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ABOUT SAIL

Steel Authority of India Limited (SAIL) is the leading steel-making company in India. It is a fully integrated iron and steel maker, producing both basic and special steels for domestic construction, engineering, power, railway, automotive and defence industries and for sale in export markets. 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 steels. SAIL produces iron and steel at five integrated plants and three special steel plants, located principally in the eastern and central regions of India and situated close to domestic sources of raw materials, including the Company's iron ore, limestone and dolomite mines. SAIL's wide range of long and flat steel products is much in demand in the domestic as well as the international market. This vital responsibility is carried out by SAIL's own Central Marketing Organization (CMO) and the International Trade Division. CMO encompasses a wide network of 38 branch offices and 47 stockyards located in major cities and towns throughout India. With technical and managerial expertise and know-how in steel making gained over four decades, SAIL's Consultancy Division (SAILCON) at New Delhi offers services and consultancy to clients world-wide. SAIL has a well-equipped Research and Development Centre for Iron and Steel (RDCIS) at Ranchi which helps to produce quality steel and develop new technologies for the steel industry. Besides, SAIL has its own in-house Centre for Engineering and Technology (CET), Management Training Institute (MTI) and Safety Organisation at Ranchi. Our captive mines are under the control of the Raw Materials Division in Calcutta. The Environment Management Division and Growth Division of SAIL operate from their headquarters in Calcutta. Almost all our plants and major units are ISO Certified. Integrated Steel Plants

Bhilai Steel Plant (BSP) in Chhattisgarh Durgapur Steel Plant (DSP) in West Bengal Rourkela Steel Plant (RSP) in Orissa Bokaro Steel Plant (BSL) in Jharkhand IISCO Steel Plant (ISP) in West Bengal

LAYOUT OF BOKARO STEEL PLANT


The location of the steel plant at Bokaro was envisaged as a coal based plant with other raw materials being far away. The captive Iron Ore Mines of Bokaro are located at Kiriburu which is near to Rourkela Steel Plant. It was Planned that Rail Wagons taking coal to Rourkela will be used after unloading, to reload with iron ore meant for Bokaro .This saves a lot of Idle capacity of railway wagons and economically benefiting S.E. Railway as a close circuit movement of coal. This plant even at conception stage was planned to be a big plant. Therefore, layout plan has space free for such an additional capacity even beyond 4 Mt per annum, say 5 or 5.5 Mt per annum. It was taken up for execution in two stages 1.7 Mt/year in 1st stage and 4 Mt/year in 2nd stage. Bokaro Steel Plant is located in south Bihar along the Ranchi Dhanbad Highway. It is on the confluence of river Damodar and River Ganga. These two rivers form the boundaries in North and East with western Boundary being S.E. Railway track of Muri-Chandrapura and Ranchi- Dhanbad highway being boundary in the south. Ranchi, Bokaro Jamshedpur forms the three points of a triangle each about 145 Km. equidistant from each other. Dhanbad is a Rail Junction point about 50 Km away, which is a Delhi-Calcutta chord line of Eastern Railways. This is the only steel Plant which is on the Branchline of railway and not on the main line. Bokaro has a good raw material base. Since it is coal based all sources of coal washeries are within 35 to 40 km from the plant. Iron Ore is from Kiriburu which is about 385 km away in south; Limestone and Dolomite from Bhawanathpur about 415 km in west and SMS Grade Stone from kuteshwar near Kathi about 600 Km west. The average travel distance of Raw Material for 1.7Mt stage is about 250 Km and for 4Mt stage 305 Km. Average Tone Km of Ingot Steel is about 1600Km for 1st stage and 1234 Km for 2nd stage. As stated earlier layout of Bokaro falls in category Oblique Sequential and has single rail track entry and exit to 2 exchange yards of S.E. Railway near Tupkadi Rail station. Their is a built in provision for expansion of individual units in their existing series without interfering with other units.

In Bokaro steel plant 48% of the internal traffic is by rail and Railways constructed a large marshalling yard with complete marshalling facilities on modern lines on a stretch of 8Km long. The amount of inter shop transportation by mechanical transport facilities of belt and chain types will be 31.6MT for the 4 MT stage (18MT for the 1.7MT stage.).The total length of the belt conveyor alone is 18Km in 1st stage and 32Km in 2nd stage. More than 300 equipments are used for internal transportation and unloading. This plant has an additional advantage with extensive repair and workshop facilities for repair, maintenance and manufacture of spare parts with a huge structural shop and m/c cum maintenance shop, large Iron Steel and Non-Ferrous foundries attached forge shop and wood working and building maintenance shop. Equally big is the Electrical and Instrumentation repair shop. Since the design itself provided by the plant is of 4MT capacity as provision of technologically pipelines, cables, rail tracks and road has to be maid in the initial 1.7Mt stage itself. Though construction cost at the 1st stage is high, it has definite advantage for 4MT expansion. Only the construction jobs of new units were carried out without interfering the first stage plant that was working at the time of expansion.

Steel production technology


Ingot casting Ingots Molten steel Primary rolling Billets Bars, rods, rounds

Blooms

Rails, structurals HR coils & strips Pipes CR sheets & strips Coated sheets

Continuous casting

Slabs Plates

The plant area is 1028 hectares (16876.83 acres) with two huge water reservoir at the East and West side of the plant. The water source of the plant is from a dam across the Damodar River at Tenughat about 45 KM away towards West. The drinking water for the township during the initial stage is supplied by an earthen dam across the river Ganga that is augmented with additional water from Damodar from the plant reservoir. The electric power for Bokaro plant has come from Chandrapura Thermal Power Station of the DVC grid. The power plant is on the other side of the river Damodar and for the 1st stage 140MW of power and 359 MW taken from 2nd stage from this grid. The residential township is located on the eastern side of the plant area and occupies 10,000acres with 40,000permanent houses, 1100 semi permanent houses and over 500 hutments. The wind direction for the last 50years was considered at the design stage itself and township was built at the eastern side of the plant right at the Sangam of the two rivers Ganga and Damodar:so the dust and the air pollution of the plant does not go to the township. In spite of this it is very unfortunate that the smoke emitted from the Chandrapura Thermal Power Plant of the DVC emits copious dust towards the township area thereby nullifying the designers concept of pollution free township.

RAW MATERIAL HANDLING PLANT (RMHP)


Introduction:
Raw material handling plant is one of the most important units of integrated steel plant like BSL. The progress of an industry is not indicated merely by how much it produces, but how efficiently it produces. Productivity is an indication of efficiency with which resources are converted into goods or services while output is production. Major input for steel plant comes from mines to RMHP. So for efficient production it is necessary to establish this plant at proper site in an integrated steel plant, so that all plants can easily get raw materials from this plant.

General Overview of Iron Ore Flow


OB
IRON ORE Drilling & Blasting

Truck despatch

Crushing
-10mm

Screening
10mm to 50mm

Fines

Lump

MINES STEEL PLANT Coal Flux Blast Furnace Hot Metal

Rail Despatch

Flux

Rolling Mills

Steel Melting Shop

Basic Functions:
Release of different raw material wagons from different mines by wagon tippler.

To do the blending by doing homogenous pile of raw material with the help of stacker and reclaimer. Supply of raw materials to different customer departments as per their requirement. Keep a buffer stock of raw materials in order to take care of irregularities of supply. 100%screening of high grade limestone and dolomite for RMHP. 100%screening of iron ore lump for BF

Customer Departments:
Refractory material Plant Sinter plant Blast Furnace

Sections:
The department is divided into two sections: RMS-1 RMS-2

Sources of raw material:


Name of Raw material Iron Ore Lump Iron ore fines Limestone for Sinter Plant Dolomite for sinter Plant Limestone for RMHP Dolometric Limestone Souces Kiriburu,Meghatuburu Kiriburu,Meghatuburu Bhawnathpur,kuteshwar Bhawnathpur,Birmitrapur,Sonakhan, Rajganjpur Jaisalmer Nanwara

Main Equipments
Equipments Wagon Tippler Nos 4 Make HEC Capacity 20 Wagon/HR

Stackers Reclaimers Bucket wheel Reclaimer

6 1 5 1

TRF WMI ELECON MUKUND IRON LTD. HEC IC INDIA LTD.

1200T/HR 1200T/HR 1000T/HR 500T/HR 500T/HR 500T/HR

Limestone Screening 1 Plant Limestone ore Screening Plant 1

Important Equipments:
Stacker: Function of a stacker:A stacker is used to stack the material on bed layer in a length of about 240 mts. The full pile of material forms, after about 250-350 layers of material, a homogeneous pile of raw mterial to achieve blending. Working Systems: 1. Traverse Drive system 2. Boom and Boom Conveyor System 3. Boom Hoist and Lowering System 4. Receiving Chute and proper System 5. Operating and Electrical Switch Board Cabin 6. Various Interlocks and Emergency Switch Barrel Type Reclaimer (Blender) The purpose of the reclaimer is to reclaim from the fully built-up stockpile and discharge the material on a reclaiming conveyor. Material can be reclaimed from one end of the pile, cross section wise. This process achieves blending if the stockpile is built up layer wise during formation. The machine ios centrally controlled by the operators cabin. During reclaiming operations, the machine travels in the direction of the stockpile at a slow and constant speed. The harrow, which is built in front of the machine, has a reciprocating movement which causes the material to stock down the face of the stock pile where it is reclaimed in the barrel buckets arranged on the circumference of the barrel. From here, the material is discharged out of the buckets on to a belt

conveyor inside the barrel, which transfers it to the reclaiming conveyor running along the length of the conveyor.

Bucket Wheel Reclaimer: The reclaimer is the type of rotary wheel type, with a traveling gallery, a hinged boom mounted on a rotating structure for slewing. An operators cabin is vertically suspended and is located at the end of the boom. The boom is 32 mts long and can be lifted up and down to reclaim raw materials. The machine travels along rails, which straddle the yard conveyor. The machine is capable of reclaiming at the rate of 500 ton per hour. Slewing of the boom conveyor assists reclaiming operations and permits the reclaiming of longitudinal piles on both the sides of the reclaimer track. During reclaiming operations, the rotating bucket wheel scoop up the raw materials and discharges them to the yard conveyor via boom conveyor and central chute. Wagon Tippler: It consists of a rotor having three rotor ring. Each ring is made up of two rigidly coupled symmetrical structure members. It works on tilting mechanism. It is used to empty the wagon full of raw materials in to the hoppers below. Iron Lump Ore Screen Plant: Its function is to screen out 10 mm Size of iron lump ore and send to sinter plant and to screen out +10 mm to -40 mm Size of iron ore lump And send to Blast Furnace. In this system, iron Ore Lump is send to conveyors. This conveyor feeds material to the screen. After screening the 10 mm size Iron Ore goes to the sintering plant bins through conveyors. Required Size of Lumps goes to the Blast Furnace through conveyors. Tram Car Pusher It is an electrically operated pusher car. Its function is to haul the railway Wagons to the Wagon Tippler. It works only on one track preceding the tippler. It has got three operating speeds of : 0.25 mts per second 0.5 mts per second and 1.0 mts per second.

It has a capacity of pushing 28/56 wagons of 60 tones material on railway track on horizontal strench and straight line.

Transfer Car Operation: The stacker can be transferred from one KPC to another KPC and the reclaimers from one bed to another with the help of this car. For transferring the reclaimer or stackers: transfer car is to be placed in position in such a way that the rails of the stacker /reclaimer track are aligned with corresponding rails of the transfer car with a tolerance of 1/16 inches. Necessary packing is to be put below the transfer car rails and Wheels. Conveyor AND their Control: Rubber belt conveyor of different sizes is used in this plant are used for conveying material from place to place. Total length of the conveyor is 42 kilometers. All the stacking and reclaiming conveyors can be operated in three ways. The names are: 1. Local + Individual 2. Local + Sequence and 3. Master Control Desk.

Bed Preparation Plan:


Name of Raw Materials Iron Ore Lump Iron ore fines Flux LS:DL=45:55 LS SMS(JSM) Dolomite-LS No. of Beds 4 6 4 1 3 Capacity 40000T per Bed 50000T per Bed 30000T per Bed 10000T per Bed 10000T per Bed

COKE OVEN AND BY-PRODUCT PLANT


Introduction:
Coke is the most important fuel used in metallurgical industry. Coal includes different classes of fuel (solid) that occurs on the crust of earth. The entire resources of coal can be classified into two groups: Coking Coal Non Coking coal If the coal when heated in bright red in the absence if air softens swells and eventually solidifies in to a more of less solid coke, it is classified as coking or caking coal. All coking coals are caking in nature but all the caking coals are not may be coking. Coking coal on carbonization gives metallurgical or blast furnace coke. Non coking coals fail to produce blast furnace coke on carbonization. The moisture, ash , sulphur content in the coal play a vital role in deciding the quality of coke that are produced in the coke oven area. They should be on lower side.

Sections: There are four sections in coke oven and By-Product plant
Coal handling plant Coke Oven Batteries Coke Sorting plant By-Product plant

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FLOW DIAGRAM
COAL COKE

COAL HANDLING PLANT COKE OVEN BATTERIES

COKE OVEN GAS

COKE SORTING PLANT


BF COKE (2580) mm PEARL COKE (1525)mm BREEZE COKE (0-15)mm

BY PRODUCT PLANT
CRUDE TAR P SOFT C PITCH M HARD PITCH EXTA HARD PITCH HP NAPH THAL ENE CRUDE BENZOL NG BENZENE NG TOLUENE XYLENE AMM CLEA . NCO SULP. GAS

BLAST FURNACE

SINTER PLANT

CONSUMERS

Coal Handling Plant:


The coal handling plant receives coal from the following sources: Primary coking coal( found in Jharia):Dugda, Moonidih Medium Coking coal: Kargali , Kathara, Mahuda Imported Coal:Imported coal from Australia and New Zealand Through Haldia, Paradeep and Vizag Port. The coking coal blend which is charged into coke oven batteries consist of 35% prime coking coal,25% medium coking coal and 40% imported coaking coal. Due to the low ash content of imported coking coal as high as 50% imported is being used now a days.

Coke Oven Battery:


The process of coke making consists of the destructive distillation of coke in the absence of air in the coke oven batteries. Coke oven battery is called because coke making is our ultimate purpose which is fulfilled by feeding coke into the ovens in a controlled manner and those ovens when placed in a series form a battery e.m.f.

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In coke making, coal is heated in a closed in a closed chamber, thereby driving out the volatile components present in coal and leaving behind a solid coherency mass called coke. This phenomenon is called carbonization of coal .The carbonization of coal is carried out at different temperature depending on the type of coke we need. At Bokaro carbonization temperature usually kept above 900oC i.e. high temperature carbonization is done.

Design Features of BSL Coke Ovens battery: No. of Batteries=08 No. of ovens in each battery=05 Width of coking chamber(p/s)=.39m (c/s)=.43m Length of coking chamber=15.04m Useful volume of chamber=27.3m3 Coke pushing furnace=9-2series

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A typical composition of coke from SAIL plant is: Fixed carbon=77% Ash content=22-24% Volatile matters=<1% A typical composition of coke oven gas is: Methane=22-25% Hydrogen=55-60% Nitrogen=2-3% Carbon Monoxide=8-10% Carbon Dioxide=4-6% C.V=4200-4400Kcal/nm3

Coke Sorting Plant:


Coke sorting is a material handling as well as material sizing plant. The aim is here to segregate and size the sum of ovens coke in three grades as follows: BF coke Breeze Coke CSP 1 CSP 2 : +25mm to -80mm size : 0mm to -15mm size (used for sinter making) : Handles coke coming from batteries 1-4 : Handles coke coming from batteries 5-8 Pearl/Nut coke : +1500 to -25mm size(for internal use and sold to outside parties ) There are two coke sorting plant:

BY - PRODUCT PLANT:
Removal of crude for ammonia, crude benzol is carried out by employing condensation, acid treatment and absorption process in coal chemicals or 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. There are three main sections of By-Product plant, as explained below:Crude Tar recovery Plant: Removal of crude tar is carried out by employing the condensation process in coal chemicals with water cooling. Final traces of tar are removed using electro filters. By Products produced:Naphthalene, Naphthalene-oil, Wash oil, Anthracin oil, Press oil, Pitch etc.

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Ammonia Recovery Plant: Ammonia is present in the coke oven gas to the tune of 6-8gm/Nm3 and is recovered by treating with dilute sulphuric acid employing saturation oil spray absorber-crystallizer process. Crude Benzol Recovery plant: Benzol in coke oven gas is recovered by adsorption or absorption or freezing (compression and cooling) methods. This method of absorption with wash oil has predominant application in the industry. Two types of wash oil which are commonly used: Solar Oil Coal Tar wash oil By products yields are: Benzene Toluene Xylene Naphtha

Major on going projects in BSL:


Augmentation of coal storage facility 35 additional silos Extension of pre & post tippling lines to accommodate full rake 2 new wagon pushers capable of handling full rake Enhancement of unloading track from 600 T / hr to 900 T / hr

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SINTER PLANT
Sinter:
Sinter is a process agglomeration of mineral fines formed after incipient fusion

Sintering:
Sintering thus a process of preparing sinter in which a high temperature is maintained such that the material (mineral/ores fines) undergoes incipient fusion due to the burning of solid fuels present within itself. The incipient fusion imparts better porosity and thus good reactivity. Sintering plant as such is required for two basic purposes: Water management Advantageous properties of sinter Sintering as a process uses all the wastes generated in the mines site, handling and the mill zone. So it is a good source of waste management. Apart from this sinter has lots of advantages than lumps to use as a burden material in B.F. Nowadays 70% of the blast furnace burden is sinter. Raw materials used for sintering: Ore Fines Flux(Limestone Dolomite) Coke Additives: Flue dust(from blast furnace) Mill scale(from slabbing mill and HSM) LD slag from SMS Calcined Dolo(from RMHP) Lime dust(from RMHP) Sinter return(own generation)

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Different sections of sinter plant:


Raw Material section Proportioning section and stock bins Machine Building

Raw Material Section:


It deals with raw materials coming from various sources and process it to the needs of sintering plant. This section receives coke from coke oven and stores int its fuel storage yard. The coke return from B.F is also kept here for use. This coke is then charged to four roll crushers which discharges coke of -3mm size. Conveyor belt no PM-8(called RM-8 due to Russian alphabet) carries in the proportioning section. No. of coke crusher=8 Capacity=16T/Hr Type=4 roll crusher 2 upper rolls for primary crushing=-6mm 2 lower rolls for secondary crushing=-3mm Coke feed size=-12mm The speed of lower rolls is slightly greater than the upper rolls to avoid choking or clogging. The flux required for sintering comes from RMHP. It is crushed to hammer crushers to get 90% undersize of -3mm.The oversize is again recycled. No. of hammer crushers = 05

Stock Bins and proportioning section:


The function of the stock bin and proportioning section is to receive materials, prepare the raw material and store it in the bins. There are 23 bins /machine. The capacity of the bins for various raw materials is follows: Iron ore fines=3600T Limestone Fines=3000T

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Coke Breeze=1000T Mill Scale and Flue dust=6000T Hot and Cold sinter=1800T

Waste Bin section:


This section receives waste material from different departments like flue dust, from blast furnace, mill scale from slabbing mill, limestone from refractory material plant. Then this is proportioning and sent to the stock bins.

Machine Building section:


The m/c building section has three machines with sinter area of 252m 2 /m/c.6.2MT of sinter per year is produced with a productivity of 1.2T/ m 2/hr.Ther are 180 pallets per machine. A bed of 25mm is made with bed material(sinter return),then first layer is of 300mm and top layer is of 300mm with a extra coke of 1% is made up to 150mm. The ignition hood has a primary and secondary hearth In the primary hearth mixed gas is burnt from slit burners creating a temperature of about 1200 oC.In the 2nd hearth coke oven gas are burnt creating a temperature of 900 oC. The pallets then move only 26 vacuum chambers. The burn through point i.e. sintering should be achieved at 23 rd vacuum chamber. After the hot screening the sinter pass through straight line cooler with 6 blowers blowing 6X22000m 3/hr of air to cool the sinter from 300oC to below 1000 o C Cold sinter return from machine building section is -8mm,8-12mm sinter is used as bed material and +12mm sinter is used in B.F. The basicity of super fluxed sinter is 1.8 to 2.8. Nearly 52KWH of power is consumed per tone of Gross section.

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BLAST FURNACE
Introduction:
Blast Furnace can be termed as the core metallurgical reactor for the production of Hot Metal. It is a counter-current heat and mass exchanging reactor in which there is a continuous transfer of mass(O2, C,H2 ) and thermal energy between descending burden materials and ascending gases generated at the tuyer level.

Inputs:
Iron ore lump Sinter Metallurgical Coke(+25mm to -80mm)

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Limestone Manganese/Quartize(Additives) Nut Coke/Special Coke(in case of CDI)

Outputs:
Hot Metal BF Gas(used as fuel) Gangue Material in the form of slag.

Blast furnace is a counter-current heat exchanger and a chemical reactor in which Iron bearing materials, coke and flux are charged from the top of the furnace and hot air blown through tuyeres at the bottom. Combustion of coke takes place in front of tuyeres generating heat and reducing gas. C + O2= CO2 CO2 + C= 2CO (Solution loss reaction) Remaining unreduced iron oxide (FeO) reaches the lower part of the furnace (high temperature zone) and is reduced by carbon of coke (Direct Reduction reaction) at ~12000oC. 2FeO + C= Fe + CO2 (Endothermic Reaction) Metalloids reduction endothermic also takes place in this lower part of the Furnace. SiO2 + 2C= Si + 2CO MnO + C= MnO + CO P2O5 + 5C = 2P + 5CO

Sections and Functions

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INNER STATE & AERODYNAMICS IN BLAST FURNACE


LUM PY ZONE (STACK) Ferrous Burden
oo oo oo o oo o o o o oo oo o oo o oo o o oo o oO o o o o oo o O o oo oo o o O o o oo o o o o o oo o o o oo oo o o oo oo o o o oo oO oO o o o o o o o ooo oo oo oo oo oo ooo o oo oo o o ooo o O oO o o o oo oo oo o Oo O oo o o o o oo o o oo o o o oo oo O o Oo ooo o ooo o o o oo o o o ooo oo o O o o Oo ooooo oo o oo oo o ooo o oo o o oo o o o o ooo o

COH ESIVE ZONE (LOWER STACK & BOSH) ACTIVE COKE ZONE (BOSH+HE ART H)

10000C Isotherms 12000C Isotherms


COKE SLIT FUSED SLAG & Fe RACEW A Y2000OC
SLAG&COKE METAL&COKE

Tuyere Gas

MEC HANICAL SUPP ORT TO BURDEN

DEAD MAN COKE

Raw material charging section:


Receives raw material from RMHP, Coke Ovens, Sinter Plant and then supplies to the furnace top by means of Skip car. Typical size ranges of raw materials for achieving better performance are: Coke- 25-80mm (with +80mm<5%, -25<3%) Sinter 6-30mm Pellets 10-20mm Ore /Minerals

Function of charging complex:

Uninterrupted supply of raw materials in the furnace as per quality & quantity set ups.

Furnace Proper:
Raw materials are charged into it and hot blast of air at 1100o C is supplied. Due to the occurrence of exothermic reaction, reduction of iron oxide to hot metal takes place. It has 5 main sections as: Hearth Bosh Belly

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Stack Throat

Refractory Lining: Hearth Tap Hole Tuyer and Bosch Zone Belly& Stack Furnace Cooling: Bottom Hearth : Air Cooled Hearth, tuyer Zone, Bosch& Belly Stack Total No. of Stave Coolers No. of Rows Number of Stave Coolers/row : Stave Plate Coolers : Peripheral Stave Tooth Coolers : 512 : 12 : 40(minimum) : Fire clay : High density hard burnt fire clay brick : Micro-Pore carbon Blocks : Mullite Blocks/Bricks

Stave Coolers are double walled plate type coolers having arrangement for Water Circulation.

Stoves:
Hot air blast is supplied through stoves which are maintained at 1350o C with the help of combustion of mixed gas. The stoves have refractory lining of chrome magnetite from inside and fire clay outside.

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HOT BLAST STOVES


DOME

SCHEMATIC DIAGRAM

Hot Air

Hot Blast Valve

COMBUSTION CHAMBER Flue Gas & Air Gas Burner Valve

Of No.stoves : 4 / furnace Full height of stoves: 45,200mm External of the : 9000mm Cylindrical part Thickness of the wall: 605mm Dome thickness : 686mm Surface of heating 30,300 M2 No. of checker holes 4,400 - 4,720
CHECKER CHAMBER COLD AIR FROM TBS Cold Blast Valve

The combustion chamber is of half circle, half elliptical shape with working section of: 4.28 M2

HOT BLAST STOVES:


SCHEMATIC DIAGRAM ----- SUPPLY OF HOT BLAST IN THE FURNACE Hot Air 1000OC Hot Blast Main

BUSTLE MAIN

STOVE 1

STOVE 2

STOVE 3

STOVE 4

FURNACE TUYERES

10-12 ata Steam Snort valve

Cold Air from TBS Pr.2.5-2.6 Kg/CM2 , Temp. 150190OC

Auxiliaries:
Pig Casting Machine:

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There are 4 pig casting machine of two stands each having a capacity of 1700T/day of pig iron metal which is poured into moulds which are water cooled and continuously mould. The cold pigs produced are supplied to cold peak yard. Laddle Repair shop: Laddles are required for hot tapping and are repaired in ladle repair shop for defects like refractory lining lugs etc. Slag Pot Repair Shop: Slags pots are of capacity 13.5m3 are prepared and minor repair are done. Clay Mass shop: Tar bounded anhydrous clay mass is produced in this shop to close the tap hole of the furnace after tapping is done. Technical Data: No. of BF=5 Volume of each furnace=2000 m3 Working Volume=1756 m3 Capacity of Furnace=2640TPD/furnace No. of stoves per furnace=30,300 m2 Blast temperature=1100o C Max. Blast Pressure=3.2Kg/cm2 Charging Scheme=BLT Hot Metal Specification: C=4-4.5% Si=0.6-1.2% Mn=0.6-1.2% P=0.25% S=0.05% Coke Rate:

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Coke rate is the amount of coke required per ton of hot metal .It was 360Kg/THM for 95-96 and presently it is around 560Kg/THM.

Future Plans in Blast Furnace:


Upgradation of blast furnace no.2 in 2007-08 and of other furnaces in phased manner to achieve 6.5 million tons of hot metal production by 2011 2012 as per corporate plan. Cast house sgp in 4-furnace. Coal dust injection (cdi) in bf-2 & 3. Hydraulic mudgun & drilling machine in all the furnace (in 2 furnaces at present). Improved designed stoves.

STEEL MELTING SHOP 1


Introduction:
Steel making is a process of removal of impurities like carbon, silicon, Mn, sulphur and phosphorus from the hot metal by oxidation and formation of basic slag. For this the hot metal of BF is taken to LD converter after mixing in the mixture. Pure oxygen is blown through water cooled lance to remove impurities by oxidation and steel is made .Purity of oxygen is used about (99.5%). There are two Steel Melting shops, SMS-1and SMS-2.Three types are produced from these shops: Killed Steel Semi-Killed steel Reamed Steel

Raw Materials:
Apart from the hot metal from the Blast Furnace the different raw material required for the production of steelier:-

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Limestone Dolomite Aluminum Ferro Alloys

SMS-1:
At BSL SMS-1 has 5 no. of LD Converters each of 100/130T capacity .The capacity of these shop is 2.5MT/year.For oxygen blowing there are 2 water cooled lance. The oxygen pressure is 1520kg/cm2 .

VARIOUS SECTIONS
Mixer: The mixer is of 1300T capacity and temperature is about 1310+10o C, it is operated. The functions are: o It makes the hot metal from 5 BF homogenous. o It maintains the temperature. o It acts as a buffer stock. Converters: This converts hot metal into steel following an exothermic reaction.Line, scrap and hot metal are charged in a definite sequence and then oxygen lancing is done. The lime and other additions are done through a slide gate system. Lime is added as a flux to maintain the basicity of the bath. Basicity is defined as the ratio of Cao and SiO2 and it is kept between 3 to 3.5. Pit side: Steel is tapped from this side into the teeming ladles (140T) and transfer to teeming bay after deoxidation. Teeming Bay: Steel is poured from teeming ladle into moulds (placed in mould train) by operating slide gate and sent to stripper yard. Stripper yard:

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The ready ingot is stripped here from the mould and is sent to the slabbing mill, where as mould is sent back to the mould cleaning yard, where it is cleaned by water spray and coated with tar or graphite. Waste heat boiler: It cools the converter gas and generates steam which is cooled and collected in the boiler for further use.

Technical Specifications:
Capacity of SMS-1=2.5MT/year No. of Converter=5(100/130T each) No. of lances/converter=2 each (280/320NM3 /min)O2 Mode of combustion=Free Combustion.

STEEL MELTING SHOP-2


Introduction:
SMS-2 differs from SMS-1 because of blowing process and converter gas system.The mode of combustion in SMS-2 is suppressed combustion where atmospheric air is not allowed in hood area and the combustion of converter gas is suppressed which is further used as a flue.

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Flux LD Slag Dolomite Lime Jaisalmer Lime Lime Stone

Oxygen (pr. 18kg; purity 99.5%) Six hole water cooled lance with Cu tip TAP HOLE Charge:Hot metal (270T) +Scrap (25 to 30 T) %Si / (.60 to .65) <S /.050

Inputs:
Hot Metal from the blast furnace.

Outputs:
Semi-Skilled or killed steel to continuous casting m/c exclusively.

SECTIONS:
Major sections of SMS-2 are outlined below: Mixer: Same as that of SMS-1. Two converters of suppressed combustion type are there.

Converter Details:

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Oxygen blowing :being done by six hole lance (copper tip) water cooled. Pressure 18 Kg, Min and Purity 99.3% Min. Mixer Metal :collected from mixer (2 nos. 2500T capacity) %C Si S P = = = = 4 to 4.5 0.55 to 0.65 (Aug 0.60) 0.045 Max. 0.15 Max 16 to 16.5 Min

Total Blowing time :-

Flux will be added within 8 to 10 of blow. Sequence =1) 8T Lime initially 2) 4T L. D. Slag 3) Rest 12T Lime 4) Lime Stone is to added as a coolant (if required) Tapping Temperature is to be aimed > 1680 to 1700C

Metallic Charge will depend on % Silicon content of hot metal. Considering 0.60% Silicon Hot Metal & Scrap 270T to 275T 25T to 30T

Refractory lining of the converter is having MCB i.e. Mag Carbon Bricks. Tapping time 6 min is being maintained. After that tap hole is being repaired / changed. Pre/post slag arrester is being used to avoid the carry over slag. Combined blowing facility is also having in converter through 12 nos. of elements at the bottom of the converter. There are three procedure: 1. Proc. 5 i.e. upto 14 Nitrogen then Argon till tapping finish. 2. Proc. 7 i.e. upto 9 Nitrogen then Argon till tapping finish. 3. Proc. 6 i.e. 100% Argon from blow start to tapping finish.

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Steel Refining Unit: This unit homogenizes the temperature and chemical composition of liquid steel received from different LD converters. De-sulphurisation of steel is done up to a sulphur level of 0.01%.Chemical composition of steel is also done by adding pre-requisite quantity of Ferro-alloys. End point temp. Control of liquid steel is done by heating/cooling the melt. Continuous Caster: It is the heart of SMS-2 and has the following main point. Tundish: Refractory lined buffer vessel designed to continuously feed liquid metal from ladle to CC mould at regulated flow rate. Mould: Solidification of liquid metal starts here. It is generally made by copper using primary cooling mode. At the beginning of casting a dummy bar is inserted inside the mould to avoid free fall of steel. Continuous lubrication between mould wall and steel is done by mould powder. It also acts as a coolant. Secondary Cooling Zone: Partly solidified after leaving the mould enters its secondary cooling zone comprising arrays of rollers and water spray-nozzles. Roller support and guide its downward movement of strand and water spray cools the strand resulting its complete casting. Straightening Rolls: These are located at the end of st 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 strand has been straightened, it is cut to required length using acetylene torch cutting machine. HIGHLIGHTS OF BSL CONCASTER Mould-Straight with adjustable withdrawing cooling. Dummy bar system-Top charging Containment-Segmental design Bending-Continuous with 8 mm curvature.

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Roller Type-Split design Metallurgical Length-29.5m Cooling-Air mix cooling Automation-Mould level control, Turndish level control, secondary cooling, breakout prediction, Computer aided quality assurance, Material tracing. etc.

Advantages of CCS:
Higher Yield Lower energy consumption. Lower operating casts Elimination of primary mills.

CONTINUOUS CASTING SHOP


Introduction:
All the crude steel was processed through the conventional ingot route .But keeping in view the benefits of continuous casting such as low investment/production cost, energy efficiency, better quality and improved pollution control, Bokaro steel plant updated by replacing the ingot route by installing continuous casting in SMS-II.

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Concast shop is provided with a SRU, caster, Turndish Preparation area, Slab area, Slab yard and RERS (Replaceable equipment repair shop).

SRU
In SRU the steel is refined to make it suitable for casting of desired quality. First the steel is killed by removing O2 to <5ppm by addition of Si or Al. Two porous plugs have been provided in the bottom of ladle for purging. Argon gas is used for purging during the treatment. Timming is done to make the chemical composition of order quality. Sulphur is reduced below 0.015% by making a suitable synthetic slag of Cao=50% and Al 2O3=30%.Finally before dispatch CaSi /caf wire is added to the ladle so as to reduce /eliminate Al2O3 choking at caster.

CASTER
There are two twin stranded slab casters which can cast 940-1850 with of slab with a thickness of 200,225 & 250mm.

SLAB YARD
Mainly handles the slabs for dispatch to hot strip mill.

TURNDISH PREPARATION AREA


It is used to prepare the Tundishes for casting & RERS for repair of mould, Bender and segments.

REPLACEABLE EQUIPMENT REPAIR SHOP

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The shop houses two cranes of capacity 55/10t and one crane of capacity 16/5t.It has got three sections i.e. roller repair, mould repair and alignment general repair section.

Features of CCM:
Type of Machine Length of mould Number of strands Cooling bow radius Machine speed Cooling : : : : : : Low head machine with straight mould and. Segmented stranded guide. 900mm 2x2 8 meters. 0.2M/min-1.9M/min. Air mist cooling.

Casting Size:
Thickness Width Length : : : 200mm, 225mm, 250mm 950-1850mm 9-10.5metres

Others
Metallurgical length Dummy Bar Cutting system Average heat size Tundish capacity : : : : : 29.7metres Top charging Torch cutting (acetylene) 302T 50T

SLABBING MILL
Introduction:
Slabbing Mill acts the primary means producing slabs of different specifications by rolling the steel ingots from SMS-1 but with the advent of continuous casting roots, the slabbing mill has been rendered useless.

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Inputs:
Ingots from stripper yard of SMS-1(Size: 17T, 20T, 25T, 28T)

Outputs:
Slab for internal customers i.e. HSM as well as external customers.

Functioning:
The main function of slabbing mill is heating, rolling and conditioning.

Sections:
There are four major sections. Ingot Storage Yard: It has a capacity to store70000T of Ingots and served with two 75/20T over head tong crases. Soaking Pit: With the help of soaker cranes (50/40T) ingots are charged into the soaking pits where they are heated by mixed gas to a temperature of 1300o +20o C for about 3-4hrs for hot ingot and up to 10hrs for cold ingots. Soaking pit is lined with refractory material. Mill Proper: After soaking is complete the ingots are taken out and placed on a roller table in a tilter. For the above purpose ingot buggy and pusher car are used. The receiving temperature is about 1250 o Cat which slab is rolled. Actually mill proper has been divided into parts which are: Post-1-Pushing the ingot from tilter to roller table. Post 2- Hot working /Milling of ingots are done here. The mill is of universal type, since rolling of ingots can be done from all sides. The mill produces slab of thickness 150-300mm and width 7501850mm and length up to 10300mm.The mills has two horizontal rolls of diameter1250mm and two vertical rolls of diameter 1000mm.The power required for the horizontal rolls is 6.7MW and vertical rolls is 1.85MW.Rollers are balanced hydraulically and thickness is controlled by moving the gap between the rolls.

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Post 3- Hot/ Cold Scraffing of rolled slab is done here.The mill uses oxygen flame to melt 1mm sheet of slab so as to remove surface defects Viz:-scabs, blisters, embedded scaleetc.scarfing losses is about 2% of total ingot weight. Post 4- With the help of shearing hydraulically the fish tail of slab is cut from front end and tail end. Slab length is maintained at a desired length. Post 5- Piling up of various slabs for sending to slab yard with the help of two pillars is done. Slab Yard: It receives and stock slabs which are further supplied to HSM. It is also required to the external customers. Whole slab yard area is divided in to Stacks and further piling is done in a particular manner with 15-16slabs in a single pile.

HOT STRIP MILL


Introduction:
The plastic deformation of a metal above its recrystallisation temperature by squeezing it between a pair of rolls is called hot rolling. The HSM at BSL is of continuous 2000mm mill. It is referred as 2000mm mill because the barrel length of the rolls used in this mill is 2000mm.

Inputs:

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Slabs from slabbing mill and CCD.

Output:
Slabs with dimensions:Thickness 170 to 230mm Width 950 to 1650mm Maximum weight 28 tonn Length 7700 to 10500mm Coils with dimensions: Strip thickness 1.9 to 12mm Strip width 950 to 1650mm Maximum weight 27tonn Coil inside diameter- 850mm Coil outer diameter 2300mm

Sections:
There are 11 posts and their function is outlined below: Post 1: Control movement of slab transfer car, kick of end roller table no.10,11,12,13. Post 2: Regulate the movement of pushers and the roller table in front of the number 1 & 2. Post - 3: Pusher of furnace 3 and roller table in front of furnace 3. Post 4: Discharging of slabs from furnace 3 and roller table in front of furnace 3. Post 5: Hot charging of slabs from slabbing mill and receiving bick balk slab/dummy bars. Post - 6: Direct feeding of hot slab from post no. 5. Post 7: Discharging of slabs from furnace 1&2. Post 8: Consist of roughing group, guides, VSB and de-scalars.

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Post 9: Consists of finishing tables (strands), AC & coopers. Post 10: Consists of flying shear. Post 11: Consists of coilers, ROT & conveyors operation is controlled.

Main Units:
Reheating Furnace: Its principle function is to heat the cold or hot slabs to the rolling temperature of 1250oC.It has three main sections: Slab Charging System Furnace Proper Slab discharging system Evaporation Cooling System: Its purpose is to Cool the Skid pipes using de- aerated and dematerialized water at its boiling point at 7-8kg/cm2 pressure. Each furnace has 3 4 skid pipes. Roughing Group: The roughing group train consists of vertical scale breaker, 2 high roughing stands and four high universal roughing stands followed by finishing stand. Finishing Stand: It consist of flying shear, finishing scale breaker and seven four (4- high) finishing stand. It is followed by run out table. Coilers: Mill is provided with four coilers out of which two are continuously used where as third is called hot spare coiler,coilers are designed for coiling of 12mm thick strip.

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HOT ROLLED COIL FINISHING


Introduction:
Though HRCF is situated at a distance from HSM mill still it is considered as part of HSM.In hot rolled coil finishing the coils are rolled in the 2000mm wide strip mill and are further subjected to shearing and slitting process to obtain slit and sheet coils of desired and pre determined sizes as per customer needs.

Sections:

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Major sections of HRCF are Coil Yard Shearing and Slitting lines -1&2 Off gauge shearing lines Additional coil yard Shipping area

FLOW DIAGRAM OF HRCF MATERIAL


HSM HR coil HRCF

COIL YARD

ADDITIONAL COIL YARD

CRM

SHEARING LINE

DESPATCH

SHEARING LINE- 1

SHEARING LINE-2

HR PLATE

HR SHEET

HR PLATE / SHEET YARD

SHIPPING

DESPATCH

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UNIT NAME
Sheet shearing line Unit no. 1 Sheet shearing Line 2

PRODUCTS
3.10X1850mm sheet 2.5m-12mm length 1.5-4X1850mm sheet 1.5-6m length

CAPACITY
645000T/tear 475000T/Year

Coil slitting Line

1.5-8X1350mm,150mm Min width slit coils

400000T/year

Coil Yard:
It is meant for storing the coils. It is connected to HSM by conveyor. Coil yard is housed in LM bay and is having storage of 1200sq.mm with 8-13 days of storing capacity. It is serviced by 6 EOT cranes of 50/10T capacity fitted with lifting tongs. The internal customers of HRCF are cold Rolling mill. Coil is stacked in coil yard in such a manner that best utilization of space is achieved according to size of material. Proper inventory and record should be kept for smooth perfect operation of coil yard.

Shearing and Slitting line:


This line is situated in KL bay of HRCF .All the finishing lines have their feeding point situated in coil yard and outlet in finishing shipping area. Shearing line no. 1 is primarily used for shearing thick gauge material and line no. 2for thin gauge material. All the strips above 5 mm in thickness are shearing in line no. 1and below 5mm thickness are sheared in line no. 2 i.e. plates in line no.1 & for sheet in line no. 2.

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COLD ROLLING MILL


Introduction:
Cold rolling mill is defined as a compressive deformation process in which there is either a continuous or stepwise deformation with more than one rolls. Hot rolled steel is generally cold rolled at ambient temperature to produce material of following characteristics: Thinner gauge material Material with improved strength Bright smooth and dense surface finish

Inputs:
Coils from HSM through HRCF

Products:
Sheet Gauges Sheet gauges Sail Auto SAILCOR Galvanized Sheet Tin Mill Black Plates(TMBP)

SECTIONS:
Major sections of CRM complex along with their functions are:-

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HR COIL 130000 PL-I 61000 PL-I 45000

TM-I 63000

TM-II 42000

Pickling Lines: The strip of coil coming from HSM has a layer of scale(mixture of different iron oxides) with a thickness of 5-20.The strip is de-scaled with a combination of mechanical and chemical dissolution in pickling line. Removal of scale is performed by chemically treating the surface of hot rolled strip with acid. In BSL there are two continuous pickling line consisting of un-coilers, welding m/c, loopers, acid tanks and coiler.PL-1 is H2SO4 line where as PL-2 is HCL line. \ Tandem Mill:

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In Tandem mill pickled strip is fed between every hard rolls in a continuous fashion where the strip is engaged in several roll stands simultaneously enabling high tension force is applied.The roll arrangement is 4-high with five strands. Application of coolant water with mineral oil emulsion is provided continuously during cold rolling thus reduces the friction and heat generation at the roll bite. There are two tandem mills i.e. Tandem Mill -1 and Tandem Mill-2 with Tandem Mill-2 being automated.

TM-I 63000
ANN-I 30000 ANN-II 30000 ANN-III 15000

SPM-I 45000

SPM-II 25000

SSL-I 8000

SSL-II 5000 CR SHEET

SSL-III 3000 CR COIL

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TM-II 42000

ECL 9000

CAL 9000

HDGL 18000

FULL HARD

DCR 15000

GP/GC

TMBP 4000
Annealing Zone:

GC SHEE T

GP SHEE T

GP COIL

During cold rolling the material is work hardened which causes loss in ductility and build up of internal stresses. Annealing of cold rolled strip is carried out in order to eliminate internal stresses and to restore the lost ductility and grain structure. Annealing involve heat treating the strip to a temperature of 600-650o C. In BSL annealing area is divided into three sections.,AN-1,AN-2,AN3.The total CRM complex is divided in to following three zones:Zone 1: It comprises of PL-1 &2, TM-1&2 Zone 2: It comprises of: Hood Annealing 1 & 2(EF Bay) 2000mm 4 High single stand non-reversing skin pass mill. 1420mm,4 High stand non reversing SPM-2

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Sheet shearing lines no.1,2,3,4&5 Slitting line no. 1&2 Zone 3: It comprises of: Hood Annealing 3 Electrolytic cleaning Continuous annealing line(CAL) Double Coil Reduction mill(DCR) Shipping Bay Hot dip galvanizing line(HDGL) HDGL shipping bay HDGC: This consist of the following sections: Hot dip galvanizing line Continuous coil corrugation line Galvanized sheet shearing line Auxiliaries: This comprise of: Anti corrosive shop Metal tone shop Area repair shop

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ROLL GRINDING AND BEARING SHOP


Main Function:
To ensure time by supply of ground/turned/short blasted and assembled rolls to slabbing mill, Hot strip Mill and Cold Rolling Mill. To provide supply and maintain the rolls of various mills to grind them as per the required norm,finish and rough to achieve max. life rolls. To assemble, disassemble, inspect maintain various types of chokes, roll neck bearing including the antifriction bearing. To reclaim rolls by roll welding in order to achieve max. roll economy. Grinding of shear blades of HRCF, CRM and add jobs.

Set up & facility:


There are four settings in RGBS 1) RGBS (HSM) This caters to the needs of slabbing mill and HSM. 2) RGBS (CRM) This shop serves to Tandem Mill, skin Pass mill-1, Pickling line rolls associated with tandem Mill-1 and shearing Line. 3) RGBS (CRM-2) serves to Tandem mill 2, SPM 2, HDLG and Pickling line 2. 4) Planning and Maintain system It deals with planning and maintenance.

Equipments:
Roll grinding m/c: It is used for grind of used rolls from various mills and to impart required surface finish & crown on them after each campaign. We have total no. of 10 grinding m/c , Russia & Japan make. Roll turning Lathe: It is used for turning of slabbing mill rolls of HSM, where turning finish is sufficient.

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Roll Welding m/c: Horizontal and vertical rolls of slabbing mill, vertical stand rolls and edges rolls of strips mill are reclaimed by this m/c. Work roll assembly/disassembly m/c: It is used for taking out chocks with bearing from used olls return from mill & subsequent assembly on ground rolls. Back up roll assembly/disassembly m/c: Washing m/c: Roll assembly are washed with spray of hot water to remove the accumulation of screw down grease, mill scale etc. Shot Blasting m/c: It is used to give rough surface finish to increase bite & avoid sticking during annealing and also to enable roll product to retain subsequent painting. Polishing m/c: Sleeve journals of oil film bearing are polished on this m/c to a very high degree of finish using extra fine mery paper. This improves working life of bearing. Chock tilter: It is used for tilting of back up roll chocks during assembly /disassembly of oil filled bearing at various angles to facilitate the assembly/removal of various parts. Tanks: It is used for washing/cleaning/lubricating process. Low freq. induction hardening m/c: It is used for hardening of rolls from 400 to 700 dia. & 50,000 mm in length. Vertical annealing furnace: Used rolls with residual stress are annealed in the furnace in order to give the roll to adequate condition for re-hardening treatment, preventing cracks in rapid heat up, conditioning the structure suitable for re-hardening. Tempering furnace: It used for stabilization process after re-hardening operations. Ultrasonic flow detector: It is used to detect & determine location of internal defects on barrel & neck of rolls.

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