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ABSTRACT
In this regard after visiting the site and collecting the necessary
dimensions a 3Dimensional modeling using CATIA has been done for the
existing and modified design. Also the model has been imported to ANSYS
and the von-mises stresses have been obtained by applying fixed support
constraint
and loading conditions and the stresses induced in the trunnion ring is
around 25.32 N/mm2 in the existing trunnion and 36.5 N/mm2 in the
modified trunnion ring. With the material of ASTM-A36 of the trunnion, the
existing Factor of safety is reduced fTom 11 to 8 and as per the norms for
the structural the allowed factor of safety shall be above 5. Hence the
design is safe for the operation. The data is presented with 3D model of
objects, meshed images and von-mises
stresses. The present analysis was done only in static case. This can be
further
SOCIAL RESPONSIBILITY
Peripheral development and special concern for the displaced persons underling the
Visakhapatnam steel plant's commitment and concern for the social and regional development
around it. As a special gesture for the welfare of the displaced persons, Visakhapatnam steel plant
provided them with over 5,900 jobs, which constitute more than 1/3 of its total non-executive
manpower. In the recruitment policies of VSP displaced persons have been given several
concessions in the areas of educational qualifications, age and skill levels. As a part of social
responsibility VSP took a massive afforestration program has been launched in and around the
plant. Out of the total 9,200 hectares of area 3,600 hectares has been ear marked for afforestation.
Along the land boundary of VSP a green belt of half a kilometer has been delineated for
afforestation. 1.4 lakh trees have been planted in 100 hectares during 94-95 and 1.22 lakhs of trees
has been planted in 207 hectares during 95-96.3 million trees for 3MT of steel was the slogan
ofVSP.
That target also achieved. VSP has been complying with statutory standards of both
Andhra Pradesh pollution control board and central pollution control board. It has been closely
maintaining 31 major stack emissions and 8 ambient air-monitoring areas out side steel plant. I
Vision:
To be a continuously growing world-class company.
We shall:
.:. Deliver high quality and cost competitive products and be the first
choice of the customer.
people.
Core-values:
.:. Commitment
India is the third largest producer of iron and steel in the common
wealth nations (surpassed only by the UK and Canada) and is 16th among
the steel producers of the world. At present, India's capacity of steel
production is nearly
The Tata Iron and Steel Co., Jamshedpur (Bihar), Indian iron and steel
Co., Burnapur (West Bengal), Visveswaraya iron and steel limited, badhravali
(Karnataka) and a few electric arc furnaces were the only steel plants in India
until 1955.three new public sector plants under Hindustan steel Ltd,. Were
established in the period 1955-60 at Bhilai (MP), Rourkela (Orissa) and
Durgapur
(WB). Each of these has their own coke-ovens which supply the large amount
of coke needed for steel manufacturer. The plant at Bhilai and Durgapur
employs the basic open-hearth process of steel making. The Rourkela plant is
unique in the fact that it employs L-D process for manufacturing 75% of steel.
The output of the remainder (Le., balance of25% of steel) is by the basic
open-hearth process.
At present there are eight integrated steel plants and about 174 mini
steel plants. The integrated steel plant located at Jamshedpur (TISCO) is the
only private sector plant, and the rest are in public sector. Integrated steel
plants in public sector are:
liquid steel per annum to be converted to 2.656 million tons per annum of
saleable
steel. In addition, Visakhapatnam steel plant will produce annually about 5.56
lakh tons of pig iron and various by-products for sale.
LOCATION:
CLIMATE:
Visakhapatnam has warm and humid climate. April to June are the
warmest months of the year and December to February are the coldest
months of
the year. The city benefits ITom the Southwest monsoons (June to
September) & Northeast monsoons (October to December). The average
annual rainfall is 973.6mm and highest mean montWy maximum
temperature is 37.8 degrees centigrade.
THE DEPARTMENTS:
Core Zone: Blast Furnace, Coke Ovens, Steel Melt Shop, Mills,
Sinter Plant, and Raw Material Handling Plant.
tallest ovens constructed in the country. There are three batteries, each
having 67 ovens. Each oven is having a volume of 41.6 cu.m and can
hold 31.6 T of dry coal charge. The carbonization time is 16 hours. A
mixture of blast furnace gas and coke oven gas having a calorific value
of 1000 Kcal/NM3 supplies the heat for carbonization. Another feature is
the dry cooling of coke carried out by the inert gas nitrogen thus,
reducing pollution considerably. Besides, a bio-chemical plant
separately undertakes the treatment of effluents. By-products like
benzene, toluene, xylene, naphthalene, coal tar, creosote oil, pitch,
ammonium sulphate and benzol products are also recovered from the
coke ovens gas. VSP produces, among other by-products, pushkala a
prime fertilizer based on ammonium sulphate.
Sinter Plant:
Blast Furnace:
RollinS! Mills:
MODERN TECHNOLOGY:
these are:
1. 7-meter height coke ovens ofVSP are the tallest so far built
in the
country. Dry quenching of coke has been adopted which will not only
improve the quality of coke and economics of coke production, but also
contribute significantly to the reduction of environment pollution.
2. Base mix yard for sinter plant introduced for the first time in
the
3. With useful volume of 3200 cubic meters each the two blast
furnaces have bell less top charging equipment and 100% cast house
slag granulation. The granulation of the entire molten slag arising at the
furnace cast house avoids the need to transport molten slag and
optimizes utilization of slag.
5. The VSP have three sophisticated and large rolling mills with
the
blast furnace grade lime stone from the Kotni-sonor deposits in MP. Most
of cocking coal requirement will be met by imports through the
Visakhapatnam harbor while the balance will come from the Bengal-Bihar
area. Coal for power generation will come from Anantha deposits of Talc
her region in Orissa. POWER SUPPLY:
WATER SUPPLY:
Product Mix:
The product mix of
compnses
. Wire Rods
. Bars
. Angles
Channe
. ls
. Beams
. Rounds
. Billets
The Plant also produces Pig Iron, Granulated Slag and Coal Chemicals.
The rolled products find extensive usage in the Construction,
Inftastructure, Railways, Power, Oil, defense, and Transport and Ship
Building sectors. Bars and Rods are used mainly for re-inforced concrete
work for housing, construction of dams, buildings & factories,
manufacture of agricultural implements, fabrication of light engineering
components. The Wire Rods are used in Wire Drawing industry for
electrodes, transmission lines and weld ability requirements. The
structurals find application in engineering, house building, agricultural
implements, machinery, transmission towers, etc.
third converter in SMS the shop has the potential to produce about 3.0MT
of liquid steel. Accordingly, it is proposed to install one more converter
and two additional bloom casters in SMS-l, within the area provided for
the future expansion. As a result, SMS-2 need not be installed. To achieve
the production of3.0 MT per year the following is a must:
~ Lime used as flux should have 90-92 %(CaO + MgO) and Si02
content
exceed 5 days.
~ The blowing time should not be more than 18 minutes and the
gas
FACILITIES:
3.0 MT Stage
3,000,000 1,915,000
2. Facilities 905,000
(a)
(b)Hot
L-D metal mixers
Converters 2x1300T
2x1333
(c) Continuous casting machines 3x4-strand 2x 1300-7 torpedo cars of 300T cap
3x133M3
6x4 -strand
REFRACTORIES FOR SMS:
to 1.0 Mt of HIM can be held with this lining over a year.
~ High alumina bricks line steel teeming ladles as working lining and
~
medium heat duty fireclay bricks as back up. Life is 15-20 heats. ~
~ Mixer lining is by high duty magnesite bricks, and back-up lining
Fire clay and high grog bricks line Tundishes and slag boxes. Stopper rods
for tundishes are corundum graphite mono-block stopper rods, Al203
graphite nozzles. Submerged nozzle is
corundum graphite; lining life of tundishes is 10 heats for
working lining.
LAYOUT:
The LD Converter building 36m towards north end and a new scrap
aisle is provide adjacent to the charging aisle. The ladle preparation bay
is extended by the north end to facility installation of new ladle
preparation bay is extended by the north end to facilitate installation of
new ladle preparation facilities. The continuous casting department is
extended by 102m towards north end for relocation of CCM-4 and housing
the 5th and 6th bloom casters.
CONVERTERS:
Timing in
min.
. Charging of scrap 3
. Charging of hot metal 4
1
. Oxygen blowing 8
. Intermediate slag off 3
Sampling, temperature
. recording etc.
5
. Steel tapping 6
. Draining of slag 2
. Preparation of converter 3
. Unforeseen days 6
Total: 50
150 145
0.95 2700
· Min. 0.1
· Minimum 0.2
SLAG YARD:
The estimated slag arising is about 2000 kg per ton of cast bloom
and one slag pot of 16M3_18M3 is adequate for one heat. The filled slag
pot fTom the converter is transported to slag yard by self propelled slag
transfer car. Two 100+20 T EOT cranes, lime spraying unit, 10T steel ball,
slag dump car etc., are
provided. Pits are provided for dumping, cooling and crushing: Operation
of dump car provided with tilting mechanism is controlled fTom a control
post. There are four lime-spraying points. After cooling, the slag cakes are
broken by 10T steel ball by magnet crane. The steel jams are used as
plant return scrap. Broken slags are removed fTom pit by shovel, pay
loader and loaded into dumpers for disposal by road. The total area
required for slag dumping is about 9800 sq.m. In
the slag yard of about 8280 sq.m. is available. Therefore, an additional
area of about 1500 sq.m. is provided by extension of slag yard 96 M
toward end.. SCRAP PROCESSING AND STORSGE YARDS:
Plant returns scrap and purchased are stored here. There are two
yards. In yard nO.1 about 38,000 T/yr. Of steel scrap is cut to require and
has two 1ST magnet cranes. In scrap yard no.2 about 60,000 T/yr. Of
scrap is processed. This yard has four 1ST magnet cranes. The sized
purchased scrap is received by rail. This yard can store about 19 days
stock. Oxy-acetylene torches and 02 lancing do cutting of scrap. An
alligator type scrap-cutting shear is provided in each yard for preparing
scrap to be added during argon rinsing. Self-loading and unloading trucks
will be used for transport of scrap to SMS.
SKULL BREAKER: