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AN INDUSTRIAL REPORT ON
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Acknowledgement
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INDEX
5 Sinter Plant 14
6 Blast Furnace 16
9 Skelp Mill 25
10 Merchant Mill 26
11 Section Mill 29
INTRODUCTION
Durgapur Steel Plant, SAIL, was set up with the British collaboration in the late fifties
with an initial capacity of one million tonnes of crude steel per annum. The capacity was
subsequently enhanced to 1.6 million tonnes in the late sixties. The plant undertook a large-scale
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modernisation programme in the early nineties. The technological upgradation of the plant was
matched with a massive training programmes of its human resources. Since then DSP has acquired
the ISO 9000:2001 Quality Assurance Systems and has emerged as one of the most modern plants
in the country. Encouraged with a participative style of management, the Durgapur steel collective
has amply demonstrated its determination to forge ahead in the highly competitive market scenario
that has emerged over the years.
Initiated during the 1950s, Durgapur Steel Plant changed the face of India, bringing with it a
lot of technical and industrial growth for the country as a whole. The plant was set up with an initial
annual capacity of one million tonnes of crude steel per year. However, as time progressed, the
capacity of Durgapur Steel Plant (DSP) was later expanded to 1.6 million tonnes in the 1970s. Three
decades after its commencement, a massive modernization program was undertaken, which
brought a number of technological developments in the plant. The yearly capacity of the plant was
also increased to 2.088 million tonnes of hot metal, 1.8 million tonnes crude steel and 1.586 million
tonnes saleable steel.
The modernized DSP now has state-of the-art technology for quality steel making. The
modernized units have brought about improved productivity, substantial improvement in energy
conservation and better quality products. DSPs Steel Making complex and the entire mills zone,
comprising its Blooming & Billet Mill, Merchant Mill, Skelp Mill, Section Mill and Wheel & Axle Plant,
are covered under ISO: 9002 quality assurance certification.
Durgapur Steel Plant is the third integrated steel plant of the then Hindustan Steels
Limited to come up under Public Sector in India. Durgapur was selected as location of the plant, for
its proximity to coal-fields, the Grand Trunk Road (NH-2), Kolkata - Delhi main railway track,
Kolkata port, power from Damodar Valley Corporation and water from Durgapur Barrage on river
Damodar.
Finished products of Durgapur Steel Plant are used in various sectors which are mentioned in the
table below:
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Raw Material Handling Plant is the starting point of steel making process. The objective of
RMHP is to receive, unload, stack and supply all the raw materials required for steel making i.e.
Iron ore, Limestone, and Dolomite. Apart from this, RMHP also deals with Sinter mix preparation
using state of the art automation system.
Iron ore, coal and limestone are the three most basic raw materials of Durgapur Steel Plant.
The plant draws its coal from the Jharia-Raniganj coal belt, while some amount of prime coking
coal, with fairly low ash content, is imported as well. The iron ore, on the other hand, is derived
from the mines at Bolani, in Orissa. Lime stone comes from the Birmitrapur (Orissa), Jaisalmer
(Rajasthan), and Jukehi and Nandwara (Madhya Pradesh). Durgapur Steel Plant consumes a total of
about 7.4 million tonnes of different raw materials annually
1. Tippling of wagons.
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7. High grade limestone, dolomite & iron ore lump supply to BOF.
Major Equipments:
4 in number
For stacking on beds as well as reclaiming from beds
Two beds for Iron ore and two beds for flux
1 in number
For Sinter-mix preparation (i.e. stacking for Sinter-mix)
1 in number
To reclaim the Sinter-mix
Major sections:
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There are 8 dust extraction system and 8 dust suppression system for pollution control.
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The ovens are charged using charging cars. The charge is heated inside in the ovens in the
absence of air up to the temperature of 1000 1050 degrees. This process generally takes 16-19 hrs
which is called coking period. After the coking period, coke produced is pushed out of the oven into
coke bucket after which is taken to dry.During the process of carbonization of coal, a number of
valuable chemicals are obtained. This department also deals with the recovery and processing of
these chemicals.
1. Coal Handling
2. Coal washery
4. Coal Chemicals
Blending
Silos
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Primary
Crusher
Service
Pneumatic Selective Crushing
Bunkers 4 of
Classifier
4000T each
Unit
Secondary
Crusher
Coal for
BF coke
making
To Battery
Major Sections:
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(a) Charging Car: Takes coal from service bunkers to individual ovens
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As fuel
As reducing agent
SINTER PLANT
Sintering is the process of agglomeration of fines by incipient fusion caused by heat available
from the fuel contained in the charge. The objective of sinter plant is to provide good quality
sinter, an efficient feed to Blast Furnace.
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The process of sintering started in 1940 and flourished in countries where there was coke
shortage. Advantages of using sinter are:
(a) To utilize all waste of fines nature like Mill scale, Ferro Scrap, LD slag etc.
Major equipments:
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Moist charge is rolled to nodulise the fines and decrease the size
range of particles and consequently improve the permeability of
sinter bed.
Sinter plant is a Heavy Power consuming plant and it consumes about 1/4 th of the total power.
There are 4 ESPs (Electrostatic Precipitators) provided for each machine which perform the
process of cleaning the gases obtained during suction. These are vital as the gases have lot of
dust particles.
BLAST FURNACE
Blast Furnace is the most important part of an integrated steel plant. It is considered as the
heart of an ISP. The objective of Blast Furnace is to take the raw material from RMHP, coke from
Coke Ovens and Sinter from Sinter Plant and convert it into pig iron or Hot Metal. Coke serves as
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the heat source and reducing agent while Limestone and Dolomite are used as flux, which
combines with gangue to produce slag. A Blast Furnace is so called because it uses air blast as
oxygen source for the process. The solid charging materials like sinter,sized iron ore,coke etc. are
charged form the top of the furnace.The hot air blast at 11000c-13000c and 5.75 kg/cm 2 is blown
from the tuyeres located at the bottom of the furnace.The oxygen from the air blast reacts with the
coke and generates heat and carbin monoxide.These gases while ascending upwards reacts with
the coke and generates heat and carbon monoxide.These gases while ascending upwards reacts
with the descending charge materials.Eventually the charge melts and hot metal and slag are
produced and tapped out.The top gases are collected and refined and used for preheating the blast.
There are four Blast Furnaces in DSP, out of which 3 are in running condition.
At present in Durgapur Steel Plant there are four Blast Furnaces of which the details are as following:
Coke
Hot Blast
Blast
Hot Blas BF Gas Clean BF
Furnace GCP
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Gas
Hot metal
Slag
PCM
SMS
Process:
Raw materials i.e. iron ore, Sinter and coke are charged into the furnace from top in required
proportions. Air enriched with oxygen is preheated in stoves. Preheated air is blown through Tuyeres
in the bosh region. These are symmetrically located openings. The raw material descending through
various temperature zones are heated up and get smelted. The reducing gases rise up and go out
through ascension pipes. The hot metal and slag obtained through smelting of raw materials trickle
down and accumulate in the hearth, which is the bottom part of the furnace. The slag, being lighter
than Hot Metal, floats on it.
The hot metal and slag are tapped through Tap Holes, drilled using drilling machines. The hot metal
thus obtained is sent to SMS to make steel or to PCM to make pigs. The slag is either dumped in the
slag yard or granulated in slag granulation plant (SGP).
Blast Furnace 3 and 4 have SGP and hence the slag coming out of these Furnaces is granulated.
The gas ascending through the descending column is called BF gas and has high calorific value of 850
Kcal/Nm3. It is used as fuel at many departments in the plant. This gas has to be cleaned before
being used as fuel. For this purpose, a gas cleaning plant is located in the Blast Furnace area.
The gas coming out of Blast Furnace contains about 25-27 gm/Nm 3 of dust and unless it is
cleaned, it cannot be used as fuel. The cleaning process is done in four stages. In the first stage, the
gas is subjected to a sudden expansion in primary dust catcher. Then, it is given a cyclonic motion in
a secondary dust catcher. The gas coming out at this stage has about 5-7 gm/Nm 3 of dust.
In the third stage, the gas is counter currently washed with water in gas washer. The gas coming out
is then sent into a set of electrostatic precipitators, where it is cleaned to the maximum extent. The
gas leaving ESPs has a dust content of 9-11 mg/Nm 3
Details of Furnaces:
#1* #2 #3 #4
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No. of stoves 3 3 3 3
*not working
Design parameters:
Parameter BF #2 & 3 BF # 4
No. of tuyers 18 20
This process was first used successfully in a place called Linz in Austria and then at Donawitz in
Austria. The name LD process came from the names of these places.
Basic Oxygen Furnace was added under modernization of DSP. It has a capacity of 1.876 MTPA.
Hot Metal coming out of the Blast Furnace is collected in ladles and poured into mixers. The mixers
(2) serve the purpose of storing as well as homogenization of temperature and composition. Coke
oven gas is used here to maintain the temperature at 1260 o C. the quantity of raw materials for
producing one tonne of steel are as follows:
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Scrap 65.9 kg
Dolomite 31.3 kg
Fe- Mn 1.11 kg
Fe- Si 1.32 kg
Al 0.15 kg
The shop has three converters each having a capacity of 110-130T per heat. The converters were
commissioned by Mannessmann Demag of Germany. Each converter has its own lance system for
blowing oxygen at high pressure so as to form an emulsion on the surface of metal which increases
the surface area to such an extent that separation of impurities takes place very fast.
The oxygen blowing rate through the lance is 415 Nm 3/min. and the blowing pressure is 14.2 to 14.3
bars from top. The tap to tap time of BOF is approximately 57 minutes out of which oxygen blowing
time is 18 min. the gas obtained from BOF converter has a calorific value of 2100 Kcal/Nm 3 which
acts as a fuel.
BOF has an online process monitoring system. The system uses VAX/VMS system which works on the
principle of virtual memory. The higher level of computerization caters to the need of quick retrieval
of data about operation parameters.
CCP, one of the critical features of DSP is the first billet caster in any ISP in SAIL. The
machines are designed and supplied by Concast Standard AG, Switzerland. Presently, we have two
machines with six strands in each, capable of producing billets of sizes varying from 80 mm 2 to 150
mm2.
Under traditional route, liquid steel is allowed to solidify into separate moulds and come out as ingots,
which are then rolled to get the billets. Continuous casting route bypasses the steps of soaking and
rolling in blooming and billet mill.
No. of machines 2
No. of strands/machines 6
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Casting Radius 6m
Molten steel is taken to ladle treatment section. The purpose of ladle treatment is to homogenize
the temperature and composition, floatation of non-metallic inclusions and to facilitate active slag
metal reactions. A dummy bar is inserted in the mould, up to 100 mm with the help of pinch rolls.
The mould is surrounded by 4 mm water jackets through which primary water is circulated internally.
Primary cooling is thus done by demineralized water. Other zones are kept cool by industrial water.
The billets formed are cut to proper lengths and are allowed to cool in air and then packed and
sent to stock yard.
NLCP came up during during modernization in 94-95. This plant came up to cater to the need of BOF.
The main function of this plant is to produce lime from naturally available limestone. Lime is mainly
required in steel making process to reduce sulphur and phosphorous content of steel. Presently,
Limestone from Jaisalmer is used as input material for the plant.
There are three kilns (Annular kiln shaped), of capacity 300T/day , one is kept standby, each kiln
is a vertical cylindrical structure. Limestone, which is charged from the top, gradually descends
through the kiln, where it is subjected to controlled heating by two firing zones preventing the
charge from direct exposure to base flame. Coke oven gas at 5500 mm water pressure is used as fuel
for heating. Temperature range of heating is 1200 0 C - 1250o C
The calcination process is almost complete as the charge reaches the bottom portion of lower
combustion zone and the calcined lime is discharged into a silo by Lime Discharging device.
NLCP has got bunkers and conveyors for storage, handling and supply of fluxes to converter shop.
ROLLING MILLS
The process of plastically deforming metal by passing it between rolls is known as rolling.
TYPES OF MILLS:-
A. PRIMARY MILLS
Blooming & Billet Mill
B. FINISHING MILLS
Section mill
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Skelp mill
Merchant mill
Wheel and axle plant
Process:-
Soaking pit furnaces are used for reheating the ingots at 1280 o C. There are 20 soaking pit furnaces
with capacity 110T. Fuel used is CO and BF gases in the ratio of 1:4. The reheating time is usually
1.5 times the Track Time. After soaking the ingots are lifted by means of vertical ingot charger
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cranes for soaking. It is a two high charger reversible type with two 2X3000 HP DC motors at the
mills speed of 0/40/60 rpm.
Here 1200T shear is used to cut fish tail, and then the blooms are put in the bloom transfer bank.
There is a two high reversible mill driven by 4500HP DC motor. The rolls are spring balanced and
driven with a speed of 0/80/120 rpm.
Major Equipments:
Blooming mill
Soaking Pits:
Roll diameters varies from 915 mm to 1100 mm, top roll hydraulically
balanced and can be moved up and down, while bottom roll is fixed
Front and back ends of blooms which develop fish tails are sheared
using1200T shear
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Important Parameters:
(a) Pit Time: This is the amount of time the ingots have to be placed in the soaking pits.
This is equal to 1.5 times the track time, which is around 3 to 4.5 hrs for hot ingots and
around 12 hrs for cold ingots.
Billet Mill
Blooms produced in Blooming Mill are further rolled into billets of various sizes. The capacity of
Billet Mill is 0.957 tonne per annum. The products of this mill are 50 mm square to 125 mm square
Billets and 140 to 240 mm * 75/80 mm skelp slabs.
Major Equipments:
Vertical rolls on first and fourth strands & remaining are horizontal, 1
to 4 are roughing stands each run by 800 HP DC motor (1 & 2) and
1000 HP DC motor (3 &4)
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SKELP MILL
Skelp mill came up during the expansion of plant to 1.6 MTPA in late 60s. It was designed
and elected by a UK firm, Loewy Robertson Company Limited. Skelp is a narrow section with bevel
edge with included angle of 70 o. Mostly used for making pipes and tubes. The annual capacity of
this mill is 0.25 million tonnes.
Process:-
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Skelp mill receives slabs from Billet Mill by rail transfer bogies. The slabs are taken on to charging
table from the bogie. The slabs are fed to a reheating furnace by a Ram charger. The furnace is of
side charge and side charging type. The furnace is fired by a mixture of coke oven and Blast
Furnace gas in a ratio of 1:1.
The furnace has a heating capacity of 60T/Hr. The slabs are sent to the mill section, which consists
of 11 horizontal strands and 6 vertical strands. These are arranged as shown below:
Where H refers to horizontal strands and E refers to vertical strands. The roughing mill constitutes
strands from E1 to H6 while H7 to H 11 constitute the finishing mill.
After rolling, the skelp or strip is coiled and the coil is dispatched to customers.
MERCHANT MILL
Merchant Mill takes billets of size 100 mm 2 from CCP and produces ribbed TMT bars of various
diameters.
The capacity of Merchant Mill is 0.28 million tone per annum thermo mechanically treated (TMT)
ribbed bars of dia. 16, 18, 20, 22, 25, 28 mm.
Grade- IS2062
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Process:-
Reheating furnace has a two zone type arrangements for side charging and discharging. The output
of furnace is 70 TPH. Temperature inside the furnace is 1250 1300 o C. Separating skids are used
to placed the billets on the furnace charging table. The mechanism consists of stationary and power
operated carry over skids .The fuel used is CO gas with 3000 BTU/ft 3 of calorific value. The air for
combustion is preheated in metallic recuperators.
By using push-out bar, billets are discharged from the furnace to the first mill stand. For this, there
is a pinch roll arrangement near the furnace. A pendulum shear is located between the pinch roll
and first stand to cut the front end of the billets.
The mill has 13 horizontal stands in which 7 are roughing, 4 intermediate and 2 are finishing
stands. In between 7 & 8 stand, a crop cum cobble shear is provided to cut front end of all the
rolled stocks passing out of the 7 th stand. It is also used for cutting the rolled stock into pieces in
case cobble is formed.
Four 180 repeaters provided between 9 & 14 stands (13th stand is not there). These repeaters are
provided to reduce the overall length of the mill.
After the finishing mills Thermax carriages are situated for spraying water at high pressure on the
rolled bars (to impart required structure). There is a rotary shear, which cuts the rod into the pre
determined lengths, which are then accommodated in the cooling beds. After this the bars are cut
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to final sizes (as per customers demand) in the Bar Shears and sent to dispatch area after bundling
and strapping.
Apart from conventional rolling, Slit Rolling is also done where we get two rods parallel from a
single billet. (for section 16 mm rolling)
Major Equipments:
Reheating furnaces:
Capacity 70 TPH
To pull out and feed billets into the first mill stand
(b) Mill:
Also used for cutting the rolled stock in case cobble is formed in
intermediate and finishing mill.
(d) Repeaters:
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3 in number
Sprays water at high pressure on the rolled bars. Finished rod receives
intense cooling, resulting in formation of a martensite structure
surrounding the ferrite-particle core.
SECTION MILL
Blooms from blooming mill are taken and rolled in section mill to produce light and medium
structural like Joists, Channels and Angles. The capacity of Section Mill is 0.212 million tone per
annum.
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Input -Blooms
Products:
Major Equipments:
2 continuous end charge end discharge type with11 burners each ,CO
gas mixed with BF gas used as fuel
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2 stands of 24x68
3 cold straightening machines (two m/c having 3 rolls on the top & 4
at the bottom)
Bottom rolls driven by 165 HP motor and Top rolls are friction driven
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In Wheel and Axle plant of Durgapur Steel Plant, wheels are produced by pressing and rolling while
axles are produced by forging. Subsequently both are heat treated and machined. For the ease of
production, wheel manufacturing section and axle manufacturing sections are located in two
different bays. Tested wheel and tested axles finally meet in assembly section. The existing wheel
plant at Durgapur Steel Plant is sourced with bottom poured cast ingots from existing ingot casting
facility of the plant for the production of wheels for locos and coaches.
The raw material for wheel is 12 side fluted bottom poured steel ingot of diameter 16-
14.Below is a figure of ingot.
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Process:
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tonnes hand operated axle forging hammer. The process takes around 9-10 minutes and the
finishing temperature is 850o C. It is then air-cooled.
Ultrasonic test is carried out, checking physical roundness of every axle is done. Axle is then
sawed and is first rough turned and then finish turned.
The axles are inspected for dimensional accuracy at every stage of the process and for
surface & diameter defects after completion.
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