A Project Report on

VISAKHAPATNAM STEEL PLANT

Submitted in partial fulfillment of the requirement for the award

of
DIPLOMA IN MECHANICAL ENGINEERING

Submitted by

K.PRASANTH

(16009-M-096)

Under the guidance

Of
Mr.K.SRINIVAS RAO, Mgr (M)
MMSM Dept., VSP

GOVERNMENT POLYTECHNIC , VISAKHAPATNAM

2018-2019
 GOVERNMENT POLYTECHNIC

VISAKHAPATNAM

CERTIFICATE
This is to certify that the following bonafide students of Government
Polytechnic, Visakhapatnam have under gone Industrial Training for six
months as part of V semester of diploma in Mechanical Engineering at
“RINL VISAKHAPATNAM STEEL PLANT” , during the period from
21 MAY 2018 – 15 NOV 2018.

STUDENT NAME PIN

K.PRASANTH 16009-M-096

During the above Period their conduct and performance was Found to be
.
 INDEX

1 . INTRODUCTION

 Introduction to Visakhapatnam Steel Plant(VSP)

 Vision , Mission and Objectives

 Major products of VSP

 Major units in plant

 Role of various departments in converting from ore to steel.

 Ore to steel block diagram

2 . MEDIUM MERCHANT AND STRUCTURAL MILL (MMSM)

 Introduction to MMSM

 Description of process in

 MMSM Walking Beam Reheating Furnace:

 Components of reheating furnace

 Equipment specifications

 Furnace constructionfeatures

 Fixed and movingbeams

 Combustion systems

3 . CONCLUSION
 ABSTRACT

In the steel making process, rolling mills play a vital role in transforming
the steel to finished products. Rolling mills at VSP consists of LMMM, WRM
& MMSM. The blooms from SMS are charged into reheating furnaces of
MMSM for heating then up to 1200 deg and subsequent rolling. Reheating
furnace at MMSM of 130 T/hr capacities is running with these by-product
energies as fuel and yielding limited output up to 150 T/hr of steel for rolling.
This project report deals with the study of rolling mills in steel plant. A
keen study of the system was made in “Medium Merchant and Structural
Mill (MMSM)” at Visakhapatnam Steel Plant (VSP), the first integrated and
most modernized steel plant in the country.
This project describes the basic principle and working of the system in
detail with specifications.
 ACKNOWLEDGEMENT

The work submitted here is performed as project work under the

valuable guidance of Mr.GHULAM SARWER Assistant General Manager,
Department of Mechanical Engineering. We thank him for guidance and
participation in developing the project work.

We wish to express our deep sense of gratitude to Mr.K.SRINIVAS

RAO,Manager(Mgr) Mechanical Department at Medium Merchant And
Structural Mill at VISAKHAPATNAM STEEL PLANT for providing
facilities to carry out the project along with efficient guidance to complete
our work fulfledgely.

We would like to express our heart full thanks to Sri R.BHASKAR

RAO, Head of Department of Mechanical Engineering for standing like a
backbone for us throughout completion of project and suggesting us
professionally with patience.

It gives us great pleasure to express our heartfelt gratitude to our

beloved principal D.PHANINDRA PRASAD who encouraged us in taking a
project in our interested area to carry our project.
CHAPTER

1 INTRODUCTION

HIGHLIGHTS:

 Introduction to Visakhapatnam Steel Plant

(VSP)

 Vision , Mission andObjectives

 Major products of VSP

 Major units in plant

 Role of various departments in converting from

ore to steel.

 Ore to steel block diagram

INTRODUCTION TO VISAKHAPATNAM
STEEL PLANT (VSP):
Steel comprises one of the most important inputs in
all Visakhapatnam steel plant, the first coastal based steel
plant of India is located 16kms south west of city of
destiny i.e. Visakhapatnam. Bestowed with modern
technologies, VSP has an installed capacity of 3 million
tones per annum of liquid steel and 2.656 million tonnes
of saleable steel. At VSP there is emphasis on total
automation, seamless integration and efficient up
gradation, which result in wide range of long and
structural products to meet stringent demands of
discerning customers within India and abroad. VSP
products meet exalting international quality standards
such as JIS, DIN, and BIS, BS etc.
VSP has become the first integrated steel plant in the
country to be certified to all the three international
standards for quality (ISO-9001), for environment
management (ISO-14001) and for occupational health and
safety (OHSAS-18001).

VSP exports quality pig iron and steel products to

Srilanka, Myanmar, Nepal, middle-East, USA and South
East Asia (pig iron). Having a total manpower of about
16755 VSP has envisaged a labour productivity of not
less than 262 tonnes per man year of liquid steel which is
the best in the country and comparable with international
levels.

VSP TECHONOLOGY: STATE-OF-THE-ART

TECHNOLOGY:

 7m tall coke oven batteries with coke dry

quenching
 Biggest blast furnaces in the country

 Bell – less top charging system in the blast furnace.

 100% slag granulation at the blast furnace cast

house .

 Suppressed combustion LD-gas recovery system .

 100% continuous casting of liquid steel.

 “TEMPCORE” & “STELMOR” cooling process in LMMM

and WRM respectively.

 Extensive waste heat recovery system .

 Comprehensive pollution control measures

VISION

To be a continuously growing world class company we shall

• Harness our growth potential and sustain profitable growth.

• Deliver high quality and cost competitive products and
be the first choice of customers.
• Create an inspiring work environment to unleash the
creative energy of people.
• Achieve excellence in enterprise management.
• Be respected corporate citizen, ensure clean and green
environment and develop vibrant communities around
 MISSION

 To attain 16 million ton liquid steel capacity through

technological up-gradation, operational efficiency and
expansion; to produce steel at international standards of
cost and quality; and to meet the aspirations of the
stakeholders.

OBJECTIVES

 Expand plant capacity to 6.3Mt by 2011-12 with the

mission to expand further in subsequent phases as per
Corporate Plan.
 Revamping existing Blast Furnaces to make them energy
efficient to contemporary levels and in the process increase their
capacity by 1 Mt, thus total hot metal capacity to 7.5 Mt
 Be amongst top five lowest cost liquid steel producers in the
world
 Achieve higher levels of customer satisfaction
 Vibrant work culture in the organization
 Be proactive in conserving environment, maintaining
high levels of safety & addressing social concerns
 Major Units

Department Annual Capacity(‘000T) Units(3.0 MTStage)

Coke Ovens 2,261 4 batteries,(3) of67

Ovens &7Meters Height

Sinter Plant 5,256 2 Sinter Machinesof 312

SQ.Mtr grate area each

Blast Furnance 3,400 2 furnaces of 3200 Cu.Mtr.

Volume each

Steel Melt Shop 3,000 3 LD Converters each of

133 Cu.mtr. volume and
Six 4 strand bloom
casters

LMMM 710 4 Strand finishing Mill

WRM 850 2 x 10strand finishing Mill

MMSM 850 6 Strand Finishing Mill

Main Products of VSP

Steel products By-Products

Angles Flats Nut Coke Granulated slag

Billets Rounds Coke Dust Lime Fines

Channels Re-Bars Coal Tar Ammonium
Sulphate

Beams Wire-Bars Anthracene Benzene

Squares HP Naphthalene Toulene,
Xylene,
Wash
Oil

MAJOR DEPARTMENTS

Raw Material handling plant (RMHP)

The Raw Material Handling Plant (RMHP) receives

the basic raw materials required for the Steel making
process from various sources through railway wagons
and by road. These are Stacked by stackers and reclaimed
by reclaimers and distributed to various departments of
VSP through conveyor system. The Iron Ore Fines, Iron
Ore Lump, Sized Iron Ore, Limestone (BF&SMSgrades),
Dolomite (BF & SMS grades),
 Sand, Quartzite and Manganese lumps are stacked at
Ore& Flux Yard. The Imported Coking Coal (ICC),
Medium Coking Coal (MCC), Boiler Coal (BC) are
stacked in Coal Yard. Coke is sent directly to Blast
Furnace after tippling from ore and flux wagon tipplers .
Raw Materials to the tune of 12-13 Million tons
required for producing 3million Tones of Liquid Steel.

The raw materials are sent to various departments as indicated

below :

 Sinter Plant: Iron Ore Fines, Lime stone (BF),

Dolomite, Sand and LD slag.
 Blast Furnace : Sized Iron Ore, Limestone (BF)/ LD slag,
Manganese Lump, Quartzite and Coke.
 SMS: Dolomite (SMS), Sized Iron Ore, Dolo chips.
 CRMP: Limestone (SMS), Dolomite (SMS), Dolo
chips.
 TPP: Crushed Boiler Coal.
 COCCP: Imported coking coal (ICC), Medium
coking coal (MCC).

The Raw Material Handling Plant is divided into two sections

Coal Handling Plant (CHP) and Ore Handling Plant (OHP).

Coke Ovens & Coal Chemical Plant (CO &

CCP)
 Coking coal after selective crushing and proper blending is
subjected to destructive distillation (heating in the absence of
air) in the Coke Ovens. A Coke Oven After heating for nearly a
period of 16-18 hours at a temperature of about 1100 o C, coke is
obtained and is used as a fuel as well as reducing agent in the
Blast Furnace.

 The Coke Ovens of VSP are engineering feats by themselves.

They are the tallest ovens constructed in the country.

 A Coke Oven comprise of two hollow chambers namely ‘coal

chamber’ and ‘heating chamber’.In the heating chamber a
gaseous fuel such as Blast Furnace Gas, Coke Oven Gas etc. is
burnt.The heat so generated is conducted through the common
wall to heat & carbonize the Coking Coal placed in the adjacent
coal chamber.
 Number of ovens built in series one after the other form a Coke
Oven Battery.The Plant has 3 batteries of 7mtr. tall ovens with
each battery consisting of 67 ovens.

 Another feature is the dry cooling of coke carried out by the inert
gas nitrogen thus, reducing pollution considerably.
 Besides a bio-chemical plant separately undertakes the
treatment of effluents. By-products like benzene, toluene,
xylene, napthalene, coal tar, creosote oil, pitch, ammonium
sulphate and benzol products are also recovered from the coke
ovens gas. VSP produces, among other by-products, pushkala a
prime fertilizer based on ammonium sulphate.

Sinter plant (SP)

 Iron ore fines, coke breeze, limestone and dolomite along with
recycled metallurgical wastes are converted into a hard and
porous ferrous agglomerated ferrous material(mass) called
‘Sinter’ at the Sinter Plant, which forms 80% of iron bearing
charge in the Blast Furnace.

 Sinter is A BETTER FEED MATERIAL to Blast Furnace in

comparison to Iron Ore lumps and its usage in Blast Furnaces help
in increasing productivity, decreasing the coke rate & improving
the quality of Hot Metal produced.

 The Sinter Plant comprises of two sinter machines each having

312 square meters of grate area with a total production capacity of
5.256 million tonnes per annum.
 Blast Furnace (BF)

 VSP has two Blast Furnaces named as “Godavari” & “Krishna”

with an effective volume of 3200 cu.m, each of which are the
largest in the country equipped with Paulworth Bell less top
equipment with conveyor charging.

 Blast Furnace is charged with coke, iron ore and sinter from the
top and produces about 5000 tonnes of molten iron per day. Its
novel circular cast house with four tap holes ensures continuous
tapping of hot metal. The annual production capacity of these
Blast Furnaces is 3.4 million tonnes of liquid iron.

 Provision exists for granulation of 100% liquid slag at blast

furnace cast house and utilization of blast furnace gas top
pressure (1.5-2.0 atmospheric pressure) to generate 12 MW of
power in each furnace by employing gas expansion turbines.
 STEEL MELTING SHOP (SMS)

Steel is an alloy of iron with carbon up to 1.8%. Hot metal

produced in the blast furnaces contain impurities such as carbon (3.5-
4.25%), silicon (0.4-0.5%), manganese (03.- 0.4%), sulphur(0.04%max)
and phosphorus (0.14% max) is not suitable as a common engineering
material to Improve the quality that impurities are to be eliminated or
decreased by oxidation process.
 VSP employs three top blown oxygen converters called LD-
convertors each having 133m3 volume capable of producing three million
tons of liquid steel annually. 99.5% of pure oxygen at 15-16 KSCG
pressure is blown in the convertor through an oxygen lance having
convergent – divergent copper nozzles at the blowing end. Oxygen oxidizes
the impurities present in the hot metal that are fixed as slag with basic
fluxes such as lime. During the process heat is generated by exothermic
reactions of oxidation of metalloids like Si, Mn, p & c and temperatures
rising 1700ºC enabling refining and slag formation. Different grades of
steel of superior quality can be made by this process by controlling the
oxygen blow or addition of various Ferro alloys or special additives such
as FeSi, FeMn, Si-Mn, coke breeze, Al in required quantities while liquid
steel is being tapped from the convertor into a steel ladle. Convertor gas
produced as a byproduct is used as secondary fuel
 CONTINUOUS CASTING DEPARTMENT
(CCD)

Continuous casting may be defined as teaming of liquid steel in a mould

with a false bottom through which partially solidified bar is continuously
withdrawn at the same rate at which liquid steel is teamed in the mould.
Facilities at a continuous casting machine include a lift and turntable for
ladles, copper mould, oscillating system tundish, primary and secondary
cooling arrangement to cool the steel bloom. Gas cutting machines is used
for cutting the blooms in required lengths of 6m long. At VSP we have six-
4strand continuous casting machines capable of producing 2.82 million tons
per year blooms of size 250*250mm and 250*320mm. The entire quantity of
molten steel produced (100%) is continuously cast in radial bloom casters,
which help in energy conservation as well as production of superior quality
products.
 ROLLING MILLS

Blooms produced in SMS-CCD do not find much applications as

such and are required to be shaped into products such as billets, round,
squares, angles (equal and unequal), channels, I-PE beams, HE
beams, wire rod and reinforcements by rolling them in, there
sophisticated high capacity, high speed, fully automated rolling mills,
namely Light and Medium Merchant Mills(LMMM), Wire Rod Mills
(WRM) and Medium Merchant and Structural Mill (MMSM).

LIGHT AND MEDIUM MERCHANT MILL

(LMMM)
The cast blooms from continuous casting department are heated and rolled in
high the two speed and fully automated rolling mills namely Light &
Medium Merchant Mill (LMMM) and Medium Merchant & Structural Mill
(MMSM). The billets produced in LMMM are further rolled in Bar Mill / Wire
Rod Mill (WRM). The finished products include wire rods & long products
like Reinforcement bars, rounds, squares, flats, angles, channels, billets etc.
LMMM comprises of two units in the billets/break down mill 250*320 mm
size blooms are rolled into billets of 125 mm size after heating them in two nos.
of walking beam furnaces of 200T/hr capacity each. This unit comprises of 7
stands (2 horizontal 859/1200mm dia) and 5 alternations vertical and horizontal
stands (730/1000 mm dia and 630/1000 mm dia) billets are supplied from this
mill to bar mill of LMMM, wire rod mills (WRM).

WIRE ROD MILL (WRM)

 The Wire Rod Mill of VSP is high speed 4 strand No-Twist
continuous mill designed to produce 8,50,000 T of wire rod coils. The
mill is designed to produce plain wire rods from 5.5 mm to 12.7 mm
diameter and Rebar in 8mm, 10mm and 12mm diameter in coil form.
However sizes up to 14mm are being rolled presently. Rolled billets of
125 mm x 125 mm square cross section, length ranging from 9.8 m to
10.4 m and weighing approx 1250 kgs are used as input material. The
mill is designed to roll steel stock of 0.9% max Carbon content.

MEDIUM MERCHANTAND STRUCTURAL MILL

(MMSM)
 The Medium Merchant and Structural Mill (MMSM) is one of the modern
rolling mills of Visakhapatnam Steel Plant. This is a single strand continuous
mill having production capacity of 8,50,000 T/year. The important feature of
this mill is that Universal beams (parallel flange) have been rolled first time in
India using Universal stands. Parallel flange beams have advantage over
conventional beams as, for the same weight; the section is stronger and
stiffer due to greater moment of inertia and higher radius of gyration.

ROLL SHOPAND REPAIR SHOP

 Roll Shop and repair shop plays a major role in fulfilling the
technological needs of all the mills and caters in respect of Roll Pass
Design, Roll redressing, roll assembles, guides, and few maintenance
spares. During Rolling, Roll passes tend to wear out and gradually lose
their initial shape resulting in the size or surface finish of the product being
rolled deviated from the allowable tolerances. This is remedied by
Redressing that is by turning the rolls to restoring the width and depth of
pass to its original dimensions. The main activities are roll pass design,
redressing of rolls, new rolls turning, assembly of rolls with bearings,
preparation of guides, and their service and manufacturing or repair of mill
maintenance spares. The roll pass design section designs development of
new sections, modification of existing pass designs for improving the
productivity and quality, preparation of rolling schedules, groove detail and
distribution and template drawings, part programming for grooving of rolls
on CNC lathes.
Process Flow Diagram
CHAPTER

2
MEDIUM MERCHANT AND STRUCTURAL MILL
(MMSM)

HIGHLIGHTS:

MMSM:

Introduction to MMSM

 Description of process in
MMSM Walking Beam Reheating Furnace:

 Components of reheating furnace

 Equipment specifications

 Furnace constructionfeatures

 Fixed and moving beams

 Combustion systems
 INTRODUCTION :
In Medium Merchant and Structural Mills (MMSM)
The blooms of size 250x250 mm are heated to
temperatures around 1200 c and rolled into different
Categories of bars and structurals like rounds, squares,
flats, angles, channels, HE and IPE beams by timely
estimation of demand.

MAJOR FACILITIES:
In order to meet the production requirements, the
following major facilities are available in MMSM.

CHARGING GRID & FURNACE:

-3 charging grids.
-2 x 130 t/hr top and bottom fired walking beam furnaces
with evaporative cooling system.
MILL PROPER:
• The mill train of MMSM consists of a total of 20 stands as follows:

• Roughing train consists of 8 stands as

 two high horizontal stands,

 vertical standards

 combination stands

• Intermediate train has 6 mill stands as per details given below

 high horizontal stands

 combination stands

 horizontal stands/2 universal stands

• Finishing train consists of 6 stands namely

 combination stands

 horizontal stands/4 universal stands

 The important feature of this mill is that Universal beams (both parallel and
wide flange) have been rolled first time in India using Universal stands.
Parallel flange beams have advantage over conventional beams as per the
same weight the section is stronger and stiffer due to greater moment of
inertia and higher radius of gyration.

• COOLING BEDS STRAIGHTENER & BATCHING:

• 120 m long double sided rake type coolingbed.
• 2 straightening machines, one in eachline.
• 2 collecting beds and batch transfer equipment.

• FINISHINGAREA:
 - 2 cold saw lines each consisting of one stationary saw
and two movable saws.
- 2 x 24 m bundling machines and 2 x 24m and 2 x 12
m piling machines .
- Online refinishing line.

MMSM PRODUCTS :

Rounds Angles Mc Ismb Flat Blt

40 75*75*8 100*50*5 150 150*10 65*65

45 90*90*6 125*65*5.3 175 150*12 75*75

46 90*90*8 150*75*5.7 120 90*90

48 100*100*8
50 100*100*10
53
56
60
63
65
70
71
80
PROCESS DESCRIPTION:
 The input material to the mill is continuous cast blooms
of size 250x250mm. Two walking beam type furnaces
are provided for reheating the blooms. For charging the
furnace the blooms are loaded on the bloom charging
grids in batches by magnet cranes. Blooms are
visually inspected on the charging grids and weighed
one by one on a weigh scale incorporated in the
charging roller table, aligned in front of the furnace and
charged into the walking beam furnace by a bloom
charging device. The heated blooms from the furnace
are discharged one by one onto the delivery roller table
by bloom discharging device for feeding them to the
first stand of roughing train. During transportation to
the first roughing stand, the blooms are descaled on all
4 sides by a hydraulic descaler.
 The mill train consists of continuous roughing,
intermediate and finishing group of stands. Depending
on the section being rolled the combined stands,
provided on each of the continuous trains, are arranged
in a horizontal or vertical position. In case of the rolling
of beams suitable no. Of horizontal stands, provided in
the continuous intermediate and finishing trains are
replaced by universal stands.

 Generally the front ends of the bars are cut by shears

installed before the intermediate train and finishing
train. Front end cropping, dividing of finished bars into
multiple sale lengths for cooling bed, emergency
cutting and test piece sample cutting is done by the
shear provided after the finishing group. Inline size
measurement is done for rounds, squares, and flats on
equipment provided after finishing group of stands.

 Following the shear after the finishing train is a series of

water boxes and roller tables complete with water
spraying nozzles for controlled and rapid cooling of
divided bars after which they are directed with the help
of a diverter switch to the double sided cooling bed.
The finishing of cooled bars is done on inline automatic
finishing lines installed after each cooling bedside.
This finishing lines is provided with facilities for
straightening, cutting, inspecting, sorting according to
surface quality and length, counting, piling, bundling,
tying, weighing and tagging with embossed metallic
tags.

 EOT cranes having 20-tonnes capacity,10m crane rail

height and fitted with Rotating rolling, spreader beam
and magnet/slings is available for removing to the
piled and bundled products storage area.
MMSM TECHNICAL DATA:

 CAPACITY : 8,50,000 T/YEAR

 PRODUCTS : ANGLES, CHANNELS, BEAMS,
FLATS, ROUNDS & SQUARES
 SP. FUEL CONSUMPTION : 340 X 1,000 KCAL/T
 SP. POWER CONSUMPTION : 93.92 KWH/T
 ROLLING RATE : 222 T/HOUR
FLOW DIAGRAM OF MMSM DEPARTMENT

Blooms from SMS 250mm/250mm/6m

Walking beam furnance – 1200 ºC

Mill stands (1to20) material reduction

Cooling Bed cooling upto 100 ºC

Batching batch formation

Saw cutting customer length

Piling and Bundling packing

Stacking

Despatch to customer
INTRODUCTION TO REHEATING FURNACE
Re-heating furnace is the equipment which is used to
re- heat the already cast material which enables to
allow the material for plastic deformation to get the
desired shapes of the product.

Quantity of heat to be imparted to the charges :-

If the charges is to be heated in a furnace, heat must

be first generated in the furnace. The heat must then be
transferred to the material which is to be heated.
The heat that is to be imparted to the charge equals to
the weight of charge times temperature rise

i.e. H=msttimes mean sp.Heat of

charge.
m=weight at charges
s=specific heat of charge
t=rise in temperature.

Transmission of heat to the surface of the charge :

In furnace heat is transferred by conduction,
convection & radiation. Most of heat transfer to the charge
takes place by radiation
i.e. radiation from walls and flames etc., about 90-
95% of heat transfer takes place by radiation.

It is obvious that to transfer heat to the charge, the

heat must be generated by burning of fuel . During this
process furnace equipment like dampers, burners, and
supporting skids, various valves and elements of cooling
system are to be controlled and keep them in good
operating conditions. Furnace atmosphere is to be strictly
maintained.
 IMPORTANT COMPONENTS OF THE
FURNANCE:
The reheating furnace includes the following components:

 Furnace structural framework

 Walking beam driving mechanism

 Walking beam and fixed beams

 Combustion air fan

 Burners

 Waste gas exhaust system

 Refractory and insulation

 Fuel system, evaporative cooling system, lubrication

and hydraulic system

The specifications of the blooms being fed intothe furnace are:

Blooms Size

Thickness 250mm
Width 250mm
Length 6000mm
Weight 2900kgs

EQUIPMENT SPECIFICATION:
The walking beam furnace is used for heating blooms of plane
carbon steel, low alloy steel, free cutting steel, medium and
 high carbon steels from ambient to about 1200˚C
• The furnace is charged in two rows for 6mts long blooms

Type :

Number (total) …… Top and bottom fired

walking beam furnace
Nominal output …… Two
Charge temp at inlet …… 250T/hr
Charge temp at outlet …… Ambient

Temp. difference between ……. 1200ºC

Surface and core (max.) …… 30

 FURNANCE CONSTRUCTION FEATURES :

The furnace is fabricated from steel plates adequately reinforced with

structural steel members for the robust construction. Steel plates and
steel members of heavy section are provided to support the hearth .

1. Charging and discharging doors:

The furnace is provided with charging and discharging doors of suitable

dimensions. The doors fabricated from structural steel sections and
lined with refractory materials. The doors are balanced by
counterweights and operated through electric drives. The discharge
doors are of water-cooled type. The door openings and door peripheries
are fitted with heat resistant casting.

2. Side doors:

A sufficient number of side doors are arranged over the entire furnace
length at the workload level. Arrangement for manual operation,
locking in open position and wedged guides for ensuring proper
tightness in closed position is provided. These doors and the opening
periphery are made of heat resistant casting with refractory lining.
Clean out doors at the furnace hearth level are also provided.

For sealing the gaps at the bottom hearth around walking beam post,
water troughs made out of corrosion resistant steel plates of adequate
thickness are provided.

3.Charging and discharging side front walls:

The charging and discharging side front are equipped with

water-cooled Lintels that support the roof noses
COMBUSTION SYSTEMS:

1. Burner:

Adequate number of burners of suitable design to

fire mixed gas in per heating, heating(top and bottom) and
soaking zones (top and bottom) are provided.

2. Combustion air fan:

The furnace is provided with two nos. of combustion

air fan, one in operation and one as a standby. The rated
capacity of the fan is 30% higher than the volume of air
required for maximum connected load of the burners
considering 10% excess air.
3. Waste Gas Recovery System :

a. Chimney : products of combustion are exhausted from

the preheating section of the furnace through
underground flue channel leading to a chimney .
b. Dampers : Dampers for automatic pressure controlling
the waste gas is made of heat resistant material to
withstand the temperature of the waste gases.
c. Air and Gas recuperators : connection type multi
tubular air and gas recuperator is provided in the gas
flue channel. The unit is designed for preheating the
inlet air to the burner manifold to a temperature of
around 380ºc.

d. Dilution air fan : A centrifugal lower complete with

accessories is provided for supplying cold air in
the waste gas flue upstream of the recuperator to
prevent the recuperator tubes from overheating.
 e. Legging : The combustion air pipe and gas pie between
the recuperators and the burners is lagged externally
with insulating materials. Internally with refractory
material depending on the diameter. The lagging is
protected by galvanized sheet steel wrapping.

4. Refractories and insulation:

a. The roof of the furnace is flat suspended type, which is

built up with shaped roof hanger bricks made out of
superheat duty firebricks. The roof hanger bricks are
backed up with a layer of insulating matter. The roof brick
hanger is made up of heat resistant steels.
b. The wall is lined with high alumina firebricks backed up
With cold faced insulating bricks and insulating blocks.
c. The furnance hearth is lined with high alumina firebricks
backed up with a cold faced insulating bricks and
insulating blocks.
d. The doors are lined with high temperature insulating
castables.The waste gas flue upstream of the recuperator
is lined with heat duty firebricks backed up with clod-
faced insulating bricks. Down stream of the recuperator
is line up with medium heat duty firebricks backed up
with cold-faced insulating bricks. One ventilation course
of red brick is provided between the refractory brick and
concrete walls. Thickness of the refractory layers in the
waste gas flue is so chosen that the maximum
temperature on the flue concrete face doesn’t exceed 150ºc.
The basic walking beam system consists out of a lifting
and drive frame which work independent from each other.
During the lift movement the lift frame will be lifted or
lowered by means of rollers and an increasing slope
beam. The movement forward and backward will be
executed by the drive frame with rollers. The advantage
of this system compared to the system with the eccentric
drive is the variable pitch distance of the
 walking beam system. The sealing between the stationary and
movement hearth is done using a water sealing unit.

Audiovisual alarms:

Audio visual alarms are provided for abnormal conditions Of the

following parameters,

 Over temperature of each zone of the furnace.

 Low furnace pressure
 High temperature of combustion air
 Over temperature of waste gas before recuperator
 High oxygen content of wastegas
 Low pressure of mixed gas supply
 Low pressure of cooling water supply

Safety interlocks:

Complete safety control equipment to protect the furnace in

the case of mixed gas, combustion air, and cooling water and
power failure is provided. In the event of any of these failures
occurs or system does not have normal required pressure at the
supply header, the safety shut off valve in the mixed gas line at
inlet to the furnace will automatically shut off with the
consequent audio visual alarms.

SALIENT FEATURES :
o Walking beam type reheating furnace
o 4 walking & 4 fixed skids
o 130 T/Hr capacity (150 t/hr max)
o Single or two row charging and discharging
o Top and bottom fired
 o Long flame and flat flame burners
o three heating zones, two soaking zones

ZONE 1 - 12 top heating flat flame burners

ZONE 2 - 12 top heating flat flame burners
ZONE 3 - 8 bottom heating long flame burner
ZONE 4 - 18 top soaking flat flame burners
ZONE 5 - 9 bottom soaking long flame burner.

o Evaporative cooling systems

o Two steam turbines and one motor drive centrifugal Pump
o In line air and gas recuperators for waste heat recovery
o Auto purging of zones
o Input of furnace heating material – blooms of 250*250mm
cross section and around 6 m long
o Stack height 80 m (chimmne)
o Fuel- mixed gas (BF+LD=CO) with 2000kcal/nm3
of calorific value
o Discharging temp.1200 – 1240ºc
o Duration 64 sec.

NORMAL OPERATING PARAMETERS :

 Mixed gas pressure – 600 mmwc
 Combustion air pressure – 900 mmwc
 ECS drum pressure – 15bar
 Indirect cooling water pressure – 4.5bar
 Instrument air pressure – 4.5bar
 Drum level – 20 to 50 mm
 Feed water pressure - >20bar
 Furnace pressure – 0.4 to 1.0mmwc
  Skid flow
 Fixed
o Post circuit – 19nm3/hr
o Skid circuit – 62nm3/hr
 Moving
o Post circuit – 52nm3/hr
o Skid circuit – 62nm3/hr
 Hot air exhaust – 370ºc
 Dilution temp. set point –720ºc
 Gas recuperator meatl temp. max – 430ºc
 Air recuperator metal temp. max – 620ºc

WALKING BEAMS (SKIDS):

Operation:
Blooms are moved forward step by step,
avoiding any friction or rubbing during its conveyance
through the furnace. The blooms are gently lifted from
the stationary beams, moved forward by walking beam
and gently placed on stationary beams. Both walking and
stationary beams are properly supported on vertical
posts. The walking beam supporting posts are fastened to
a movable frame which are equipped with rollers and
permit the vertical and horizontal movement for the
transfer of the blooms. The walking beams and
stationary beams are fabricated out of seamless steam
tubes.

Vertical and Horizontal Movements:

 Vertical and horizontal movements of the beams are
obtained through separate hydraulic cylinders. The operation of the
cylinders ensures gradual startup and gradual stoppage during lifting
and lowering and horizontal movement.

Charging and Discharging Equipment:

The blooms are conveyed and positioned in front of the
furnace on roller table by electrical control. After positioning the blooms
on the roller table, the blooms are transferred on the charging table by
means of charging device in single row or in two rows. The blooms are
discharged from the furnace separately from each row by means of
discharging device. Two discharging devices are suitable for single row
or two-row operation.

Hydraulic Power Pack Unit:

A centrally located hydraulic power pack unit is provided
for the furnace for operation of the various hydraulic cylinders for
walking beam mechanism. The power pack unit consists of fluid tanks,
pumps with drive and control, necessary solenoid valves, flow control
valves, check valves, pressure relief valves, filters etc. One standby
pump with drive unit is also provided.

Grease Lubrication System:

An automatically controlled centralized lubrication system
is provided with necessary safety arrangement for lubrication of all
moving parts.

Skids and Support Tube Cooling System:

Evaporative cooling system (ECS) is provided for cooling
skids and support tubes. Steam generated is diverted to plant
steam network. The evaporative cooling system comprises of
separating drums, recirculation pumps,demineralised water, storage
tanks, feed pumps with necessary pipes, valves,fittings,gadgets
and necessary instrumentation.
 WAKLKING BEAM FURNANCES

.
The walking beam furnace overcomes many of the problems of
pusher furnaces and permits heating of the bottom face of the
stock. This allows shorter stock heating times and furnace lengths
and thus better control of heating rates, uniform stock discharge
temperatures and operational flexibility. In common with top and
bottom fired pusher furnaces, however, much of the furnace is
below the level of the mill; this may be a constraint in some
applications. Its figure is as shown.

Fig-23
 WALKING BEAM FURNANCE IN MMSM :

Walking Beam Furnance heat the steel blooms casted in ccd , to the rolling
temperature of 1200°C. Two pushers push the bloom into the furnace from
the bloom charging side. Blooms travel on skid pipes through heating
zones and then solid hearth in soaking zones.
The furnace has five zones out of which three are called heating zones and
two are soaking zones. There are in total 59 burners. The combustion air
is preheated to 450- 500°C in air recepurator and Gas is preheated to 350-
400°C in gas recepurator. Flue gases are used for preheating the
combustion air before being exhausted to the atmosphere through chimney.
Finally, the flue gases are exhausted out through the stack. Furnace
pressure in soaking zone is maintained positive.
Control and measuring instruments required to control furnace pressure
and temperature as well as efficient fuel utilization are provided.
Evaporative cooling system (ECS) is used for skid pipe cooling during
which waste heat steam is produced.
 MMSM is equipped with two, top and bottom fired walking beam type
reheating furnaces each having a capacity of 130T/hr. Walking Beam
Furnaces will be utilized to reheat the blooms of 250mm thick x
250mm width x 6000mm long in two rows to 1200°C. The stock will
travel through the furnace by means of walking and stationery beams,
properly lined, which will be cooled by means of an ECS producing
steam.
FURNACE DIMENSIONS

Table:-1

Centerline distance between charging and 25,500mm

discharging roller

tables

Overall width of the furnace 14,510mm

Inside length of the furnace(from charging to the 21,700mm

discharging door)

Maximum effective length 20,700mm

Inside width(wall to wall) 13,500mm

Maximum effective width 13,000mm

Maximum effective area 240m2

Upper level of the rollers and skid tubes 1060mm

Pit lower level 8,400mm

Top level of the stack 80,000mm

Bloom size 250*250mm

Furnace hearth output 0.5T/m2.hr

 CONCLUSION

The Objective of the Industrial Training is to expose the

Student to industrial atmosphere for better understanding of the basic
structure of the organization and prevailing working environment in the
industry.

During my training at VISAKHAPATNAM STEEL

PLANT , I worked at different sections and acquired knowledge
regarding variety of equipment, machinery and their functioning
pattern.

I learnt the importance of coordinating between

superior and sub-ordinates for smooth functioning of the industry. I also
developed my communication skills and personal characteristics.

I conclude that this Industrial training helped me a lot in

developing my technical knowledge, self-confidence and moral
strength.