PLANT AND FACILITY

I (LURGI)
Bhushan Steel has ten DRI with combined capacity of 5000 Mt per day. This DRI complex
has RMHS, day hopper for storage of Iron ore and Coal, rotary kiln, discharge cooler, high
intensity magnetic separator. DRI production process is one in which the solid metallic iron
is obtained directly from solid iron ore without subjecting the ore or the metal to fusion.DRI
is used as the raw material for the steel making process

Sinter Plant (CHINA SHOUGANG, OUTOTECH GERMANY)

Iron ore Fines from mines along with other additives like carbon (coke fines) fluxes as
refining agent and mill scale is mix in the proportionate to get the quality of sinter as 54%
Fe, this mix is being processed in blending plant, this mix is charged in the furnace for
combustion to convert into the agglomerate called sinter. The size of sinter is 6-40 mm
which is charged in the blast furnace for the melting.

Sinter is used as major raw material in the Blast furnace in order to facilitate the melting and
to give the porosity to the charged material.

Coke Ovens (CHINA SHOUGANG, PAUL WURTH GERMANY)

Bhushan steel is operating one of the most modern battery of the time, function of the coke
oven is to convert the desired blend of the coking coal into the Coke. This blend is heated in
absence of air to remove the Volatile matter into gases. The product from coke oven is used
as the reductant/fuel in the blast furnace and the sinter plant

st Furnace (DANIELI CORUS, PAUL WURTH)

Raw material for the Blast furnace includes 80-90% sinter, 10-20% Lump ore, Blast furnace
coke, Fluxes in the proportion from the top, hot blast is blown from the Tuyeres. This blast
at 1500C to be blown from bottom with counter current principle it flows to reduce the top
descending charge. Blast furnace has various zones for melting and refining this charge
reacts chemically with hot blast. Hot blast from top has been used to preheat the stoves at
any time 1 stove is in blast and 2 stoves are on gas.

In a blast furnace, fuel, ore, and flux (limestone) are continuously supplied through the top
of the furnace, while a hot blast of air (with oxygen enrichment) is blown into the lower
section of the furnace through a series of pipes called tuyeres, so that the chemical
reactions take place throughout the furnace as the material moves downward. The end
products are usually molten metal and slag phases tapped from the bottom, and flue gases
exiting from the top of the furnace. Hot metal / Pig iron is used as the raw material for the
steel making process

Steel Melting Shop-1 (DANIELI ITALY, CONCAST INDIA)

Electric arc furnace converts Hot metal/Pig iron/Scrap/DRI into steel by using oxygen as
refining agent. An electric arc furnace (EAF) is a furnace that heats charged material by
means of an electric arc and refining by means of Oxygen. Major product from SMS 1 is
billets and blooms for long product major application in structural steel

Steel Melting Shop-2 (SMS MEVAC, SMS SIEMAG)

SMS 2 has 1 set of Con – Arc and auxiliary facility for the steel making, hot metal/Pig
iron/Scrap/DRI into steel by using oxygen as refining agent. Con arc has an flexibility to use
any of the charge mix based on the market dynamics

Advantages of Con-Arc Furnace :

 1. Flexibility of raw material to be used, it can take Solid as well as liquid charge for
steel making.

 2. This greatly reduces the energy required to make steel when compared with
primary steelmaking from ores.

 3. Con-Arc can be rapidly started and stopped, allowing the steel mill to vary
production according to demand.

Steel Melting Shop-3 (SMS MEVAC, SMS SIEMAG)

SMS 3 complex consists of 2 Basic oxygen furnaces and along with secondary metallurgy
facility as LRF/RH and 2 stands continuous caster.

Process of BOF includes usage of 90% Hot metal and 10% DRI/Scrap/Iron Ore for melting,
this inputs is converted into molten steel by blowing the oxygen with high pressure and
refining by addition of the fluxes (Lime and dololime)

Secondary metallurgy includes the addition of the prerequisite fluxes and ferroalloy it is
refined to the low and medium carbon steel. Treated steel has been converted to the slabs
in the slab casters. 70% of the slabs directly charged to the Roughing mill of the HSM
through Reheating furnace, through various quality measures we are able to produce the
most critical grades like HSLA, IF, API, and Low carbon grades

Lime - Dolo Plant

Bhushan Steel has 4 x 300 Tons per day lime calcination plant, where limestone/dolomite is
converted into the quick lime and dololime. LCP is vertical shaft reactor with counter current
reaction principle Limestone is charged from top of shaft and Coke oven gas (Reducer gas)
is being charged from bottom of shaft furnace, this reacts with each other to convert the
calcium carbonate in the calcium oxide.

Hot Strip Mill (SMS, TENOVA)

This is one of the most modern mills with facility of 2x300 TPH walking beam furnace with
which takes fuel as mixing of BFG-COG. This combination of fuel is fired in the furnace with
oxygen enrichment to give the desired rolling temperature for the Slabs. Temperature
ranges from 11500 to 12500 C depending on the section size of the Slabs. RHF is followed
by primary de-scaler, roughing mill, decoiler, finishing mill, down coiler and slab conveying
arrangement.

All the activity has been carried out in complete auto mode with minimal manual intervention
Roughing mill has 5/7/9 reversing passes based on the reduction ratio desired. Further it
has 6 Finishing stands which give the desired final size and shape of the strip.

HR SLITTING (SMS– ESMECH)

Slitting serves three purposes :

(i) HR coils are available in widths which are wider than the required for Cold Rolling. The
trimming / slitting is done with the HR Slitter.

(ii) The HR coils available may have width variation of the order of up to 20 mm, so to get
the uniform width these coils are slitted.

(iii) The edges of HR coils may get damaged during transportation because of poor
packaging and/or improper handling. In order to remove these damaged edges the HR coils
are trimmed /slitted.

PICKLING (SMS-ESMECH)

Pickling Line – 01 No.

Pickling is a metal surface treatment used to remove impurities, such as stains, inorganic
contaminants, rust or scale from ferrous metals, copper, precious metals and aluminium
alloys.

Thickness Range – 1.6 to 6mm

Width Range – 700 – 1700 mm

COLD ROLLING MILL (HITACHI, JAPAN / CMI, INDIA)

 6 Hi Mill – 3 No's
 Width Range – 1050 – 1350 mm

The primary function of Cold Rolling is to reduce the thickness of Hot Rolled Pickled strip at
room temperature. During the operation overall max reduction of up to 90 % in thickness of
the HR Coil can be achieved. Cold rolling occurs with the metal below its recrystallization
temperature (usually at room temperature), which increases the strength via strain
hardening up to 20%. It also improves the surface finish and holds tighter tolerances.
ELECTROLYTIC CLEANING LINE ( CMI-FPI, INDIA )

 Thickness – Upto 3 mm
 Width – Upto 1700 mm

Electrolytic Cleaning Line is responsible for the electrolyte cleaning of the rolled sheet
surface in order to have its surface contaminations and greases removed in two dipping
tanks containing alkaline solution and electrolyte cleaning.

ANNEALING FURNACE ( EBNER )

Total No. of Bases – 18

Annealing Furnaces are H2 furnaces with higher convection are from EBNER, AUSTRIA &
ALLIED, and MUMBAI. Complete automation in the line ensures Clean & flawless surfaces.
Annealing is a process in which metals, glass and other materials are treated to render
them less brittle and more workable. In the steel industry, the steel is heated and profile
controlled, with times and temperatures set according to the properties desired to reach an
increased ductility and relieve strains that lead to failures in service.

KATHABAR ( IMTECH DRYGENIC, USA )

Total No. of Bases – 30

BSL is having KATHABAR cooling system from IMTECH DRYGENIC, USA. By this system
we can supply dehumidify air to annealed coil for cooling of coils for best result. In this
system the liquid desiccant can remove contaminants in the air like oil & grease & filter
them out.

NON-OX GALVANIZING/GALUME LINE (ESMECH,TENOVA,CMI-

FPE,AJAX TOCCO,SPOONER,THERMOFISHER)

Galvanising Line – 2 No's

Galvanising Line – 1 No. (Galume)

The purpose of the Continuous Galvanizing line is to apply a coat of zinc onto the surface of
steel sheets in an effort to increase their corrosion resistance. There is a wide range of
control of zinc coat thickness, and the galvanised steel sheets are used for a board range of
purposes, including construction materials, automobiles and electrical appliances. GALUME
is the trade name for a sheet steel product with a highly corrosion resistant coating
containing nominally 55% aluminium and 43% zinc by weight, the balance primarily silicon
is used to effect excellent adhesion to the steel substrate. This metallic coating which is
applied using a continuous hot-dip coating process combines the galvanic corrosion
protection of zinc with the barrier protection of aluminium.

COLOR COATING LINE ( CMI-FPI, INDIA )

BSL is having Color coating line with hot laminator supplied by SMS-ESMECH with the
technology collaboration with EMG, COMENCO & GFG. Embossing (NAWOO, KOREA),
Profiling (AL-KONG, KOREA) & Tension Leveller (SMS, ESMECH) are also installed. we
used RMP,SMP & PVDF type of paint which makes us unique for appliances & high end
products.

FINISHING SECTION

 Corrugation Machine – 10 No's. (REGAL IRON,INDORE)

 Cut to Length Line - 10 No's. ( FIMMI, ESMECH )
 Slitting Line – 3 No's. (FIMMI)

Slitting Line for cold rolled steel strip coils cut in longitudinally direction to get
the strip in required width as per customer requirement