL Press, SAIL Jyoti, SAILMA, SAILCOR
and Salem Stainless.These products are proving beneficial to an array of applications in diverse fields.

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 BOKARO STEEL PLANT

Bokaro Steel Plant is the fourth integrated steel plant of SAIL. Established in the year 1964 with Soviet
collaboration, it is the first Swadeshi Steel Plant of India with maximum indigenous components and
equipment. It was later merged with SAIL first as a subsidiary and then as a unit under Public Sector Iron
& Steel Companies (Restructuring & Miscellaneous Provisions) Act 1978.

Its 1st blast furnace was started in 2nd October 1972 and on 26th February 1978 it completed the 1st phase of 1.7
MT of ingot steel production. Presently it has five blast furnaces and a total capacity To produce 4.5 MT of liquid
steel. With the continuous up gradation in technology incorporated, it is expected to cross 10MT target by 2016.
The first shop of Bokaro Steel plant got the ISO 9001 certificate in 1994 and its SAIL JYOTI products enjoy a
loyal market.

Bokaro Steel Plant is designed to produce a wide range of flat products:

• Hot rolled coils

• Hot rolled plates
• Hot rolled sheets
• Cold rolled coils(CRO)
• Cold rolled sheets
• Tin mill black plates (tmbp) Galvanised plain and corrugated (gp/ge) sheets
• Oxygen Gas Produced in Oxygen Plant.
• Hydrogen Gas

The new features added in modernization of SMS-II include two twin-strand slab casters along with a Steel
Refining Unit. The Steel Refining Unit was inaugurated on 19th September, 1997 and the Continuous Casting
Machine on 25th April, 1998. The modernization of the Hot Strip Mill saw addition of new features like high
pressure descaler, work roll bending. hydraulic automatic gauge control, quick work roll change, laminar cooling
etc. New walking beam reheating furnaces are replacing the less efficient pusher type furnace.
A new hydraulic coiler has been added and two of the existing ones revamped. With the completion of Hot Strip
Mill modernization, Bokaro is producing top quality hot rolled products that are well accepted in the global market.

Bokaro is designed to produce flat products like Hot Rolled Coil. Hot Rolled Plates, Hot Rolled Sheets
Cold Rolled Coils, Cold Rolled Sheets. Tin Mill Black Plates (TMBP) and Galvanized Plain and Corrugated

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(GP/GC) Sheets. Bokaro has provided a strong raw material base for a variety of modern engineering industries
including automobile, pipe and tube, LPG cylinder, barrel and drum producing industries.
 Area of plant 17.000 acre
 Township Area 19,000 acre

 Carbon content is 1.5% in steel at Bokaro

 Inside Bokaro steel Plant

 300 km railway track

 100 rail crossing
 70 loco is present
 10-12 gates are there for entry/exit in plant.

9
PROCESS FLOW OF STEEL PLANT

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Raw materials required for the production of steel are iron ore, limestone, manganese, dolomite, coke, and
sinter. These are supplied by RMHP, coke oven and sinter plant. Blast furnace is charged with iron ore
lump along with limestone, coke and sinter. Intense heat from in BF converts iron oxide to hot metal. This
hot metal is fed to Steel Melting Shop (SMS). Making of steel takes place here by blowing 99.95% pure
oxygen through the hot metal to remove impurities. Suitable alloys are added to produce different grade of steel.
Raw material such as limestone, ferrous alloys, dolomite, and aluminum are also required. The steel ingot produced
in SMS is goes to Slabbing mill where it is converted to rectangular slabs of appropriate thickness. From the
slabbing mill the slab goes to Hot strip mill. It also receives the slab form SMS 2 which is based on continuous
casting. It directly produced slab without producing ingot. These slabs are heated and made into sheets of different
thickness in HSF. These steel sheets are rolled in the form of coil in HRCF. These coils are cut in appropriate
dimension as specified by the customer and packed for sale. Also the coil from the HSF is sent to Cold Rolling
Mill. It produces high quality Tin Mill Black plate and galvanized product with better strength and finish. Cold
Rolling is done at temperature below re crystallization temperature to produce thin gauge plate of high density.
There is no heating of the coil here. Hot Dip Galvanization complex integrated with CRM produces high quality
zinc coated cold roll steel.

The detailed information about every department are given below :-

 Raw Material Handling Plant (RMHP)

 Coke Oven and By-Product Plant (CO & BPP)
 Sintering Plant (SP)
 Blast Fumace
 Steel Melting Shops (SMS 1 & SMS 2
 Continuous Casting Shop (CCS)
 Slabbing Mill (SM)
 Hot Strip Mill (HSM
 Hot Rolled Coil Finishing (HRCF)
 Cold Rolling Mill (CRM
 Capital Repair (Electrical)
 General Maintenance
 Heavy Maintenance
 Turbo Blower Station (TBS) and Outdoor Pipeline (ODPL)
 Machine Shop
 Foundry Shop
 Central Base Repair Shop (CBRS)
 Operational Garage(OG)

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 SHOP DESCPRICTION
 COKE OVEN & BY PRODUCT PLANT (CO&BPP)
In an integrated steel plant, Coke-Oven & By Product Plant plays an important role. It is a shop where coal is
charged and converted to coke. Coke Ovens at Bokaro are the tallest and largest built in India so far. In the first
stage (1.7MT), four batteries each of 69 ovens with facilities for coal handling and with complete by products
recovery units were built Four more batteries of similar features have been added in 4 MT expansion stage which
includes one standby battery.

 80% coal comes from Australia & New Zealand.

 20% coal comes from India mainly kiriguru mines & regions from Dugda. Kathara Kargali, Giddi
 Jharia, chandrapura, dhanbad, phusro etc.

 Ash % in coal of India is 27%

 Ash % in coal of Australia & New Zealand is 7%

There are 81 coal storage chambers where coal is stored and then from here coal is send to the charging oven coal
where 950 C is charged at of temp. 900°C to After the coal is charged it is loaded in the quenching car which
brings the charged coal to the quenching chamber where it is charged and then it becomes coke. It supplies coke,
one of the two principal raw materials to the Blast Furnace In addition to coke-oven gas produced during coke
manufacturing is used as major energy source within the integrated steel plant along with B.F gas produced during
combustion of coke in Blast Furnace.

The entire resources of coal can be classified into two groups!

1 Coking Coal
2. Non-Coking Coal

If the coal when heated to bright red in absence of air softens swells and eventually solidifies into a more or less
coke, it is classified as coking or caking coal. All coking coals are caking in nature but all caking coal are not
coking. Coking coal on carbonization gives metallurgical or blast furnace coke. Non-coking coal fails to produce
blast furnace coke on carbonization. The moisture, ash, sulphur and phosphorous content in the coal play a vital
role in deciding the quality of coke that will be produced in the coke-oven area. They lower all side should the be
on

There are four sections in coke-ovens and by product plant, they are:

1. Coal Handling Plant

2. Coke-Oven Batteries
3. Coke Sorting Pit
4. By Product Plant

The main purpose of this plant is to produce quality coke in large quantities along with useful coke-oven
gas, while conserving limited reserve of quality coking coal and practicing economy in environment
SAIL control measures. The process of making coke consists of destructive distillation of coal in the absence of air.
The coal is heated in a closed chamber thereby driving out of volatile components present in the coal and leave
behind the residue called coke. These closed chambers are known as Coke-Oven Batteries, there are 8 batteries in
BSL. There are 69 ovens in each battery. The carbonization temperature is usually kept in the range 1473k-1573.

The composition achieved after carbonization is

 Fixed carbon: 77%

 Ash content: 22%

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 Volatile matter: 1
A typical composition of coke-oven gas (CO Gas) is:

• Methane: 22-25%
• Hydrogen: 55-60%
• Nitrogen: 2-3%
• Carbon-monoxide: 8-10%
• Carbon dioxide: 4-6%
• Calorific value: 4200-4400 Kcal/cubic meter

After coke is produced it is stored in different sizes according to the place of consumption, acid treatment
and absorption process in coal chemicals and By Product Plant. It is a technological necessity in order to
make Coke-Oven gas suitable for use as a major source of fuel in the steel plant.

1. COAL
Two Types Of Coal is Used
 Anthracite
It is type of coal which is 80% to 85% pure form and give less ash
 Bituminous
It is a medium grade of coal having high heat capacity .
80% of Anthracite and 20% of Bituminous is used in Coke Oven.
2. COAL TIPPLE
The WAGON TIPPLER is the mainly designed type of tippler to unload the raw materials. Coal is also
unloaded from the box with the help of tippler.
3. COAL SILOS
A Coal Silos is a structure for storing bulk materials . Huge amounts of coal is stored in this Silos

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 SILOS

4. HAMMER CRUSHER
The exported coal are in very big sizes , and the coke oven requires a limited size to be dumped into it. So,
the coals are crushed into small sizes as per requierement.
Type of crushers used.
 JAW CRUSHER
 CONE CRUSHER
 IMPACT CRUSHER
5. COKE OVEN BATTRIES
The industrial product of coke from coal is called “Coking”. The coal is baked in airless kiln a(COKE
FURNACE) or “COKE OVEN” at the temp. as high as 2000’c but usually around 1000 to 1,100’c temp
is used.
This process vaporizes or decomposes the organic substance I the coal driving off volatile product
Including water in the coal and coal tar. Heat produced in the coke oven by providing mixture of hot mix
gas and B.F gas. The Coke Oven battery has 8 batteries with 69 ovens each, maintained meticulously in
terms of fugitive emission control, use of phenolic water and other pollution.

6. BATTRIES
The places were named as battery because it’s the place where the coal are charged and turned into coke.
Each battery contain 69 ovens capacity of each battery is 22tons &its take around 16 to 18hrs to charge
22tons of coal. After this interval of time the coal become charged and hence called COKE . They are
made up of REFACTORY BRICKS AND REFACTORY STEEL.

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COKE OVEN

BATTERY

PUSHING CAR

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 MAIN PARTS OF COKE OVEN

 CHARGING CAR
It is the car like structure which keeps above the coke oven |&it is used to charge the coke oven by
dumping the coal into it. It has a capacity of 22tons at a time. It is fully machine operated. It supplies coal
from the coal tower located btw two batteries.
 PUSHING CAR
When the coal is filled in the coal tower this car is used to level the coal inside the coal oven and when the
coke is charged both side gate is opened and with the help of ram the red hot coke is pushed out into the
guide car .
 DOOR EXTRACTOR \ GUIDE CAR
It is used collect the red hot coal and transport it to the quenching tower .
 QUENCHING TOWER
It receives the hot coke from the oven . it consist of chilled water in which red hot coke is dumped and set
there for 3mis to remove the redness of the coke.(redness of the coke is to be removed because it red ho
coke is dumped in any material due to its redness the object will start melting.)

QUENCHING TOWER

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 BY PRODUCT PLANTS

The different by products produced are as follows :-

• Crude tar
• Naphthalene
• Naphthalene oil
• Wash oil
• Press oil
 Pitch (Extra Hard Pitch & Hard Medium Pitch)
 Ammonium Sulphate
 Benzene
• Toluene
• Xylene
• Naphtha

BENZENE PLANT CRUDE TAR

NAPHTHALENE

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  SINTER PLANT

Sintering is a process of agglomeration of fine mineral particles into a porous and lumpy mass by incipient fusion
caused by heat produced by combustion of solid fuel within the mass itself.

RAW MATERIALS USED FOR SINTERING

1. Iron ore fines

2. Flux ( lime stone & dolomite )

3. Coke breeze

4. Waste Materials:

a). Flue dust ( From Blast Furnace but added in RMHP )

b). Mill scale ( From Slabbing Mill, H.S.M.&CCS)

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c). L.D.Slag (From S.M.S.)
d). Lime dust ( From R.M.P.)

5. Sinter return ( Own generation )

SINTER MACHINE

Sinter Machine Specification for each machine

There are three Sintering machines

Length - 78 M

No. of pallets - 130

Sintering area – 252M2

Bed height - 480mm

Exhauster - 02 Nos. (Each)

Aspirator - 02 Nos. (Each)

Cooler – Blower- 06 Nos. (Each)

Balling Drum - 02 Nos. (Each)

Drum Cooler - 01 No. (Each)

Straight line Cooler - 01 No. (Each)

SINTRING MACHINE

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  Agglomeration is defined as the process to prepare a suitable Blast furnace feed for smooth, proper and
efficient running of the Blast furnace operation.
The process of agglomeration can be classified as follows:
i) Briquetting.
ii) Nodulising.

• Iii)Vacuum Extrusion process.

iv) Sintering
v) Pelletizing.

TYPES OF SINTER

• Depending upon weather bases have been incorporated in the Sinter mix, sinters are divided into three
broad classes: -

(i) NON FLUXED OR ACID SINTERS: - Those where no flux is present or is added in the ore.

• (ii) BASIC SINTER OR SELF FKUXING SINTER: - Those where sufficient flux has been added in the
sinter mix to provide a basicity that is desired in the final slag, taking into consideration only the burden
acids. An extra flux is added to the BF burden, to take care of coke ash acids.

(iii) SUPER BASIC OR SUPER FLUXED SINTER: - In these type of sinters an additional flux is added
to the mix to provide for the desired final slag basicity, taking into account the acids content of both ore as
well as the coke ash.

PRINCIPLE OF THE SINTER MAKING PROCESS

• Iron one sintering is carried out by putting GREEN MIX after Mixing and Nodulizing drum (a mixture of
Base mode with iron ore fines, mixed with flux, coke breeze as a solid fuel, other additions, sinter return
fines, lime, moisture) over a traveling gate in form of permeable bed and permeable bed.

• The top layer of this sinter bed is heated to the sintering temp. (1200C-1300C) inside a Ignition Hood
furnace. In the ignition hood the air is drawn downwards, through the grate with the help of exhaust
blowers (Waste Gas Fan) connected by means of Waste gas main.

• The narrow combustion zone developed initially at the top layer by layer to the sintering level. The cold
blast drawn through the bed cools the already sintered layer the thereby gets itself heated. The heat
contained in the blast is utilized in drying and preheating the lower layers in the bed. In advance of
combustion therefore each layer gets dried and preheated by the heat transferred from the upper
combustion zones. The lower portion of the bed absorbs much of the heat in the gases.

• In the combustion zone, bonding takes place between the grains and a strong and porous aggregate is
formed. The process is over when the combustion zone has reached the lowest layer of the bed. The sinter
cake is thus tipped from the grate in hot condition . It is then broken, cooled in sinter cooler cold sized and
sent to the Blast furnace.

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 SINTER PLANT

QUALITY CHECKING MACHINE

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  STEEL MELTING SHOP & CONTINOUS CASTING SHOP
Steel making involves the process of removal of impurities like carbon, Manganese, Sulphur. Phosphorous and
other impurities from the hot metal by oxidation and formation of basic slag.

Steel at Bokaro is produced by oxygen blending (LD) process. There are five 130 ton and two 300 ton L.D
converters in Bokaro. The converters are charged with scrap. hot metal and fluxes. Pure oxygen is blown through
water-cooled lance with multi-orifice nozzle to remove impurities by oxidation and then steel is made Purity of
oxygen used is 99.5%.Approximately 60 cu m. of oxygen is used to produce one ton of steel. The tap to tap time
for the 130 ton and 300 ton converters is 60 and 80 minutes respectively.

To achieve optimum levels of performance ensuring maximum productivity. yield and quality in the process of
steel making, a process control computer has been installed in the Steel Melting Shop. Near the Steel Melting Shop
is located the Ingot Mould preparation shop. The moulds vary in size to enable production of ingots ranging from
15.6 to 38 tonnes.

There are two Steel Melting Shop (SMS), SMS-I & SMS-II. Three types of products are produced from these
shops. They are:

1. Killed Steel

2. Semi-Killed Steel

3. Reamed Steel

Apart from the hot metal from the Blast Furnace, the different raw materials required for the production of steel
are:

 Limestone
 Dolomite
 Aluminum
 Ferro-Alloys

The main functions of Steel melting shop are as follows:

• Oxygen blowing process.

• It receives hot metals from blast furnace.
• Output of smsi is in ingot form.
• Output of sms2 is in slab form.
• From sms2 it goes to continuous casting shop
• Steel melting process of removal of impurities like carbon and silicon

STEEL MELTING SHOP – I (SMS – I)

The SMS-I has 5 LD Converters each of 100/130T capacity & 75M3 working volume. Out of these 3 are
continuously in running conditions & out of other two one is under repair & other is reserve .In these converters,
we make steel through Ingot route & use 17, 20. 25 & 28 T moulds for that. Technically pure oxygen (99.9%pure)
is blown from top through a water cooled lance so as to remove the impurities of Hot metal by oxidation. As a
result of this oxygen blowing process, hot metal converts in to steel.

The steel produced at BSL is meant for products like –

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 1.- Plates
2.- Sheets
therefore of low carbon type. All the 3 types of steel (killed, semi killed & rimming) is produced at SMS-I .
Presently we only make semi killed steels .The rated capacity of the shop is 2.5MT of ingot steel.

Flow diagram of SMS -1

Different sections
The major sections of the shop are :-
1. Mixer
2. Bulk material & ferroalloy storage & magnetic yard
3. Converter
4. Slag yard
5. Pit side
6. Stripper yard, hydro- cooling and cleaning section, Graphite coating yard, mold preparation section.

 Mixer
The hot metal that comes from blast furnace is first received in mixers .which serves 3 purposes---
 It acts as a hot metal reservoir. Hot metal from mixer is supplied to the converters as per demand.
 It maintains the required temperature of hot metal by the use of burners.
 It homogenizes the composition of hot metal received from different furnaces & casts.

There are 2 mixers in the shop each of 1300T capacity. A mixer is a refractory lined cylindrical drum with charging
door at the top and a pouring spout at one side of the cylindrical surface .The mixer can be tilted with the help of
motor drive at the times of pouring out hot metal. The temperature of hot metal is maintained at 1250 –13100c with
the help of 3 co mixed gas burners, two are horizontal at two ends and one vertical near the pouring spout.
The hot metal comes to the mixer from blast furnace in hot metal ladles. These are lifted to the mixer floor and then
hot metal is charged in the mixer with the help of crane. Before the ladles are lifted, the hot metal surface which
remains covered with slag crust is pierced with the help of a conical punch or by oxygen lancing. A minimum
amount is kept in the mixer which depends on the continuity (inflow – outflow) of metal & life of the mixer.
The refractory lining (facing hot metal) of the mixer is of fire brick in the roof and chrome magnesite in the
bottom and end wall. After supplying about 0.7-0.8 MT of hot metal, mixer is declared down for capital repair.
A special feature of the mixer is its self returning mechanism. i.e. in case of power failure when it is

23
pouring out hot metal it will automatically return to its original position. This has been effected by forwarding the
axis of rotation from its geometrical axis by 300MM.The hot metal transfer from the mixer zone to the converter
zone is done in mixer ladle with the help of a locomotive.

 Converter
In converter, the hot metal received from blast furnace is converted to steel by removing carbon and other elements
present. A typical analysis of hot metal received from blast furnace is:--
C- 3.5 - 4.0% , Si- 0.6-1.0% , Mn- 0.01- 0.10% , S – 0.06% max , P - 0.11 - 0.18%

Converter lining

The refractory lining of the converter may be described in 2 parts—

1. Converter body: Converter body is given a permanent lining and above it a wear lining is given.

a. permanent lining :- The full height of converter body is given a permanent lining of chrome magnesite
bricks.

b. Wear lining: - Varying thickness of wear lining of MCB is given first after the permanent lining depending
upon the position of converter body.

2. Detachable bottom: The total depth of the detachable bottom is filled with the following materials in varying
cross section- Chrome-mag, Mag - chrome & MCB.

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CONVERTER IN SMS -I
  Waste heat boiler
Since converters of SMS-I operates under open combustion system i.e. whatever co gas generated in smelting
process gets burned at the converter mouth. So the latent heat of combustion is used to operate waste heat boiler.
But now a days it is in-operative.

 Slag yard

The function of slag yard is to receive, cool, crush and dispatch the slag. The molten slag is received in lime coated
slag pots which are tilted by means of motor and rack and pinion arrangement. The molten slag is
cooled by means of water spray and crushed in to pieces by dropping a heavy weight (an ingot) on the solid slag
mass. There are magnetic cranes for the purpose of lifting and dropping the weight. After crushing the slag to
smaller pieces then transported to rubbish yard by dumper .Now a days it is used as a flux / coolant in the converter
as it contains approx. 45% –55 % Cao.

 Pit side

The pit side work can be divided in 2 main parts---

a. – Teeming b. - ladle preparation

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 a:--Teeming--- After tapping the ladle is transferred to the teeming bay by means of steel transfer car and crane. In
between tapping and teeming the ladle is held for about 10 min to allow deoxidation products to float up just after
tapping temperature of liquid steel is measured by dipping thermocouple tips.
The teeming ladle is equipped with slide gate mechanism which facilitates the opening and closing of the ladle
nozzles for teeming.

The pouring of steel in to mould is kept slow for about 5-10 seconds at the beginning and then the nozzle is fully
opened. The operator keeps a watch that the stream is vertical and compact, the nozzle is not leaking; the stream is
centered and over flowing of mould does not occur. If there is nozzle jamming it is removed by lancing oxygen.
The ingot mould filling time is normally 90-150 seconds depending upon the mould size.

The ingot mould train is moved to the holding track within 15 min and held in the holding track for
2-2.5 hours. For semi killed steel, the ingot mould train is not moved before 15 min after teeming, and finally
stripped in the stripper yard after 1-1.5 hours of teeming track time is normally 3hours.

b.-Service ladle preparation:-

Immediately after teeming the cylinder of the power pack system stationed in the teeming platform is detached
from the slide gate mechanism fitted at the bottom of the ladle, keeping the sliding plate in open position. then slag
is dumped. After that the ladle laid in the pit and oxygen lancing is done to clean the nozzle of any metal. The
mechanism is then opened both the top and bottom plates (refractory) are removed .used spring from the
mechanism are taken out. Then the nozzle (both outer and inner) condition is checked. If the nozzles are found in
good condition then some amount of air setting cement in paste is used in dressing the nozzles .The top plate is
placed with a layer of mastic (inflow mass). New tested spring are placed inside the mechanism .The bottom plate
is placed inside the machine. The machine is then closed. The gap between the sliding plate and bottom plate is
covered by the plastic clay.

The ladle is lifted vertically with the help of crane and taken to the platform and from the top of the platform well-
mix to the tune of 12kg is added in a bag to fill the nozzle with the mixture. Now the ladle is ready for placement of
tapping of heat.

 THE LANCE
Presently we are using 4 hole Lance .the inclination of all holes in the tip with respect to vertical axis is 4 0 .and
since all the nozzles are convergent divergent type .the angle of divergence is 12 degrees The length of the lance is
approx. 14.7 M The whole length of the lance is water cooled except tip which is cooled by joule- thomson effect
due to adiabatic expansion of the gases (oxygen)

The minimum lance water pressure – 8 kg / cm2 & lance water flow – 90 Nm3 /hr is maintained . Interlocks have
been provided to maintain it. If any of the parameters go below this limit during blowing Lance will lift
automatically . The average lance life is 5 – 6 in S.M.S. 1.

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 FINAL PRODUCT OF SMS – I

STEEL MELTING SHOP – II (SMS – II)

SMS-II differs from SMS-T because of blowing process and converter gas recovery system. The mode of
combustion in SMS-II is suppressed combustion where atmosphere air is not allowed in hood area and combustion
of converter gas flux suppressed which is further used Inputs: Hot metal from the blast furnace Outputs Semi-Killed
or Killed steel to continuous casting machine exclusively Sections: Major sections of SMS-II are as follows:

 Mixer: The mixer is of 2500 T capacity and the temperature is 1573 1593 K. The mixer acts as a reservoir
of hot metal homogenizes it and maintains the temperature. It acts as a buffer stock Hot metal from mixer
is supplied to converter by locos. There are two mixers in SMS-II

 Converters: This converts hot metal into steel by oxidation following an exothermic reaction. Lime, Scrap
& Following hot metal are charged in a definite sequence and then oxygen lancing is done. The lime and
other addition are done during blowing through slide gate system. Lime is added as a flux to maintain the
basicity of bath. Basicity is defined as the ratio of Calcium Oxide & Silicon Oxide and is kept between 3-
3.5. There are two converters of 300 T capacity each.

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 Steel Refining Unit: This unit homogenizes the temperature and chemical composition of liquid steel
received from different converters. Desulphurization of steel is done up to a Sulphur level of 0.01%.
 Adding prerequisite quantities of Ferro-alloys also dose chemical correction of steel. End point temperature
control of liquid steel is done by heating or cooling the melt.

 Continuous Caster: It is the heart of SMS-II and has following main parts :-

• Tundish: It is refractory liquid buffer vessel designed to continuously feed liquid metal from ladle to
continuous casting mould at regulated flow rate.
• Mould: Solidification of metal starts in the mould. Copper using primary cooling mode generally makes it.
At the beginning of casting, a dummy bar is inserted inside the mould to avoid free fall of steel. Continuous
lubrication between and steel is provided by mould powder. It also acts as coolant.
• Secondary Cooling Zone: The metal after leaving the mould enters in its secondary cooling comprising
arrays of rollers and water spray nozzles. Rollers support and guide its downward movement of strand and
water spray cools the strand resulting in complete casting

 Straightening Rolls: These are located at the end of strand 2 where fully solidified strand is straightened
by pairs of internally water cooled rolls and made to move over horizontally placed roller tables. After the
stand has been straightened, it is cut to required length using acetylene cutting machine.

Liquid steel sends to the continuous casting shop for making slab. Their final product is sheet & coil. In SMS II a
section has been named “slag yard”.

CONTINOUS CASTING SHOP (CCS)

There are two double stand casting machines capable of producing slabs of 950mm to 1850mm width (cold).
Thickness can be of 200mm, 225mm or 250mm. Converter metal of SMS is further refined in the Steel Refining
Unit (SRU) and cast into slabs in the casting machine, In the process of casting, metal is poured into tundish from
the ladle and from tundish. metal flows into caster mould. Normally it takes 60 to 65 minutes for casting 290-300
tonnes of metal in to slab. Depending upon the slab width, the rate of
pouring can be from 0.9 metres/minute to 1.8 metres/minute. The yield ratio (liquid metal to slab) in caster is 97-
98% where as in earlier route (liquid metal-ingot slab) yield ratio is about 80%. In caster, chemical uniformity from
slab to slab is better. Now plant is producing better quality slabs at lower production cost after modernization

Advantages of Continuous Casting:

 It gives higher yield.

 2. Energy consumption is low.
 3 Operating cast is low.
 4. Role of primary mills gets eliminated.
 
Continuous casting, also called strand casting, is the process whereby molten metal is solidified into a
"semifinished" billet, bloom, or slab for subsequent rolling in the finishing mills. Prior to the introduction of
continuous casting in the 1950s, steel was poured into stationary molds to form ingots. Since then, "continuous
casting" has evolved to achieve improved yield, quality, productivity and cost efficiency. It allows lower-cost
production of metal sections with better quality, due to the inherently lower costs of continuous, standardized
production of a product, as well as providing increased control over the process through automation. This process is
used most frequently to cast steel (in terms of tonnage cast). Aluminium and copper are also continuously cast.

THE PROCESS
 1.Molten metal, from some nearby source, is poured into a tundish
 (A tundish is a container that is located above the mold,it holds the liquid metal for the casting)

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 2. This particular casting operation uses the force of gravity to fill the mold and to help move along the
continuous metal casting.

 3. The tundish is placed about 80-90 feet above the ground level .

 4. The tundish is constantly supplied with molten steel to keep the process going.

 5. The whole process is controlled to ensure there is smooth flow of molten steel through tundish

 Further, the impurities and slag are filtered in tundish before they move into the mold.

 7. The entrance of the mold is filled with inert gases to prevent reaction of molten steel with the gases in
the environment like oxygen.

 8. The molten metal moves swiftly through the mold and it does not completely solidify in it.

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9. The entire mold is cooled with water that flows along the outer surface.

 10. The metal casting moves outside the mold with the help of different sets of rollers.

 11. While one set of rollers bend the metal cast, another set will straighten it.

 12. This helps to change the direction of flow of the steel slab from vertical to horizontal.

 BLAST FURNACE
Blast Furnace can be termed as the core metallurgical reactor for the production of hot metal. It is a
counter-current heat & mass exchange rector in which there is continuous transfer of mass (oxygen.
carbon, hydrogen) & thermal energy between descending burden materials and ascending gases generated
at tuyer level.
Iron present in the form of oxides in ore is extracted in the Blast Fumace by interaction of ore, coke and
limestone at high temperatures. Besides providing heat, coke reduces the iron oxides present in the ore
Limestone and Dolomite combine with the impurities and form slag. This slag floats on the surface of the
hot metal in the furnace. Both slag and metal are tapped at regular intervals. The Blast Furnace at Bokaro
are the largest in India having a useful volume of 2000 M Cube and a production capacity of 2640 tonnes
of basic iron per day. There are five Blast furnaces in 4 MT stage with total iron production capacity to the tune of
4.585.000 tonnes per year. The charging system is fully automatic. Materials are fed in to skips by means of
converse. The furnace has a hearth diameter of 9750 mm, useful height of 29.6 m and has 20 tuyeres and 4 stoves
with a total heating surface of 30.300 sq.m per stove

The inputs required for the Blast Furnace are as follows:

• Iron-Ore Lamp
• Sinter
• Metallurgical Coke (25mm to 80mm)
• Lime-Stone
• Manganese
• Nut Coke

The outputs from the Blast Furnace are as follows

• Hot Metal
• Blast Furnace (BF) gas
•

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Gangue Material in the form of slag
Different sections of Blast Furnace are as follows:

1. Raw Material Charging Section: This section receives raw materials from RMHP, Sintering
Plant, Cock-Ovens and then supplies them to the furnace top by means of a skip car

2. Furnace Power: Raw materials are changed into it and then hot blast of air at 1373 K is supplied.
Due to the occurrence of exothermic reaction, reduction of iron oxide to hot metal takes place. It
has five main sections, they are as follows:
 Hearth
 Bosh
 Belly
 Stack
 Throat

3 Stoves: Hot air blast is supplied through stoves, which are maintained at 1523 K with the help of
combustion if mixed gas. The stoves have refractory lining of chrome-magnetite from inside & fire
clay lining from outside.

There are total 5 Blast Furnaces (2640 ton/day).

In the BSL, each having a volume of 2000 cu.m and working volume of 1756 cum. A Blast of Hot air at 1373 k is
temperature is given to the Blast Furnace.
This blast is given at a pressure of 3.2 Kg/sq.cm.
• Hot Metal Temperature 1460-1480°C
• BF Productivity: 14 T/m Day
• Capacity of B F 4.585 MT of Hot Metal per annum

The hot metal from the furnace has the following specifications

Carbon=4.0-4.5%
Silicon=0.6-1.2%
Manganese=0.6-1.2%
Phosphorous=0.25%
Sulphur=0.05%

Cock Rate: Cock Rate is the amount of cock required per ton of hot metal. Cock Rate at present 560 Kg/THM
Earlier THM Tone of Hot Metal

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The purpose of a blast furnace is to reduce and convert iron oxides into liquid iron called "hot metal".
The blast furnace is a huge, Steel Stack lined with refractory brick. Iron ore, coke and limestone are put into the
top, and preheated air is blown into the bottom. Both the slag and iron are drained from the bottom of the
furnace.The slag is mainly used to build roads.The iron whilst molten is poured into moulds and left to solidify -
this is called cast iron and is used to make railings and storage tanks. The rest of the iron is used to make steel.
Several reactions take place before the iron is finally produced...

Oxygen in the air reacts with coke to give carbon dioxide:

C(s) + O(2)  CO2 (g)

The limestone breaks down to form carbon dioxide:

CACO 3(S)  CO2 + CaO(s)

Carbon dioxide produced in 1 + 2 react with more coke to produce carbon monoxide:

CO 2(g) + C(s)  2CO(g)

The carbon monoxide reduces the iron in the ore to give molten iron:

3CO( g) + Fe2O 3(S)  2Fe(l) +3CO2(g)

The limestone from 2, reacts with the sand to form slag (calcium silicate):

CaO(s) + SiO(s)  CaSiO3(l)

The purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called
"hot metal". The blast furnace is a huge, steel stack lined with refractory brick, where iron ore, coke and limestone
are dumped into the top, and preheated air is blown into the bottom. The raw materials require 6 to 8 hours to
descend to the bottom of the furnace where they become the final product of liquid slag and liquid iron. At furnace
temperatures of about 1800 °C, give or take 200 degrees, these liquid products are molten and trickle down to
collect in the base of the furnace, or hearth, where they are extracted at regular intervals. The hot air that was blown
into the bottom of the furnace ascends to the top in 6 to 8 seconds after going through numerous chemical
reactions. Once a blast furnace is started it will runcontinuously for four to ten years with only short, periodic stops
to perform planned maintenance.

Blast furnaces were first invented in the late 14th century and were improved most significantly by Henry
Bessemer during the Industrial Revolution. Blast furnaces will continue to be a useful tool for smelting in the
future because of the large quantities of metals it is able to extract over a long period of time.

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BLAST FURNACE

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 CONCLUSION

The training at BOKARO STEEL PLANT was very helpful

Engineering students gain theoretical knowledge through books. It is volatile and not of much use without
knowing its practical implementation

Training is one of the important aspects for an engineering student's carrier to strengthen the practical
concepts. It was an awesome experience in training as the things we all learned in our previous year was
seen implemented practically.

I had a chance to see the blast furnace and steel melting shop where the main working of steel plant is
being done and also I saw the working of various shops of the plant, which was very interesting. So the
training was more than hope to me and helped me to understand about power system more.

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