MANUAL

ON
BOKARO STEEL PLANT

BOKARO STEEL PLANT AT A GLANCE

As the fourth integrated steel plant in the Public Sector conceived in 1959,
Bokaro Steel Plant actually started taking shape in 1965 in collaboration with the
Soviet Union. The collaboration agreement was signed on 25th January 1965.The
design of the plant was envisaged with a capacity of 1.7 million tonnes (MT) per
annum in stage-I and 4 MT per annum in stage-II, with provision for further
expansion. The construction work started on 6th April 1968.

Bokaro Steel Plant was originally incorporatedas a limited company on 29th
January 1964.With the formation of the Steel Authority of India Limited
(SAIL)on 24 January 1973, it became a wholly owned subsidiary of SAIL and on
1st May 1978 it was eventually merged with SAIL through the Public Sector Iron
& Steel Companies (Restructuring & Miscellaneous Provisions) Act 1978.

The Plant is hailed as the countrys first Swadeshi steel plant,built with
maximum indigenous content in terms of equipment,material and know-how.
Its first phase of 1.7 MT ingot steel commenced on 2nd October 1972 with the
commissioning of the first Blast Furnace and completed on 26th February 1978
with the commissioning of the third Blast Furnace.

All the envisaged units of 4 MT stage have already been commissioned.The
Plant is designed to produce flat products like Hot Rolled Coils, Hot Rolled
Plates, Hot Rolled Sheets, Cold Rolled Coils, Cold Rolled Sheets, Tin Mill Black
Plates (TMBP)and Galvanised Plain and Corrugated (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.To keep pace with the latest trends in steel
making,the first phase of modernisation was sanctioned on 23rd July 1993.As the
benefits of the modernisation have been reaped,Bokaro Steel is continuously
upgrading its various production facilities to bring improvements in
productivity and quality.

THE TOWNSHIP
Bokaro Steel City is located in idyllic surroundings on the southern bank of river
Damodar with Garga, one of its tributaries, meandering along the southern and
eastern outskirts of the city. On the north, the city is flanked by the high ranges
of the Parasnath Hills and on the south; just beyond the river Garga, it is
enveloped by the Satanpur Hillocks. The vast rolling topography of the city is
2 of 26


interspersed by graded valleys and winding rivulets typical of the
Chhotanagpur Plateau. Within two decades of Bokaro Steel coming into
existence, the city has blossomed into a regional urban centre of over 8 lakh
people from different parts of the country, making the city a Mini Bharat. Bokaro
is located on the Gomoh-Chandrapura-Muri railway line. Direct train services to
all the four metros are available from Bokaro. It is located centrally between the
triangle of the other three major cities of Jharkhand - Ranchi, Jamshedpur and
Dhanbad - all of which are well connected by road and railway.
BASIC INFORMATION
Location : Southern bank of Damodar River; approx. 50 kms from
Dhanbad and 140 kms each from Ranchi and Jamshedpur
Latitude : 23
0
39'
Longitude : 86
0
09'
Altitude : 210 metres (average) varying from 195 to 224 metres
Climate : Extreme
Annual Rainfall : Average 157 cms; Maximum 195 cms
Temperature : Maximum 48
0
Celsius
: Min. 2
0
Celsius
Wind direction : South-West to North-East
Type of Soil : Loamy up to 1 to 2 metres, sandy soil below that
Total land area : 33,045.35 acres
Plant, Slag-dump, Cooling
Ponds, Ancillaries, Marshalling
Yard
: 17,208.01 acres
Township (including Airstrip) : 10,114.53 acres
Garga Reservoir : 3,886.87 acres
Railways : 1,835.94 acres

HOUSING
Permanent houses/hostels : 37,472
Total houses leased out : 4,773
The general plan of Bokaro Steel City covering approximately 10,114 acres
provides for about 37,000 residential units. The city has a number of company-
run and public schools dispersed in various sectors on the concept of primary
and secondary school districts. Of the 42 schools run by Bokaro Steel, 21 are
affiliated to the CBSE Board and 21 to Jharkhand State Secondary Education
Board. In these BSL educational institutions, there are around 1200 teachers and
31,000 students.

MEDICAL FACILITIES
The township has a modern 910-bed Bokaro General Hospital with specialised
units like Critical Care Unit, Intensive Coronary Care Unit, Haemodialysis Unit,
Nuclear Medicine Laboratory, Intensive Burns Unit, Special Care Baby Unit,
3 of 26


Psychiatry Unit, Physiotherapy Unit, Rehabilitation Unit, Cancer Therapy Unit,
CT Scan and other sophisticated facilities. An ultramodern Operation Theatre
complex, state-of-the-art Neurosurgery Intensive Care Unit and Eye Operation
Theatre with facilities for IOL implantation and Vitreo-Retinal Surgery have
been added recently. The Child Care Unit of BGH has been recognised as a Baby
Friendly Hospital by UNICEF. The Blood Bank of BGH has been given the status
of Regional Training Centre by Government of India. It is the only blood bank in
the state of Jharkhand, which has been recognised to impart training to blood
bank officers and technicians in Jharkhand.
Beds in Bokaro General Hospital - 910
Sector Health Centres - 10
Primary Health Centres in Peripheral areas - 0 4
Occupational Health Services Centre - 0 1
To take care of the employees working in the plant, an Occupational Health
Services Centre with modern facilities has been provided within the plant
premises. Bokaro General Hospital is recognised by the Indian Medical Council
for imparting training to Housemen and Interns and also by the Nursing
Council of India for training of Student Nurses. Bokaro General Hospital has the
distinction of being the only one in Jharkhand being recognised by the National
Board of Examinations, New Delhi as a centre for imparting post-graduate
training to candidates appearing for the Diplomat of National Board
examinations. The medical team boasts of around 200 skilled doctors and over
1000 paramedic staff.
Enriching Life
Bokaro Ispat Pustakalaya with a collection of over 40,000 books in various
subjects and languages meets the reading requirements of the people in the
township. In addition, 6 libraries are functioning in various sector community
centres.
Bokaro boasts of a well-maintained City Park. The park has an man-made lake
with three artificial islands, boating facilities and a lake-view restaurant.
Among other attractions of the city is a Biological Park named after Pandit
Jawaharlal Nehru. The park has a variety of animals, birds and aquatic creatures.
Small parks dot the entire city, adding green cover and recreational space for
people.
Bokaro runs a number of welfare schemes, offering various benefits to its
employees. Prominent among them are Family Benefit Scheme, Group
Insurance Scheme and Cooperative Credit Societies. In close collaboration with
4 of 26

Bokaro Industrial Area Development Authority (BIADA), Bokaro Steel has been
encouraging small scale industries since 1970-71.

EDUCATIONAL FACILITIES

Number of Schools & Colleges
Classification BSL GOVT. PRIVATE Total
Middle School (Hindi Medium) 10 --- 08 18
High Schools
Jharkhand Board 03 01 04 08
CBSE Board 16 --- 03 19
Higher Secondary School (+2 Schools)
Jharkhand Inter Council 08 -- -- 08
CBSE 05 -- 10 15
ICSE -- -- 01 01
Colleges
Degree college -- 01 03 04
Technical College (Dental) -- -- 01 01
Technical Institute (Engineering) -- -- 01 01
Women's Polytechnic -- 01 -- 01
ITI -- 01 -- 01
Some salient features
No tuition fee charged in Jharkhand Board schools; nominal fee in CBSE
schools.
School uniform allowance paid to wards of eligible employees.
72 yearly scholarships for meritorious children of BSL employees for higher
studies.
Bokaro Steel has adopted children belonging to primitive Birhor tribe,
providing them with free boarding, lodging, dresses and education.


UTILITIES & SERVICES
Water supply - Garga Dam & Tenughat Dam
Power Supply
DVC- Chandrapura - 200 MVA (contract)
Bokaro Power Supply Co. Ltd. - 1 x 12 MW (back pressure)
2 x 55 MW
3 x 60 MW
Total Road length - 392 Kms.


5 of 26

BOKARO STEEL PLANT (MAJOR DEPARTMENTS)





















Commissioning dates and Capacity of Major Units
Unit Date of
Commissionin
g
Number Capacit
y (MT)
Product
Agreement with USSR 25 Jan, 1965

Coke Ovens Sep'72
Dec'85
8 Batteries of 69 Ovens 3.48 BF Coke
Sinter Plant Sep'72
Dec'82
3 Machines of 252 m2 area 6.20 Skip sinter
Blast Furnaces Oct'72 - Jun'85 5 furnaces of 2000 m3 volume 4.585 Hot Metal
Steel Melting Shop I Jan'74
Dec'78
5 LD converters of 130 T 2.20 Ingot Steel
Steel Melting Shop II Jun'83 - Jan'85 2 LD Converters of 300 T 2.25 Liquid Steel
Continuous Casting Sep'97 -
Mar'98
2 Double Strand casting m/c 2.16 Cast Slab
Slabbing Mill Dec'74 8X4 Soaking pits of 160 T & one
1250 mm universal Slabbing Mill
1.90 Rolled slab
Hot Strip Mill Dec'75 4 reheating Furnaces, 5 roughing
& 7 finishing stands
3.36 HR Coil
Hot Rolled Coil
Finishing
Jan'76 2 Shearing line 1.1 HR Plate/Sheet
Cold Rolling Mill 1 Jun'77 Pickling Lines, Tandem Mills Saleable CR
Cold Rolling Mill 2 Sep'91 Annealing Lines, Skin Pass Mills-
2, Temper/DCR Mill-1, Shearing
lines-5, Slitting lines-3 & Hot Dip
Galvanising Complex -1
1.66 Product CR
coils/Slit coil/
sheet, slit coil,
Black Plate,
GP&GC

.. 6 of 26

BPP
Coke Oven Batteries
Sintering Plant
BF
1
BF
2
BF
3
BF
4
BF
5
Blast Furnace
300 t
Con - 1
300 t
Con - 2
Steel Melting Shop - 2 Steel Melting Shop - 1
100 t
Con - 1
100 t
Con - 2
100 t
Con - 3
100 t
Con - 4
100 t
Con - 5
TandemMill - 1
Tandem Mill - 2
Hot Strip Mill
Soaking Pit
Slabbing Mill
Skin Pass Mill
1 & 2
Hot Dip Galvanizing Line
Galvanized Sheet Shearing Line
Galvanized Sheet Corrugation Line
HR Coil
HR Plate/Sheet
CR Coil
CR Sheet
GP Coil Corrugated Sheet
Iron Ore
Fluxes
Coal
Process Flow Of Bokaro Steel Plant
R M & M H P
Continuous
Casting
Department
Reheating
Furnace
Pig Casting Machine
H R C F
BF Coke
Coke
Breeze
Pickling
Line - 2
Pickling
Line - 1 Annealing
1&2
DCR Mill
CRCF
CCAL
ECL ANN 3
Plain Sheet
Coal Chemicals

Raw Materials & Material Handling Plant
The Raw Materials and Material Handling Plant of Bokaro is responsible for receipt,
blending, storage, screening and supply of raw materials to Blast Furnaces, Sinter Plant
and Lime Dolomite Shop as per their requirements. The shop also maintains a buffer
stock of raw materials to take care of any interruption in supplies. Raw materials are
handled by four wagon tipplers, stackers and reclaimers, and transported through a
network of conveyor belts.
Basic functions:
Receive different raw materials from various mines through wagons and
their unloading & stacking with the help of tipplers & stackers
Blend raw material by making layers in beds & cross section-wise cutting
beds by re-claimer
Keep buffer stock to take care of irregularities and supply raw materials to
different Units as per their requirements
Basic facilities:
4 Rotary Wagon Tipplers - 20 Wagons/Hr each
7 Twin boom Stackers - 1200 T/Hr each
5 Barrel Type Reclaimers - 1000 T/Hr each
1 Bucket Wheel Type Reclaimer - 500 T/Hr
2 Transfer Cars, 10 Shuttle Conveyors, 11 Cranes, 8 Telphers

SOURCES OF RAW MATERIAL
Material No. of Beds
(240 M)
Stock
(N0, of Days)
Source

Iron Ore Lump 4 24 Kiriburu, Meghataburu, Bolani, Barsua
Iron Ore Fines 6 16 Kiriburu, Meghataburu, Bolani, Gua
Lime Stone BF Grade 4 13 Bhawanathpur, Khanabanjari, Purnapani
Lime Stone SMS Grade 2 21 Kuteshwar, Jaisalmer, Nanwara
Dolomite Lump
1
16 Bhawanathpur, Birmitrapur, Tulsidamar,
Sonakhand
Dolomite Chips 50 Bhutan, Salwari
Manganese Ore Barbil, Banspani
Imported Coal Autralia, NewZealand
Prime Coking Coal 46 Dugda, Munidih, Jamadoba, Belatand
Medium Coking Coal

Silos Kathara, Kedla, Rajrappa, Mahuda, Swang
Coal Middlings for Power
Plant

Kathara, Rajrappa, Kedla, Swang, Giddi,
West Bokaro, Kargali, Mahuda, Dugda,
Katrasgarh etc.


.. 7 of 26

Coke Ovens & By-product Plant
The Coke Oven Complex at Bokaro supplies high quality coke to the Blast
Furnaces. The process of coke making consists of the destructive distillation of
coal in the absence of air. The coal is heated in a closed chamber there by driving
out the volatile components present in coal and leave behind the residue called
coke. This phenomenon is called as the carboniation of coal can be carried out at
different temperature depending upon the type of coke we need. Cabonisation
temperature is 1200-1300C which is the optimum temperature to get coke of
uniform size for the given coal inputs at BSL..There a 8 Batteries of 5meter height
69 Ovens in each.
M a t e r i a l F l o w D i a g r a m : C o a l & C o k e
C o k i n g C o a l
F r o m
V a r i o u s S o u r c e
W a g o n s C o a l H a n d l i n g P l a n t
C o k e S o r t i n g P l a n t C o k e
B a t t e r y
( 8 N o s . )
B l a s t F u r n a c e
C o k e
+ 2 5 - 8 0 m m
N u t
C o k e
C o k e
B r e e z e
- 1 5 m m
B l a s t F u r n a c e
C o k e O v e n
G a s
B y P r o d u c t
P l a n t
S i n t e r P l a n t S o l d

By-Product Plant
It Consists of :
Gas Condensate Section
Ammonium Sulphate Plant
Benzol Recovery Plant
Tar Distillation Plant
Sulphuric Acid Plant
Products produced from by product plant.
N G Benzol
N G Toluene
Xylene
L S Naptha
S B Oil
PCM
Road Tar
Coal tar wash oil
Extra hard pitch
Hard medium pitch
Hot Pressed naphthalene
All by products of By Product Plant are sold through e- auction.

.. 8 of 26

Biological Oxidation Plant
BOD plant in BSL is used to remove the phenolic wastes from the water. They
are useful in reducing air and water pollution. Main features of this plant is the
biological degradation of chemical wastes. The whole process can be divided
into following satges namely Pretreatment, secondary Biological Treatment,
Disposal of Treated effluent, Bacteria culture and Maintenance.
Tech-economic factors:
CO Gas yield : 325.0 Nm3 / TDC
Coke Rate --- : 505.0 Kg / THM
Sp. Heat Consumption : 0.583 Gcal / TDC
Sp. Power consumption : 29.50 KWh /Ton of BF Coke
Ammonium Sulphate yield : 10.50 Kg/ TDC
Crude Tar yield : 30.80 Kg/ TDC
Sintering Plant
Sintering is the process where incipient fusion takes place by combustion of Coke
within moving bed of loosely packed fines of mainly Iron Ore, Coke & Flux so as to
agglomerate into a compact porous mass called SINTER.
Sintering plant at Bokaro is unique in many respects. It has a very high sintering area
per machine. It has 3 identical sinter machines in the same building with 3 separate
interchangeable conveyors tracks available to feed them. Moreover there is a provision
of storing 5000 tonnes of sinter at plant itself apart from storage of 5000 tonnes of sinter
in Blast Furnace Bunkers.
The set up of Sintering plant at Bokaro comprises of three main sections:-
a) Raw material section
b) Stock bins & Proportioning section
c) Sinter machine building section
Cleaned Water
Hot Rolling Mill Refractory Mat Plant Ore Handling Plant Coke Ovens
Raw Mat Section
Iron OreFines, LimeStone,Dolomite, Sand
Stock Bins
LimeStone Fine ,Coke Fine, Dolomite Fine
Lime Dust Fine
Waste Bins Section
Lime Dust Coarse
Mill Scale
Coke Breeze
Mill Scale, Flue
Dust, Lime Dust
Coarse
Mixed Raw Charge
Palletizing/Balling Drums
Raw Charge
(Moist & Balle)
Sinter Machine Building
Blast Furnace Deptt
Slime Thickening
Section
Lime Sludge
Hot Sinter
Return
Cold Sinter
Return
Sinter
Material Flow
Diagram
Sintering Plant
Return Sinter to Stock Bin
Flue dust to waste bin
Screened coke return to raw
material section
Raw material sinter

.. 9 of 26

Technical specification of some critical equipments:-

Sl.no Name Quantity Capacity Installation Area
01 Hammer crushers 05 250 ton/hour Raw material
02 Coke crusher 08 16 ton/hour Raw material
03 Flux Screen 10 150 ton/hour Raw material
04 Sinter Machine 03 300-450 ton/hour M/c building
05 Sinter area 252 square metre M/c building
06 Pallets 130 in each m/c M/c building
07 Vacuum chambers 26 in each m/c M/c building
08 Exhausters 6nos(2nos/m/c) 12000 m
3
/minute M/c building

Techno-economics of Sinter plant of Bokaro

Sl Parameters Norms Actual in 2007-08
01 Specific Ore fines consumption 1093kg/t of hot metal 1025kg/THM
02 Specific flux consumption 255 kg/THM 244kg/THM
03 Specific Coke consumption 85 kg/THM 86kg/THM
04 Specific Power consumption 45KWH/Tgross sinter 48.33KWH/TGS
05 Specific Heat consumption 0.024Gcal/TGS 0.025Gcal/TGS

Blast Furnaces
The aim of Blast furnace is to produce pig iron from ore and sinter, i.e. iron bearing
materials. The iron oxide of ore and sinter is reduced to iron with the help of CO and
this CO is produced inside the blast furnace by the action of air with coke. Coke serves
another purpose of supplying heat for the reactions and melting iron inside the furnace.
Part of the heat load of the furnace is also provided by the heat of the blast which is
heated up to a temperature of 1, 000C or so before it is introduced into the furnace. The
gangue material (i.e. unwanted materials like SiO2, Al2O3 etc.) of the ore, sinter and
coke are removed as slag with the help of flux provided by limestone and sinter (since
the sinter is super fluxed). Other additives like quartzite and Mn-ore are charged in the
furnace in small quantities as corrective materials for the proper furnace working and
control of analysis. Except air blast which is feed from the lower part of the furnace
through tuyers all other materials are charged from the top by means of skips.
Functions of coke in BF are manifold. It provides strong porous bed to burden and
supplies the heat load. Part of the heat load is supplied by the hot air blast. The
products of the furnace are the pig iron (hot metal) slag and blast furnace gas.
In Bokaro there are five blast furnace of 2640T/day capacity each having a working
volume of 2000M
3
. 5 Furnaces of 2000 cubic meter useful volume. All furnaces have
Bell-less Top charging System for continuous charging & better distribution of charge.
Coal Dust Injection in Furnace No. 4 and 5 and CHSGP in Furnace # 4 & 5. The
Capacity of B F 4.585 MT of Hot Metal per annum. BF Productivity: 1.4 T/m3/Day. Coke
Rate was 533 Kg/T (June08).

.. 10 of 26

The entire Blast Furnace complex may be divided in the following sections:
Raw Material Charging
Furnace Proper
Stoves
Auxiliaries
Pig Casting machine and cold pig yard
Ladle Repair Shop
Slag Dump Yard
Clay Mass Shop
Slag Ladle Repair Depot
Coke rate 586 Kg/THM (June 08)

MATERIAL FLOW DIAGRAM FOR BLAST FURNACE
Sintering
Plant
Dust catcher
In BF
Gas Cleaning
Plant
RM & MHP
SP
Process
Steam
Net work
Stove of
BF
Charging
Section
of
Blast
Furnace
Coke Ovens
For
Sale
Pig Casting
M/C
For
Distribution
Mixer of
SMS
IMF
Slag Dump
Yard
TBS
BFCHSG
/SGP
Blast Furnace
Hot Metal
Iron Ore
Lime Stone
Mn Ore
Sinter
Coke
Slag Granules
for Sale
Raw BF gas
Flue Dust
Cleaned
BF Gas
Partially
Cleaned BF Gas
Iron Ore
(Lump)
Lime Stone,
Mn Ore,
Quartzite
Sinter
Coke
Cold Pig
Process
Steam
Hot air
Cold
air
Slag
Quartzite

SMS I

The SMS I complex of BSL has 5 LD converters, each of 100/130 T capacity. Sin these
converters, technically pure oxygen (99.5%) is blown from top through a water cooled
lance so as to remove the impurities of hot metal oxidation. As a result of this oxygen
blowing process, hot metal converts into steel.


.. 11 of 26

The steel produced at BSL is meant for products like plates and sheets and therefore, of
low carbon type. All the 3 types of steel viz. Killed, Semi Killed and Rimming is
produced at SMS-I. The rated capacity of shop is 2.5 MT of ingot steel.

In converter, the hot metal received from Blast Furnace is converted to steel by
removing carbon and other element present.

The change of this metal to steel is brought by blowing 99.5% pure oxygen in converter
by supersonic speed. Before starting the oxygen blowing, the converter is properly
charged in a defined sequence. At first lime is charged in the bottom. Then scrap
addition is done with the help of a charging crane. The reaction in the converter is
highly exothermic. At that time, the scrap acts as a coolant. Finally, hot metal is charged
and oxygen blowing is done by lowering the lance and opening the oxygen shut-off
valve. The lime is added as a flux and to maintain the basicity of bath.

After the corrective measures are taken temperature and samples are taken and if
found all right the heat is tapped. During tapping of steel, required amount of
Deoxidisers ( FeMn, FeSi, Al etc) are added in the teeming ladle depending upon the
quality of steel ie. whether Rimming, Semi Killed or Killed is made after tapping, the
converter is tilted to the other side of the rimming portion of slag in the converter is
dumped in the slag pot. The slag is then transferred to the slag yard. The teeming ladle
on the other hand is transferred to the teeming bay and teeming is done.

SMS II

There are two LD Converters in the Shop each of 300 hundred Ton Capacity. SMS II
differs with SMS-I mainly because of blowing process and gas recovery system. Unlike
SMS-I, SMS-II have got suppressed combustion system, where atmospheric air is not
allowed to enter in the hood area and the combustion of converter gas is suppressed.

Capacity of SMS-II is 2.25 MT of liquid Steel. At present, mainly Killed & Semi Killed
steels are produced in the shop.

Gas Cleaning Plant widely known as GCP is meant for treating the cases generated
from the Converter. It consists of hood, skirt, stack and down take, all fabricated of steel
tubes. The gases are cooled & cleaned while they pass through this system. This gas is
used by reheating furnaces and Soaking Pits.

Continuous Casting Shop
The Continuous Casting Shop, the fastest in the country, is equipped with advanced Level-3
automation and control systems. The shop has a Ladle Furnace and a Ladle Rinsing Station
for secondary refining of steel. The shop has two fully automated Double-strand Slab
Casting Machines. These machines are equipped with Straight Moulds (unique in India) and
12 of 26


Continuous Straightening facilities to produce internally clean, defect-free and high quality
slabs, Argon Injection in Shroud and Tundish Nozzle to prevent Re-oxidation and Nitrogen
Pick-up, Eddy Current based Automatic Mould Level Control (unique in India) for better
surface quality, Dynamic Air Mist Cooling, On-line Slab Cutting, De-burring and customized
Marking. CCS produces mild steel of Drawing, Deep Drawing, Extra Deep Drawing, Boiler
and Tin Plate quality. It also produces low alloy steels like LPG, WTCR, SAILCOR and API
Grade.
The liquid Steel from the Steel Melting Shop is brought in ladles. This material is fed into
buffer vessels called furnished which inturn feeds the mould at regulated flow rates. The
mould is externally water-cooled. The solidification process starts from mould. At the start of
casting, a dummy bar is inserted in the mould to avoid free fall of liquid steel. The bar is
withdrawn as the casting progresses. The mould is oscillated to facilitate downward
movement of cast material.
The partly solidified slab after leaving the mould enters the secondary cooling zone where is
it cooled by water spray. The slab then moves to straightening rolls where it is straightened
by pairs of horizontal rolls. It is then cut into required slab length.
Slabbing Mill
Slabbing mill transforms ingots into slab by rolling. The ingots of various sizes and
weights are received from SMS I and after being rolled into slabs, they are sent to our
internal customer HSM. The capacity of the mill is 4 MT and is of universal type,
capable of rolling ingots up to 38 tons. The rolling rate varies from 600 to 800 T/Hrs
depending upon the size of the ingots and the thickness of the slab to be rolled. The
mill was commissioned on 30
th
December 1974.
We have 12 groups of Soaking pits with each group having 4 pits : Total 48 pits
wherein ingots are heated to a temperature above 1300C. On line hot and cold scarfing
M/C for surface scale / defect removal. One 1250 m roll dia 2 high reversible universal
mill to produce slabs of thickness 150 300 mm, width 950 1850 mm and length 2.5
10.5 mtr and a 2800 ton Hydraulic shear.
SECTIONS
Slabbing mill complex has been divided into four main sections. They are :
a) Ingot Storage Yard
b) Soaking Pit
c) Mill Proper
d) Slab Storage Yard
Hot Strip Mill

The Hot Strip Mill at Bokaro Steel Plant is a continuous 2,000 mm wide strip mill. It is
referred to as a 2,000 mm mill because the barrel length of the rolls used in this mill is
2,000 mm. This mill is designed to roll thin and wide strips for use in various industries
such as wagon building, tube and pipe industry, drum manufacturing, furniture
manufacturing and lastly, for use in the Cold Rolling Mill.
13 of 26



The Hot Strip Mill at Bokaro is presently rolling different grades of plain carbon and
low-alloy steel into strips 1.9 to 12 mm thick and 910 1,850 mm wide in coil form. The
dimensions of slabs are: Thickness-170 to 230 mm, Width-910 to 1,850 mm, Length - 7.7
to 10.5 m and maximum weight-32 T

The fully automatic Hot Strip Mill of Bokaro Steel has a wide range of products. This is
the only continuous Hot Strip Mill in India. The Walking Beam Reheating Furnaces
provide uniform heating, ensuring consistency in thickness throughout the length.
High-pressure De-scalers eliminate rolled-in scale. Edgers in the roughing group
maintain width within close tolerance. The Roughing Group has a Roughing Train of a
Vertical Scale Breaker, one 2-high Roughing Stand and four 4-high Universal Roughing
Stands. The Finishing Group consists of a Flying Shear, Finishing Scale Breaker and
seven 4-high Finishing Stands. Hydraulic Automatic Gauge Control system in the
finishing stands ensures close thickness tolerance. The Work Roll Bending System
ensures improved Strip Crown and Flatness. The unique Laminar Cooling System
controls coiling temperature over a wide range within close tolerance. Hydraulic
Coilers have been provided for maintaining perfect Coil Shape with On-line Strapping
system. On-line Robotic Marking on the coil helps in tracking its identity.

















Hot Rolled Coil Finishing
All the Hot Rolled coils from the Hot Strip Mill are received here for further
distribution or despatch. HR Coils rolled against direct shipment orders are sheared
and finished to customer-required sizes and despatched to customers such as Railways,
Wagon Building industry, tube makers, defence etc. The material is supplied as per
Indian specifications and many international/foreign specifications.
14 of 26


Slab
yard
Furn
aces

Furn
aces

VSB R1 R2 R3 R4 R5
F. Shear
P. R..S.
Washer
F6 F7 F8 F9 F1
0
F1
1
F1
2
C C C C
Coilers
Finishing Stands
Roughing Stands

Cold Rolling Mill
The Cold Rolling Mill at Bokaro produces high quality sheet gauge material, Tin Mill
Black Plate and Galvanised Products. Cold rolling gives thinner gauge strip of very
smooth and dense finish with better mechanical properties that are used for deep
drawing purposes, manufacturing automobile bodies, steel furnitures, drum and
barrels, railway coaches, other bending and shaping jobs and for coated steels. The
CRM complex comprises two Pickling Lines, two Tandem Mills, an Electrolytic
Cleaning Line, a Continuous Cleaning and Annealing Line, Bell Annealing Furnaces,
two Skin Pass Mills, a Double Cold Reduction Mill (DCR), Shearing Lines, Slitting Lines
and a packaging and despatch section.
The 5-stand Tandem Mill has sophisticated Hydraulic Automatic Gauge Control and
computerised mill regulation. The DCR mill can produce Tin Mill Black Plate, which is
tinned for use by the canning industry. The Hot Dip Galvanizing Line produces Zinc-
coated CR strips resistant to atmospheric, liquid and soil corrosion. Its Continuous Coil
Corrugation Line produces corrugated sheets, while the Galvanised Sheet Shearing
Line produces galvanised plain sheets. Bokaro Steel's journey of certification under the
various ISO series of standards started with this finishing mill over a decade back.
Research & Control
Total Quality Management is a key word at Bokaro. The Research and Control Labs at
Bokaro monitor all the quality parameters of the incoming raw materials and the
products made in different shops.
The R&C Lab has four major wings: Chemical, Metallurgical, Inspection and R&D. A
comprehensive network of testing labs equipped with sophisticated facilities helps
keep all processes within the specified quality norms.
Quality Assurance
In its pursuit of excellence and enhanced customer satisfaction, Bokaro has gone for
ISO 9001:2000 single certification for all units form Coke Ovens to Cold Rolling Mill
complex.
Bokaro products are well-received in both developed and developing countries.
The CR products are packaged using HDPE cloth/polythene sheet, metal sheets and
edge protectors to maintain brightness and for protection against corrosion and edge
damage during transit. Similarly the HR coils are strapped to prevent damage.
Engineering Shops
The Plant is equipped with Engineering Shops viz. Machine Shop, Structural Shop,
Forge Shop, Steel Foundry, Ingot Mould Foundry and Non-Ferrous & Cast Iron
Foundry to ensure
uninterrupted supply of spares and other accessories required for plant operation and
maintenance. Most of the items needed for maintaining the equipment are produced
in-house to minimise the load on the company exchequer. The solid infrastructure and
skilled manpower have helped fabricate Nitrogen Pressure Vessels for out sister unit.
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PPC & Sales Co-ordination
There is a Production Planning and Control Department that coordinates plant
operation and production flow at each stage of operation as per market demand.
Bokaro Steel is committed to enhancing customer satisfaction, and the PPC&SC
department establishes the crucial liaison essential for customised production.
Energy Conservation
Energy conservation is a high priority area at Bokaro. Optimisation of energy
consumption is a continuous process. The Coal Dust Injection system, better quality
Coke and Oxygen enrichment have significantly reduced the coke rate in Blast Furnace.
Efficient power distribution and load management also help in saving energy. The
Continuous Casting Shop and the Walking Beam Reheating Furnace at Hot Strip Mill
are examples of the adoption of energy efficient technology.
Environment Management
Bokaro is constantly striving for a cleaner and better tomorrow. The plant has installed
Electrostatic Precipitators in the boilers of the Power Plant in addition to all dust prone
areas and the proposal to install ESPs in Sinter Plant has been cleared for
implementation. The entire process water is recycled and effluent quality is maintained
within the statutory norms in the discharge water. The quality of water going into the
river Damodar is monitored round-the-clock. Ambient air quality in and around the
plant, township and surroundings is better than the statutory norms.
All new equipments, including the Coke Batteries being rebuilt are fitted with
environment-friendly technology. Effluents from the Coke Ovens are thoroughly
cleaned in the Biological Oxygen Demand (BOD) Plant. Tar Sludge, a process waste, is
being recycled in Coke Ovens.
Under the thrust on Solid Waste Management, 100% Flue Dust, Mill Scale and Lime
Dust are recycled. LD Slag, earlier considered a waste material, is now processed in
different fractions and used by Sinter Plant and Blast Furnace, replacing equal amount
of flux. Traffic Department also uses LD slag along the railway track, replacing
conventional stone ballast.
The plant has earnestly taken up the environment awareness drive through celebration
of Environment Month and Environment Day. Over two thousand employees are
trained every year in environment conservation and protection through specialized
training modules.
Over 42 lakh trees have been planted in massive afforestation drives which including
commercial varieties like Teak, Sheesham, Gamhar, Mahogany etc.
Bokaro has been certified under the ISO 14001:2004 Environment Management System
standards.
Safety & Fire Services
Bokaro Steel Plant gives maximum stress on safety. Systems have been upgraded and
the entire Plant is covered under OHSAS 18001 Safety Management System.
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Human Resource - The pillar of strength
To meet the challenges in the plant, continuous up gradation of skills is done through
various training programmes for technical and non-technical employees. The HRD
infrastructure for on-job and class-room courses is excellent, supplemented by
workshops for engineering skills training and hi-tech labs for training in computers and
automation systems.
Communication exercises like Samvad, Nayee Dishayen, etc have helped employees
enrich their knowledge and awareness about BSL, SAIL and global scenario of steel
industry.
Separate ISO certification received for HRD by TUV in February 2008.
Felicitation of employees, along with spouse, from different departments for
exceptional devotion/ innovative ideas, rewards for best employee of the month from
each department have taken employee morale to new heights.
From a humble beginning in 1983, the Quality Circle movement in Bokaro has come a
long way, extending beyond the plant premises to encompass students from Bokaro
Steel schools and the School of Nursing (Bokaro General Hospital). Bokaro QCs have
won laurels at SAIL, national and international levels. Human creativity is also tapped
through the avenues of Suggestion Scheme and Value Engineering workshops. The
suggestion scheme involves the employees, their spouses and their children too.
Gestures like birthday wishes to executive employees, marriage greetings and token
gift to wards of employees getting married and goodwill visits to ailing employees
have engendered a unique sense of camaraderie among people.
Corporate Social Responsibility & Peripheral Development
Bokaro Steel Plant is committed to share the benefits accrued through its just and
ethical business for the socio-economic development of people in and around Bokaro
Steel City.

The three major areas that were identified to pursue activities under Corporate Social
Responsibility were:

Peripheral development through adopting villages where comprehensive rural
development programmes could be launched. The scheme was called Bokaro
Steel Gramin Vikas Yojana;
Assuring health check-up and supply of medicines to the needy and the poor. It
was decided to pursue this under a scheme called Bokaro Steel Sarva Swasthya
Yojana.
Provide free education to the children of the under privileged and also adopt
poor children and extend support under scholarship schemes. This was to be
taken up under Bokaro Steel Shiksha Protsahan Yojana.

However with the passage of time several other activities including health camps, eye-
check-up camps including surgeries, starting of a school for the poor with several free
facilities like uniform, books & stationery and mid-day meal were started.
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Bokaro Steel is striving to reach the glow and warmth of its furnaces to people living at the
periphery of this thriving steel city. All villages and residential settlements within a radius of 20
kilometres are covered under the peripheral development programmes that benefit some 3 lakh
persons. In recent years, the stress has been on developing basic and infrastructure facilities like
roads, bridges, schools, wells, pumps etc. and renovating the existing facilities.
Regular health camps are organised to reach immunisation and free medicines to
people. Free medicines are also supplied to Ashadan, a hospital for the lepers, and to
government hospitals in the event of natural calamities. Free education for
underprivileged sections of the society through special schools like Bokaro Ispat Kalyan
Vidyalaya, Bokaro Steel Balika Vidyalaya ensures that the fruits of prosperity reach one
and all. MOU signed with A.S.I. for development of infrastructural facilities and
amenities etc at Archaeological sites of Lauria Nandangarh, Chankigarh and
Rampurwa in West Champaran district of Bihar. Initial payment of Rs. 25 lacs made in
the joint bank a/c opened with ASI at Patna.
Corporate Social Responsibilities (CSR) & Peripheral Development (PD) departments
are under Personnel & Administration Division.

Development of Ancillary Industries
In close collaboration with the Bokaro Industrial Area Development Authority
(BIADA), Bokaro Steel has been encouraging the development of small scale industries
since 1970-71. This industrial cluster has over 250 registered SSI units. Price matching
facility, purchase preference and exemptions like deposit of tender cost, earnest money
and security are extended to the ancillary units. Bokaro Steel also offers the facilities of
its testing labs and in-house R&D and consulting expertise to support the ancillaries.
Training is provided for awareness of ISO-9001 series of standards and bringing their
facilities up to mark for catering to the needs of the steel plant. This is an extension of
Bokaro Steels resolve to convert this region into a thriving business district.
Quality Management System
ISO 9001:2000 All production units from CO&BPP to CRM including RMP,
Maintenance and utilities Divisions are ISO certified.
HRD, Personnel, Town Services, Medical & Health Services and Projects are
also ISO certified
ISO 14001 EMS & 18001 OHSAS - All production units from CO&BPP to CRM are ISO
14001 EMS & 18001 OHSAS certified.
SA 8000 - Bokaro Steel Plant is SA 8000 certified.
Looking Ahead
Galvanised into a cohesive and vibrant team, Bokaro Steel is all set to build on its
achievements and forge ahead of its competitors to become the leading flat steel
producer of the country in days to come. The modernisation plans for capacity
expansion have been initiated and people are geared to make the most of the available
and upcoming facilities.
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MODERNISATION & EXPANSION OF BSL FROM 4.36 TO 7 MT
Bokaro Steel Plant (BSL), was set up and commissioned in the year 1972-73 for
production of 1.7 Mt/y of flat rolled products. Subsequently, the plant was further
expanded to 4 Mt/y in the year 1983-84.
Demand of Steel is growing steadily in India. To fulfil this demand SAIL has a
Corporate Plan for Expansion of its ISPs. Under this Plan Bokaro Steel Plant will
expand its capacity from 4.36 MT to 7.0 MT of Crude Steel.
4.1: Implementation Schedule
M/s MECON has been appointed consultant for the Expansion Plan. CET will provide
in house consultancy for Blast furnace, Sinter Plant & Coke Ovens.
4.2 Main features of the plan are:
Replacing inefficient, energy intensive, low yield and obsolete process/ technology.
Increase Hot metal production from existing Blast Furnaces through Modernisation/
Up gradation of 3 out of 5 BFs.
Reducing dependence on Coking Coal by installing facilities for Coal/ Gas injection.
Introduce appropriate pre & post treatment facilities in the Steel Melting Shop for
producing value added grades of steel.
State of art technology is being adopted.
Entering new area of market
Environment friendly operations
Conversion of higher quantities of HR Coils to value added Cold Rolled products
including Auto grades of steel with the installation of additional Cold rolling mill
Coke Oven & By Product Plant
Augmentation of coking coal storage by installing 35X2500 T silos
Rebuilding of 2 coke oven batteries 1& 2 with pollution control facility. (COB#5 already
under execution and near completion.)
Replacement of Quenching Tower with new QT with facilities to control emission.
Computerised Combustion Control System (CCCS)
Replacement of H2SO4 Plant
Commissioning of 3rd stream of Benzol Recovery & Distillation and revamping of
stream 1 & 2.
Sinter Plant
Revamping of existing machines. The sintering area will be increased from 250 to 312
m.
Productivity to increase to 1.2 T/m/ hr.
Replacement of Battery Cyclones with ESPs to bring down emission level.
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Blast Furnaces
Increase the volume of 3 Blast Furnaces from 2000 to 2365 m3.
Up gradation of 3 Blast Furnaces 1, 2 & 5 to increase the productivity from 1.5 to 2.3
T/m3/day
Installation of Slag Granulation units in all BFs (CHSGP is already provided in BF#5
and in BF-4 is already in execution and near completion).
Provision of CDI facilities in 4 BFs (BF#1 is provided with Coal Tar Injection, BF#4 & 5
already provided with CDI system)
Gas Injection system to utilize CBM gas from near by Jharia Coal field
Steel Melting Shops
Phase- out SMS-I having Ingot route
Augmentation of capacity of SMS-II from 2.16 MT to 3.2 MT by implementing a
number of de-bottlenecking schemes.
Installation of New SMS-III with Continuous Casting Shop of 3.8MTPA . The shop will
produce about 2.3488 Mt/y of HR coils through thin slabs caster and 1.4154Mt of slabs
(for rolling in existing HSM) through BOF-LF-CC route .

Rolling Mills
One Thin Slab Casting & Rolling Mill (to be installed along with SMS-III)
Provision for New Hot Rolled Galvanizing Shop shall be made in the layout of SMS-III.
Installation of a New CRM to produce 1.2 MTPA

Oxygen Plant
Installation of 2 x 1250 tpd ASUs including additional gaseous storage vessels (for
Oxygen, Nitrogen and Argon) has been envisaged. The plant is being implemented on
BOO basis
Other Facilities
I. Transportation
A new Railway Exchange Yard to be constructed near Tupkadih Railway station to
receive Middling /CDI Coal and dispatch finished products from Strip Mill of New
SMS
II. Power Requirement
Additional Power requirement shall be made available from BPSCL. BPSCL is
installing 2x250MW New Power Plant to enhance its generation capacity.
III. Water Requirement
It is envisaged to meet the additional requirement of water by recycling of Sewage &
Industrial effluents to the maximum extent after suitable treatment
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Environment Management
I. Air Pollution Control
In the existing systems for control of outflow of fugitive dust from generating
sources, dust extraction systems, dust suppression systems and fume extraction
systems have been envisaged for the various plant premises to keep the dust
concentration well below the threshold limit value (TLV).
II. Effluent Treatment Plant
An effluent treatment plant has been envisaged for the new CRM Complex for
removal of the pollutants.
4.3 Result of Expansion
Sl. No. Description Capacity
1. Hot Metal (MT) 7.44
2. Crude Steel (MT) 7.00
3. Saleable Steel (MT) 6.53
4. Yield of Saleable Steel from Liquid Steel (%) 91.4
5. Specific Energy consumption (Gkcal) 5.5
6. Coke rate Kg/THM 395

State of the Art technology is being adopted.
Entering new segments of market
Environment friendly operations
Saving energy by reducing dependence on Coking Coal by installing facilities for Coal/
Gas injection.
Replacing inefficient, energy-intensive, low-yield and obsolete process/ technology.
Increase Hot metal production from existing Blast Furnaces through Modernisation/
Up gradation of 3 out of 5 BFs.
Reducing dependence on Coking Coal by installing facilities for Coal/ Gas injection.
Introduce appropriate pre & post-treatment facilities in the Steel Melting Shop for
producing value added grades of steel.
Conversion of higher quantities of HR Coils to value-added Cold Rolled products
including Auto grades of steel with the installation of additional Cold rolling mill.






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TECHNO ECONOMICS

























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T TO OT TA AL L E EN NE ER RG GY Y C CO ON NS SU UM ME ED D
6.89
7.09
6.6
6.9
7.2
7.5
04-05 05-06 06-07 07-08
G Gc ca al l/ /T TC CS S
448.0
440.0
425
435
445
455
465
475
485
495
04-05 05-06 06-07 07-08
E EN NE ER RG GY Y C CO ON NS SU UM MP PT TI IO ON N
K KW WH H/ /T TS SS S
1133
1132
1130
1135
1140
1145
1150
1155
1160
04-05 05-06 06-07 07-08
TOTAL METALLIC INPUT
K Kg g/ /T T C CS S
512
520
500
505
510
515
520
525
530
535
04-05 05-06 06-07 07-08
C CO OK KE E R RA AT TE E
Kg/T HM

Comparative Statement of Profit/Productivity


Year Profit
(Rs. in Crores)
Productivity
(T/M/Yr)
2003-04 1120 141.3
2004-05 3290 151.34
2005-06 2056 173.94
2006-07 2737 231.84
2007-08 2830 244.78


Production of 2007-08

Product Target (07-08) Production Performance
Hot Metal 52.0 46.6 90
Crude Steel 48.5 41.3 85
Cast Slab 32.0 28.5 89
H. R. Coil 40.0 36.0 90
C. R. Product 11.6 7.8 67
Saleable Steel 42.0 39.0 96



Comparative Statement of Purchase/Production Cost

Ingredients 2006-07
(Rs/Ton)
2007-08
(Rs/Ton)
%
Change
2008-09
(Rs/Ton)
% Change
(from 07-
08)
Imported
Coal
6970 6346 -9 16700 163
Indigenous
Coal
3844 4159 8 6500 56
Coke 11977 11584 -3 30000 158
Ferro Alloy 42000 49000 16 87600 79

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Comparative Statement of Production Cost



Effective
Ingredients
(2007-08)
(Rs/Ton)
(2008-09)
(Rs/Ton)
BF Coke Hot
Metal
Saleable
Steel
BF Coke Hot
Metal
Saleable
Steel
Raw
Material
7762 6051 8759 20443 13952 18293
Others 1565 2945 10222 1580 3667 9956
Total 9327 8996 18981 22023 17619 28249


Production Target of 2008-09


Product Planned Target (08-09) Production of 1
st
Qtr.
Hot Metal 50.5 9.29
Crude Steel 47.0 8.18
Cast Slab 32.0 6.16
H. R. Coil 42.1 7.35
C. R. Product 10.0 1.50
Saleable Steel 41.1 7.63












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