TRAINING REPORT ON

BHILAI STEEL PLANT

DURATION 26.05.2014 - 07.06.2014

REPORT SUBMITTED BY: -

KUNAL SINGH (12119037)

INSTITUTION:- NATIONAL INSTITUTE OF TECHNOLOGY RAIPUR

DEPARTMENT OF MECHANICAL ENGINEERING

A Brief Introduction To Bhilai Steel Plant

Bhilai Steel Plant, a unit of Steel Authority of India Ltd. is a
public sector undertaking and was conceived under Indo-USSR
Treaty in the 2nd Five year plan. This was in accordance with
erstwhile government policy for strengthening economy and self
reliance through development of core sector. The plant is located
at the central position of India, which is one of the major iron belt
of India, and it is about 40 kilometer from Raipur, capital of
Chattisgarh. The captive mines of the plant located at DalliRajahara supplies iron ore and lime stone used to be available
from Nandini captive mines. At present lime stone is procured
from outside. The other major raw material, coal is purchased
from outside either through import or from indigenous market.

Bhilai Steel Plant, an integrated steel works, was commissioned

in 1959 with production capacity of 1.0 million tonne of steel. In
successive phases, capacity was enhanced to 2.5 and 4.0 million
tonne in the year 1962 and 1984 respectively. Figure depicts
facilities available with Bhilai Steel Plant for 4.0 mt production.
As of now this is the largest steel plant in India with present
capacity utilisation more than 100% for three consecutive years.

Bhilai Steel Plant, an integrated steel works, was commissioned

in 1959 with production capacity of 1.0 million tonne of steel. In
successive phases, capacity was enhanced to 2.5 and 4.0 million
tonne in the year 1962 and 1984 respectively. Figure depicts
facilities available with Bhilai Steel Plant for 4.0 mt production.
As of now this is the largest steel plant in India with present
capacity utilisation more than 100% for three consecutive years.

Bhilai Steel Plant - Major Landmarks

Signing of Agreement for setting up of the plant

Feb. 02, 1955

Commencement of work at site

May 06, 1956

Commissioning of Coke Oven Battery # 1

Jan. 31, 1959

Commissioning of Blast Furnace # 1

Feb. 04, 1959

Commissioning of Power & Blowing Station

Jun. 04, 1959

Commissioning of Steel Melting Shop O.H. Fce # 1

Oct. 11, 1959

Commissioning of Blooming Mill 1150 stand

Nov. 12, 1959

Commissioning of Billet Mill

Dec. 24, 1959

Commissioning of Rail & Structural Mill

Oct.27, 1960

Commissioning of Sintering Plant # 1

Jul. 03, 1961

Commissioning of Merchant Mill

Feb. 02, 1961

Commissioning of Wire Rod Mill

Sep. 01, 1967

Commissioning of Sintering Plant #2

Aug. 01, 1979

Commissioning of Plate Mill

Mar. 31, 1983

Commissioning of Converter #1

Jul. 29, 1984

Commissioning of Continuous Casting Shop M/C #1

Mar. 15, 1986

Commissioning of First Twin Hearth (at SMS-1)

Sep. 12, 1986

Commissioning of Blast Furnace #7

Aug. 30, 1987

Commissioning of Coke Oven Battery

Mar. 31, 1988

Commissioning of Second Twin Hearth

Jan. 01, 1990

Commissioning of VAD unit at SMS-2

Jan. 17, 1991

Commissioning of Third Twin Hearth

Jun 29, 1992

Commissioning of Fourth Twin Hearth

Jan 21, 1998

Commissioning of Ladle Furnace at SMS-2

Dec 23, 1999

Commissioning of RH Degasser Unit at SMS-2

Mar. 30, 2000

Commissioning of Sintering Plant # 3

Dec. 12, 2001

Only Steel Plant in India to cross 5 MT

Mar 31, 2006

Curde Steel Production in the financial year.

Bhilai's expansion & modernisation to 7.5 MT

Feb. 09, 2008

capacity inaugurated
Bhilai repeats 5 MT + performance

Mar. 31, 2008

BSP FLOW PROCESS

PLANT OVERVIEW
S.No.

Department

Unit

Capacity

Coke Oven

8 Batteries of 65 ovens and 4.3

M high
2 Batteries of 67 ovens and 7.0 M
high

3.3 million ton

of BF Coke

BLAST
FURNACE

3 Furnaces of 1033 Cum

3 Furnaces of 1719 Cum
1 Furnace of 2000 Cum

4.71 mt of hot
metal

SMS-1

4 Twin Hearth Furnaces

2.5 mt of steel

SMS-2

3 BOF of 100/130 T capacity

1.425 mt of steel

CONCAST

1000/700/500 mm Cont. Billet

Mill

1.425 mt of steel

BBM

3 BOF of 100/130 T capacity

1000/700/500 mm Cont. Billet
Mill

2.15 mt of bloom

RAIL AND
STRUCTURAL
MILL

950/800 2 high reverseing Mill

.75 mt of product

WIRE ROD
MILL

4 strand continious Mill

.4 mt of product

MERCHANT
MILL

350 mm Cross Country Mill

.5 mt of product

10

SINTERED
PLANT

1) 4 Machine of 50 Sq M hearth
area
2) 3 machine of 75 Sq M and 1
Machine and 1 Machine of 80 Sq
M hearth area
3) 1 Machine of 320 Sq M hearth
area

8.3 mt of sinter

BLAST FURNACES
What is a Blast Furnace? BF is a counter current heat and mass
exchanger, inwhich solid raw materials are charged from the
top of the furnace and hot blast is sent through the bottom via
tuyeres. The heat is transferred from the gas to theburden and
oxygen from the burden to the gas. Gas ascends up the furnace
while burden and coke descend down through the furnace. The
counter current nature of the reactions makes the overall
process an extremely efficient one.
In the blast furnace process iron ore and reducing
agents (coke, coal) are transformed to hot metal, and slag is
formed from the gangue of the ore burden and the ash of coke
and coal. Hot metal and liquid slag do not mix and remain
separate from each other with the slag floating on top of the
denser iron. The iron can then be separated from the slag in the
cast house. The other product from the Blast Furnace is dust
laden blast furnace gas, which is further cleaned in the gas
cleaning plant and is used as a fuel all over the plant.

Blast Furnace constructional features:

A blast furnace has a typical conical shape. The sections from top down are:
> Throat, where the burden surface is.
> The shaft or stack, where the ores are heated and reduction starts.
> The bosh parallel or belly and
> The bosh, where the reduction is completed and the ores are melted down. The
hearth, where the molten material is collected and is cast via the tap hole

MACHINING ASSEMBLY & RE-ENGINEERING SERVICES-1

( MARS-1).
MARS-1 has a vital role to play in maintaining the plant equipment so
for as it supplies the bulk of spare parts required by the various units. It
acquires an added significance by virtue of the finishing line of
manufacturing activities of engineering shop . The product mix so
arranged so as to meet the demand of both heavy and small spares. The
shop is housed in three machining bays, 21 meters x182 meters each
with an assembly bay of 24 meters x 96 meters .A total of 196 machine
tools are engaged in direct production of spares, where- as the
remaining contribute indi- rectly towards shop production. Apart from
these, there are 12 Heat Treatment / Heating furnaces 22 material
handling equipment (cranes,jib cranes transfer cars). The Annual
production plan for MARS-1 during 2007-2008 is 6,40,000 credit
hours.
MAIN ACTIVITIES:Function wise MARS-1 carries out the following activities:
1. Manufacture of spares, changables, tools, tackles etc. Required for
maintenance and operation of various departments.
2. Overhauling and repair of equipment sub - assemblies to the extent
of those that can be transported to MARS-1.
3. Reclamation of worn-out spares .
4. Repair of certain equipment at site-especially where machining at
site is required.
5. Manufacturing and modification of equipment / spares for
development work from the point of view of import substitution,cost
reduction ,etc.

BLOOMING & BILLET MILL

Blooming & Billet Mill popularly known as "Mother Mill", is a
primary mill designed to roll 2.5 MT/ Annum of ingots into semies in
the form of blooms & billets. A two high reversing blooming mill and
12 stands continuous billet mill are part of this department. The
1150mm two high reversing Blooming Mill is designed to roll steel
ingots into blooms for Continuous Billet Mill and Rail & Structural
Mill. Average weight of steel ingots which are used for rolling is 8 to 9
Ton.
BLOOMING MILL
The heated ingot are placed on the ingot buggy (two ingots at a time)
by means of tongs crane which delivers it on to the receiving roller
table of Blooming Mill.The Blooming Mill is a 2-High horizontal
stand, equipped with individually driven rolls. Each roll of the
Blooming Mill is driven by 930 V, 8000 KW, 0-20-80 rpm motor.
Length of Roll - 2800 mm
Dia. of Roll - 1150 mm (Min.1100mm & Max.1180mm)
The Mill can roll square and rectangular blooms and also narrow width
slab. Common Sizes of Blooms and Narrow Width Slabs
i) 320 x 320 mm
ii) 265 x 340 mm
iii) 260 x 300 mm
iv) Shaped blooms for Beam-450mm & Beam-600mm
v) Narrow Width Slab 200 x 320 mm
vi) Narrow Width Slab 200 x 420 mm

BILLET MILL
The Billet Mill has been designed to roll billets from blooms of cross
section 325x325 sq.mm in 6 to 12 passes depending on cross section of
billets to be produced in the Mill. The capacity of the Mill was
designed to roll 15,01,000 Tonns/Year. But with modified output size
of billets the mill is now capable of rolling to million tones per year.
The Mill consists of 12 working stands arranged in three groups.
a. The First group contains Two 2-High Horizontal stands with a 90
deg. tilter in between. These stands are equipped with rolls of diameter
1000mm and length 1200mm.
b. The Second group called the roughing group contains 4 stand - 2
each of Horizontal and Vertical stands arranged alternately. These
stands are equipped with rolls of diameter 700mm.
c. The Third group called the finishing group located after the transfer
table contains 6 stands - 3 horizontal and 3 vertical stands arranged
alternately. These stands are equipped with rolls of diameter 500mm.
SECTION OF BILLETS ROLLED ARE
1. 150 x 150 mm

2. 110 x 110 mm

3. 105 x 105 mm

4. 100 x 100 mm

5. 90 x 90 mm

WIRE ROD MILL

The 4 strand 250mm continuous Wire Rod Mill, commissioned on
September 1 1967, was designed to roll 6, 7, 8, 10mm diameter wire
rods from square billets of 80mm x 80mm cross section (of length 11
to 11.8 meters) with rated capacity of 4,00,000 T per annum. The billet
size was further enhanced to 85 mm2, 90 mm2, 100 mm2, 105 mm2 to
improve in coil weight from 540 Kgs. to 930 Kgs. After the revamping
of Right Side, sections 5.5 - 12 mm dia. wire rods are rolled in B ,
C&D strands, whereas 8mm & 10mm are rolled on left side (A strand).
BRIEF DESCRIPTION OF THE MILL
Inspected billets are fed on the charging grate of the furnace by
magnetic finger cranes. The billets are fed one by one to the furnace,
through roll table and draw-in- roller mechanism. Billets are moved
into the furnace by means of pushers at the charging end. Soaked
billets are ejected out by means of Ejector Ram from the discharging
end.
The reheating furnace of the size 18Mx 12M is having 28
burners, which includes 14 in the heating zone and 14 in the soaking
zone. Mixed (Coke Oven & Blast Furnace) gas with calorific value of
1800 K Cal/Cum is used in the furnace as fuel. Capacity of the furnace
is 120T/Hr. Gas and air is preheated to 250c and 450c in metallic and
ceramic recuperators respectively.
The roughing group consists of nine horizontal stands in
which combined drive is provided for stands 2-3 and 4-5; whereas
stands 1, 6, 7, 8 and 9 are individually driven. All the drives are
controlled by thyristor converter.
Flying Shear is provided after stand no. 9 for front-end cutting
& cobble cutting. First intermediate group has 6 horizontal stands, out
of which stand No. 12 & 13 are not being used. Stand No. 10 & 11/14
& 15 are used for rolling on all the strands. After stand No. 15, the Mill
is divided in four strands, old line (A) and Modernised line (B,C&D).