IMPORTANT FEATURES

MILL BUILDER: Skoda Exports, Czech Republic.

ODA EXPORTS, CZECH REPUBLIC
COMMISSIONED ON:28th March 1992 28TH

MAR`1992
Installed Capacity:8,50,000tonnes.50,000
Tons/Year
TYPE OF MILL :High Speed Continuous Two High
Hot Rolling Mill.IGH SPEED CONTINUOUS TWO
HIGH HOT ROLLING MILL
UNIQUE FEATURE: Rolling of Parallel flanged I
and H beams using universal cassettes.
ROLLING OF PARALLEL FLANGED H AND I
BEAMS USING UNIVERSAL CASSETTE
MAXIMUM MILL SPEED : 9 m/s9
999 m9m/sec
ROLLING RATE : 222 tonnes/hr2 Tons/H22r

Products of MMSM
Merchant products like Squares, Rounds and Flats
which are further processed by customers.
Structural products like Angles, Channels and Beams
etc.

PRODUCTS

SPECIFICATIONS

Rounds

40-80

Squares

40-90

Channels

100-180

Equal Angles

75X75X6-10 & 110X110X6-12

Unequal Angles

80X60X6-10 & 100X75X6-12

Flats

100X10-20 & 150X10-20

T-bars

100X100

H-E Beams

96X100 & 114X120

I-Beams

ISMB-125,175,180 ,IPE 100-180

GRADES ROLLED

MILD STEEL
MEDIUM CARBON STEEL
HIGH CARBON STEEL
ALLOY STEEL LIKE:
a)Spring Steel
b)Manganese Steel
c)Chromium Steel
d)Copper Steel

SALIENT FEATURES
3 Charging grids of 90t/hr. capacity.
Charging conveyors to transfer the blooms.
Bloom pusher for charging the blooms into the
furnace.

SALIENT FEATURES
RE- HEATING FURNACE
SUPPLIED BY M/S STEIN HEURTEY OF FRANCE

2 x 130 T/hr top and bottom fired walking beam type reheating furnaces .
4 moving and 4 fixed skids for transfer of blooms.
Input bloom size: 250mm X 250mm Cross section, 6 -12
meters length and weighs 2780-5560 kgs (approx).
Furnace effective length: 20 metres
Furnace inside width : 13 metres
Furnace effective area: 240 m2
Chimney height :80 metres
Type of burners: Flat flame and Long flame type
Number of burners: 59
Number of zones: 5 zones (top and bottom fired)
2 top heating + 1 bottom heating
1 top soaking + 1 bottom soaking
Fuel used: Mixed gas (coke oven gas + BF gas + LD gas) of
calorific value 2000kcal/mm3
Evaporative cooling system for skids cooling.
Convective and cross flow type air and gas recuperators for
pre-heating gas and air.

 Bloom temperature :1100-12000C

Pre-heated air temperature: 4500C
Pre-heated gas temperature:3500C
PLC based automatic furnace control system.
Blooms de-scaling with 18 MPa pressure water.
Charging of blooms is done with pusher and discharging with
extractor.
Walking beam cycle time: 64 seconds
15 % of heat input requirement is met from recovering heat
energy from flue gas by pre-heating combustion air and gas.
De-mineralized and De-aerated water (DMDA water) is used
for skid tubes cooling (ECS system).

Steam generated from skid tubes cooling is sent to plant

network.

FURNACE CROSS -SECTION

MILL PROPER:
Supplied by M/S ZDAS of CZECH Republic

Considering the wide range of product mix and very high

capacity requirement , a fully continuous 20 stand
arrangement has been adopted
The mill train is divided into 3 groups
Roughing mill train, Intermediate Finishing mill train.
ROUGHING MILL:

4 Two- high horizontal stands 630mm diameter

2 vertical stands 630mm diameter
2 combinational stands 630mm diameter which are
replaceable by either horizontal stand or by vertical stands
INTERMEDIATE MILL:

1 Two- high horizontal stands 630mm diameter

3 combinational stands 630mm diameter which are
replaceable by either horizontal stand or by vertical stands
2 horizontal stands 630mm diameter which are replaceable by
two 1060mm/710mm universal stands for rolling beams .
FINISHING MILL:

2 combinational stands 500mm diameter which are

replaceable by either horizontal stand or by vertical stands
4 horizontal stands 500mm diameter which are replaceable by
two 900mm/600mm universal stands for rolling beams

H-- HOROZONTAL STAND

V VERTICAL STAND
C-COMBINATION STAND

MAJOR UNIT PROCESSES INVOLVED

Heating of blooms in re-heating furnace.

Rolling of heated blooms to pre-determined size and
shape.
Cooling and straightening of rolled products.
Cutting and packeting.
Stacking and Despatching.

MILL PROPER

MILL STANDS

SPECIAL FEATURES OF MILL PROPER

Quick stand changing facilities to reduce set up time

Automatic engagement of spindles in the working roll
Automatic connection of electrical supply, grease, hydraulic, lube oil and
roll cooling water connection without manual intervention
Hydraulic roll balancing system
Motorized drive for roll gap adjustment
Roll neck bearings: Radial --Four row cylindrical roller bearings
o Axial----Antifriction taper-roller thrust bearings
Telescopic spindles
Possibility to change gear ratio
Self aligned roll cooling water showers
Movable rest bars for mounting guides and guards.

ROLL MATERIAL

ROUGHING AND INTERMEDIATE MILL ROLLS (Dia 630 rolls)

CAST STEEL

FINISHING MILL ROLLS (Dia 500 rolls) & UNIVERSAL MILL

ROLLS SPHEROIDISED GRAPHITE CAST IRON

SHEARS
8000 KN Shear: Placed before roughing mill stand and serves to crop badquality bloom front end and for dividing 12 metre long blooms into halves
2500 KN Shear: Crank type flying shear located after roughing mill train
to crop the front end and scrap the rolling stock in to pieces in case of failure
in the following mill trains
800 KN Shear: Crank type flying shear located after intermediate mill train
to crop the end portions and scrap the rolling stock in to pieces in case of
failure in the following mill train or cooling bed equipment
500 KN Shear: Crank type flying shear located after finishing mill train to
crop the end portions and to cut the rolled bars into cooling bed length.

COOLING BED:
120 metre long double side rake type cooling bed.
EQUIPPED WITH:

SWITCH WITH CONVEYOR: Serves for guiding of mill products

alternatively on a left side and right side of cooling bed
SUPPLYING CONVEYOR: Serves for mill product transportation in to
two sides of the double sided cooling bed (at 2.5 to 15 m/sec)
SEPARATING BAR: Serves for separating mill products following quickly
one after another
BRAKING FLAPS: Serves for placing mill products from supplying
conveyor to cooling grates
COOLING GRATES: Rake type cooling grates having 45 notches and
serves to transport mill products to outlet conveyor after cooling
120 nos of cooling fans on each side of the cooling bed are installed to
cool the rolled material

ROLLER SRAIGHTNER
PLACED BEHIND EACH SIDE OF THE COOLING BED FOR
STRAIGHTENING ROLLED PRODUCTS
Total no of rolls :9
No of top rolls: 4 (Only axially adjusted) and motor driven
No of bottom rolls : 5 (Axially and vertically adjustable) and
friction driven
Straightener speed: 2.5 to 12 m/sec

BATCHING OF PRODUCTS

Batching grate arrests the bar after passing through

the straightener
Batching of pre-selected number of bars for cutting by
cold circular saws.

FINISHING SHOP
COLD CIRCULAR SAWS:
2 Cold saw lines each consisting of one stationary and 2
mobile saws for cutting the finished products to customer
lengths
Blade diameter 1600 to 1450mm
Blade thickness: 8 to 10mm
Peripheral speed of saw blade 145 m/sec
Max layer width 1400mm
Pressure water for saw blade : 8MPa

Teeth hardening system : Flame hardening/Induction

hardening .

BUNDLING OF FINISHED PRODUCTS

Bundling is done for ROUNDS.
2X24 metre bundling machines.
Max bundle weight: 10 Tons.

AUTOMATIC TYING AND WELDING of Piles/Bundles:

An unique facility in India

6 tying machines in piling and 4 tying machines in bundling

machines

AUXILLIARY SYSTEMS
Hydraulic and lubrication cellars for all mill plant.
Cellar for water station of De-scaling equipment.
High pressure water station for cold saw blades cooling.
3 Electrical control rooms (ECRs) for electrical equipment
control.
Ventilation systems for ECRSs and Cellars.
Fire protection systems.
13 nos of Electrical Overhead Travel cranes.
Scale flushing systems.
Pipe line distribution systems for water, compressed air,
Nitrogen Oxygen and Steam etc.

AUTOMATION IN THE PLANT

STACKING

Hydraulics
Hydraulics is a topic in applied science and engineering dealing with
the mechanical properties of fluids. On a very basic level Hydraulics
is used for the generation, control, and transmission of fluids in
order to produce some mechanical work or in general as a part of
river engineering.

THE BASIC LAWS OF HYDRAULICS

Fluid Mechanics provides the theoretical foundation of hydraulics

and focuses mainly on its engineering applications. The basic laws
of fluid dynamics that govern the working of any hydraulic system
are:

Pascal's Law: It states that pressure exerted anywhere in a

confined incompressible fluid is transmitted equally in all directions
throughout the fluid such that the pressure ratio (initial difference)
remains the same. The siphon, Hydraulic jack, Hydraulic press and

braking system for automobiles are some examples of application

of this law.

The relationship between pressure, force and area is given by

P=F/AT

This relationship is very useful for obtaining a mechanical

advantage. As per the Pascals law the pressure in a fluid remains
the same everywhere which implies that the ratio of force and area
must remain constant. This fact can be used to lift greater weights
with lesser forces as shown in the figure.

Rashtriya Ispat Nigam Limited

Vizag Steel Plant,
Visakhapatnam 530 031
India

Basic components of hydraulic systems

THE CLASSIFICATION OF HYDRAULIC SYSTEMS IS NOT VERY
CLEAR CUT EVEN THOUGH FOR THE SAKE OF EASE IN
DISCUSSION WE WILL CENTRE OUR FOCUS ONLY ON THE
INSTRUMENTS WHICH ARE MOSTLY USED IN A BASIC HYDRAULIC
SYSTEM.
1.TANK OR RESERVOIR OF HYDRAULIC FLUID
2. MOTOR DRIVEN PUMP
3. PRESSURE GAUGE
4. PRESSURE RELIEF VALVE
5. DIRECTION CONTROL VALVE
6. CYLINDER AND ACTUATOR
7. AN ADDITIONAL REGENERATIVE SYSTEM IS ALSO OFTEN USED
1.TANK:
IT IS THE RESERVOIR WHERE THE WORKING FLUID OF THE
SYSTEM IS STORED WHEN IT IS NOT CIRCULATING IN THE
SYSTEM.ITS VOLUME SHOULD BE PROPERLY CACLULATED AND
MAINTAINANCE SHOULD BE PROPERLY SUPERVISED. THE MAJOR
TWO TYPES OF TANKS IN TERMS OF DESIGN ARE :
A) OPEN TANK

B) CLOSED TANK

2. PUMPS: Pumps convert mechanical energy into fluid energy.

Turbines exactly the opposite, convert fluid energy to
mechanical form.

Classification of pumps based on the method by which

mechanical energy is transferred to the fluid
Positive-displacement pumps
Kinetic pumps
3. PRESSURE GAUGE : A carefully calibrated pressure gauge is
essential to maintain the pressure in the system or line within the
safe working range . This increases the working life of equipments
and results in lesser break-down allowing more available time for all
the equipments.
4. PRESSURE RELIEF VALVE: A pressure relief valve to maintain
the desired pressure in the working line is to be deployed in
conjunction with a pressure relief valve. The control of this valve is
through diferrent modes e.g. spring loaded pressure relief
valve,manually operated pressure relief valve.
5. DIRECTION CONTROL VALVE: The direction of flow of working
fluid of the system and thereby the direction of application of
pressure can be controlled by the direction control valves.
The direction control valve can be operated by various means e.g.
solenoid operated, manually operated,spring-loaded,etc
6.CYLINDER AND ACTUATOR: A cylinder uses pressurized fluid or
air to create a linear foce or motion. The working fluid is pumped
into one side of the cylinder under pressure,causing that side of the
cylinder to expand, and advancing the actuator or piston. The fluid
on the other side of the piston must be allowed to escape freely.If
the incompressible fluid was trapped the cylinder could not
advance. The force the cylinder can exert is proportional to the
cross sectional area of the cylinder.
7.REGENERATIVE SYSTEM: Figure shows a regenerative circuit that
is used to speed up the extending speed of a double-acting
hydraulic cylinder. Here the pipelines to both ends of the

hydraulic cylinder are connected to pump, one end (A) through the
2 / 3 way DCV and the other end (B) directly. The operation of the
cylinder during the retraction stroke is the same as that of a regular
double-acting cylinder. Fluid flows through the DCV zero
position from the actuator A side during retraction. In this position,
fluid from the pump directly enters the rod end of the cylinder
(direct connection). Fluid in the blank end drains back to the tank
through the DCV as the cylinder retracts. When the DCV is shifted
to 1 position due to manual actuation, the cylinder extends. The
speed of extension is greater than that for a regular double-acting
cylinder because flow from the rod end (QR) regenerates with the
pump flow (QP) to provide a total flow rate (QT), which is greater
than the pump flow rate to the A side of the cylinder. ( Area of
blank end is more than rod end, thereby blank end provide least
resistance )

REGENERATIVE SYSTEM
C= Double-acting cylinder
P = Pump
E = Electric Motor
T = Tank
F = Filter
R = Relief Valve
D =2-position, 3 way , Manually operated and
Spring return DCV

COMMON PROBLEMS WITH REMEDIES

Expanded table:
VALVES:

CYLINDERS:

Boosters:

BOOSTERS CONTINUED:

FLUID MOTORS:

FLUID MOTORS CONTD.:

VANE PUMPS:

VANE PUMPS CONTD.:

VANE PUMPS CONTD.:

VANE PUMPS CONTD.:

VANE PUMPS CONTD.:

VANE PUMPS CONTD.:

VANE PUMPS CONTD.:

RADIAL PISTON PUMPS:

RADIAL PISTON PUMPS CONTD.:

RADIAL PISTON PUMPS CONTD.:

HYDRAULICS SYSTEM:

HYDRAULIC CIRCUIT DESIGN AND

ANALYSIS
A Hydraulic circuit is a group of components such as pumps,
actuators, and control valves so arranged that they will perform a
useful task. When analyzing or designing a hydraulic circuit, the
following three important considerations must be taken
into account:
1. Safety of operation
2. Performance of desired function
3. Efficiency of operation
It is very important for the fluid power ( Hydraulics and
Pneumatics) designer to have a working knowledge of components
and how they operate in a circuit. Hydraulic circuits are developed
through the use of graphical symbols for all components. The
symbols have to conform to the ANSI specification.

Plant Details

The major plants and facilities at VSP are:

1. Raw Material and Iron Making

a. Blast Furnace 2
b. Coke Plant with 3 Batteries
c. Sinter Plants 2
d. Refractory Department
e. Raw Material Handling Yards and Associated facilities

2. Long Product
a. Medium Merchant Mill
b. Light Merchant Mill
c. LD shop
d. Rebar mill
e. Wire and Rod Mill

3. Secondary Products
a. Benzene Plant
b. Ammonium Sulphate Plant
c. Tar Plant
d. Slag Plant

4. Shared Services

a. Power Plant
b. Blowers and Pump Houses
c. Industrial Gases
d. Fuel Management
e. Waste Recycling Plant
f. Environment and Occupational health

5. Miscellaneous

a. Information Technology Services

b. Canteen Services
c. Safety and Ergonomics
d. Security and Fire Brigade
e. Research and Development
f. Laboratory

g. Hospital

GENERAL DESCRIPTION

Basic steel is a mixture of iron, carbon and other alloying elements.

There are four common grades of steel:
A. low carbon steel,
B. mild carbon steel,
C. medium carbon steel and
D. high carbon steel (the higher the carbon content, the stronger
and harder the steel).

Low carbon steels used to make car bodies, whereas high carbon
steels are used to make cutting tools and rails.
Steel often is mixed, or "alloyed," with other elements (e.g.,
chromium, nickel, manganese, molybdenum, selenium, tungsten,
titanium or vanadium) to give it special properties, such as
increased strength, durability or resistance to heat and corrosion.
Steel alloys contain from 5% to 50% of one or more alloy metals;
alloys with less than 50% iron content are considered ferro-alloys
rather than steel. The most common steel alloy is stainless steel (a
combination of basic steel, chromium and nickel), a corrosionresistant metal that has a variety of applications.
Integrated steel mills are typically vast complexes with three major
sections:
A. blast furnaces that transform iron ore, coke (a purified form
of coal) and limestone into iron;
B. steel-making furnaces that refine iron into semi finished
steel; and
C. finishing mills that turn semi finished steel into basic steel
products (e.g., bars, pipes, sheets, rods or wire).

Integrated steel mills operate their own power generation facilities,

water treatment plants, fire brigades and medical services.
Integrated steel companies operate private iron and coal mines to
supply their mills. Integrated steel mills are huge complexes that
consume enormous amounts of water, coal, iron ore and limestone.

Materials and Equipment

The following are the major materials required for Steel Mills
o Iron ore, limestone, coal, alloy additives, scrap metal
o Fuel oil, Natural gas, water, oxygen.
o Coke ovens and coke oven gas, blast furnaces, basic
oxygen furnaces, reheating furnaces, conditioning
furnaces.
o Continuous strand casting machines, rolling mills (hot),
blooming mills.
o Gear sets.
o Fans, blowers.
o Ladles, kettles, bins, tongs, molds.
o Conveyors, forklifts, cranes, railcars, rail lines
o Electric power generation facilities
Most of these materials are delivered to the site by rail or ship; iron
ore, coal and limestone. Steel mills store up to six weeks' supply of
certain raw materials (e.g., coal, limestone) in the premises.

Process Description
The steel-making process at VSP entails the following processes:
1. Sizing of Iron Ore, Coke, Dolamite, Limestone, etc
The raw materials are stored in material yards. The raw material is
picked up using conveyer belts and sent for crushing. Using 2 levels
of crushers (primary and secondary) the ore is crushed to the
required grain using filters. Similarly, coal, limestone and Dolomite
is also crushed to the required grade. Using a magnetic separator
ferrous impurities are separated out.
2. Refining coal into coke
The first step in steel making is the transformation of coal into a
purer form known as coke. Coke provides heat, provides
permeability, supports burden materials and also acts as a reducing
agent. Coke is a hard, dark grey material that burns longer, hotter
and cleaner than coal and is the fuel used to smelt iron ore into
iron.

Major units of Coke Ovens are

a. Coal Preparation Plant
Coal from storage yard is sent to foreign objects separation section
where in Ferromagnetic articles and coal lumps of above 150 mm
size are removed. Coal is transported by conveyors to 16 Nos. of
storage bins (capacity 800 tons each). Coals from various sources
are stored in separate storage bins and are mixed in definite
proportions with the help of propositioning devices located at the

bottom of each storage bin (also called silo). The coal-blend is

crushed to -3mm size using impact crushers. Thus coal, crushed &
blended, is conveyed to two coal towers, each of 4000 t capacities.
b. Coke Oven Batteries
A coke oven battery is a monolithic structure of refractory
brickwork, primarily of high quality Silica and Fireclay bricks of
different shapes and sizes. There are 3 coke oven batteries, each of
67 ovens and 7m height. Each oven has an effective volume of 41.6
M3. Coking coals after crushing and blending is subjected to
destructive distillation (heating in absence of air) in the ovens.
Heating is done for a pre-determined coking period (about 16-18
hrs.) up to the required temperature (1050 +/- 50 OC. Adjacent to
each oven there are two heating chambers. The coal charged into
the oven is heated indirectly by burning fuel gases, in the heating
chamber. Conduction/Convection thus transmits heat to the coal
mass through the refractory brick walls. Beneath the ovens
and heating chambers, regenerators are located. The hot
combustion gases from the heating chambers pass through these
separators, which are filled with refractory brickwork, before they
are sent out through chimney. By this, heat energy in recovered
from the waste gases and the same in used in heating the ovens.
After continuous heating of coal for 16-18 hours coke is formed.
The coke mass at a temperature of 1050 +/- 50 OC is pushed out
of the coke oven by means of a pusher car and sent to Coke Dry
Cooling Plant.
c. Coke Dry cooling Plant
Each battery is provided with one dry cooling installation
comprising 4 cooling chambers. Each cooling chamber can cool 5052 coke/hr. The red-hot coke from a battery is transported to the
top of the cooling chamber in a bucket and charged into it.
The residence time of coke in the chamber is 2 to 2.1 Hrs.
Circulating gases are forced by mill fan into the distribution

channels in the lower part of the cooling chamber. The gases flow
upward and coke moves downward in the cooling chamber. The
heated gases coming out from the cooling chambers at about 750
800OC go to primary dust catchers, waste heat boilers and
secondary dust catchers. The temperature of cooled coke is in the
range of 180 200 OC.
d. Coke Chemicals Recovery
The chemicals that need to be removed from coke oven gas are
benzene, ammonia and benzol hydrocarbon. Tar is removed first by
cooling of the coke oven gas by spraying liquor over coke gas.
Nearly 60% of the tar gets condensed and is separated out. The
remaining gas flows to Primary Gas Coolers (PGC), where it is
subjected to cooling water and the gas is cooled to 25C and nearly
all the tar gets removed. The gas is then passed through saturators
where 5% sulphuric Acid solution is maintained. Then the gas
bubbles through it, ammonia reacts to form ammonium sulphate
and is separated out and dried. The gas is then passed through
final gas coolers that removed naphthalene and then passed into
benzol scrubbers that remove benzol from the gas which is distilled
to remove benzene, toluene, Sol-110 and CB-II. Passing hydrogen
gas of required purity does this. Hydrogen is extracted from coal
gas by using a molecular sieve.
e. Coke Sorting Plant
Coke is crushed and sorted to make it of size 25-70mm which is
used in the blast furnace.

3.

Sintering Plant

Sintering is the process of agglomeration of fine ore particles into

porous mass due to incipient fusion caused by the combustion of
fuel present within the mass. The Sinter plant manufactures sinter
as per blast furnace requirement and recycles the metallurgical

waste that is generated in the process. The usage of sinter in the

furnace improves the productivity, reduces the coke requirements
and allows fine control over the slag chemistry. Since the fine iron
ore particles cannot be directly charged in the furnace by making
sinter, natural resources are saved. Raw materials for the sintering
process are Iron ore fines, Limestone, Dolomite, Coke breeze,
Quartzite/River sand, Lime Fines, Metallurgical waste and
Manganese Ore fines. There are 2 sinter-making machines each of
312m2 grate area. The pallet is filled with sinter mix and ignited. 2
suction fans blow in the air at 1500m3/min, which flows down from
the hot top layer to the colder bottom layers. The sinter is then
crushed, cooled and sent to the BF.
Raw Material composition is as below (kg per tonne of
sinter)

Iron Ore Fines 848

Dolomite 109
Limestone 97
Coke Breeze - 56
Sand - 9
Lime - 7
LD Slag - 4
Met. Waste - 63

4.

Blast Furnace

The raw materials for iron making (iron ore, limestone and coke)
are stockpiled in outdoor storage yards. The charge travels along a
conveyor belt, up a ramp, and finally is dumped into a blast furnace
to smelt the charge into molten iron and slag. The 2 blastfurnaces
are called Krishna and Godavari with a rated capacity of 3.4 MT
annually. Before the charge is dumped into the blast furnace, a
series of tank-shaped stoves next to the furnace are heated. In
these stoves, air is heated to 2,000 degrees Fahrenheit and

blasted into the furnace at approximately 400 miles an hour.

Normally, the stoves are used on a staggered basis; while some are
"on blast" (forcing hot air into the blast furnace), others will be "on
gas" (heating air); this maintains a continuous rate of production.
When the charge is dumped into the blast furnace, it is suspended
in midair by continuous blasts of hot air rushing up from the bottom
of the furnace. Continuous exposure to the extremely hot air
causes the charge to melt and slowly drop to the bottom of the
blast furnace. Approximately halfway down the furnace, the
limestone in the charge reacts with the impurities present in the
coke and iron ore, drawing them out to form a lava-like material
called slag; as slag forms, pure iron is left behind. Eventually, the
molten charge (which has been separated into slag and pure iron at
this point) collects in a brick-lined reservoir at the bottom of the
furnace, called the hearth. Because slag is lighter than iron, the
slag lies above the iron in the hearth. The hot reduction gasses of
combustion ascends through the furnace through the charge falling
from top and imparts its heat to the charge. This gas contains high
amount of carbon monoxide and is reused. When enough iron has
accumulated, the hearth is tapped. First, a hole is drilled through a
clay-filled taphole in the hearth above the iron to let the slag pour
out. The slag is collected in a slag ladle. Once the slag has been
tapped, a lower taphole is opened to allow the molten iron to flow
into ladles. While most iron made at a steel plant is used to make
steel, some part is cooled into crude ingots known as "pig iron" and
sold directly to foundries.

The main features of the furnace are

Circular cast house with cranes

Four tapholes
Cast house slag granulation
Useful volume of 3200m3 with 12m diameter hearth
PLC controlled PW charging system
Gas expansion turbine station for gas recovery
O2 enrichment

There are 4 double strand pig casting machines with capacity of

1700 tonnes per day each. There are 30 open ladles of capacity
140 tonnes and 7 TLCs of 300 tonnes capacity.

5.

Steel Melting Shop (SMS)

There are 4 BOF at VSP. In the first step of the basic oxygen
process, the BOF is tilted toward a charging platform where scrap
steel is charged into the furnace. Then, a ladle of molten iron is
moved by crane and poured into the BOF; the molten iron will make
between 60% and 80% of the total charge. Fully charged, the BOF
is returned to an upright position, and a long, water-cooled pipe
called an "oxygen lance" is lowered into the furnace near the
surface of the molten charge. Once in place, the oxygen lance
blows pure oxygen into the furnace at extreme pressure and speed
(in excess of the speed of sound). The molten charge, saturated
with oxygen, begins to burn at a very high temperature. A
measured amount of lime is then released into the furnace; the
lime reacts with the charge's impurities and forms a slag, which
rises to the top of the molten charge and is discarded. After the
oxygen "blow" has ended (usually after 20 minutes), the BOF
is tilted toward the "teeming platform" where the refined molten
charge rushes through a taphole into a rail-mounted ladle. Carbon
and other alloying agents (e.g., tungsten, titanium, molybdenum)
are added to the charge to create molten steel. The steel moves
through the curved casting machine to a horizontal position, it
solidifies throughout, and roller machines flatten the steel to a
predetermined thickness. Finally, at regular intervals, mechanical
shears cut the continuous strand of steel into "blooms, LD gases,
emitted from the mouth of the converter are collected and cleaned.
Each converter is provided with a separate gas cleaning system.
The gas is extracted at the converter mouth through an adjustable
skirt, movable cooling hood and a fixed cooling hood where the gas
is cooled down to temperature of about 1100 deg. C and then led to
a two-stage venturi scrubber where the gas is cleaned and further
cooled to about 70 degC with dust content below100 mg/m3 . With

electrostatic precipitators, the gas can be cleaned to a dust content

of <5mg/N m3 for use as a fuel inside the works. The slag
generated from LD converters is cooled dry and sent to Waste
Recycling Plant for recovery of metallic and fluxes.

6.

Wire Rod Mill and Merchant Mill

Blooms are reheated in walking beam furnace and steel slabs are
shaped into rods, bars, rails, angles, channels etc of different sizes.
Steel wire is wound around the coiler into a tight coil.

Utilities
The major utilities, which are critical for the manufacturing process,
are Steam, Power, Water, Air, Oxygen, Argon and Nitrogen.
a. Power
The power requirement of VSP is around 221 Mw at full load. The
captive power generation of VSP is 270 Mw i.e VSP is self sufficient
to meet all the power need of the plant under normal working. In
case partial power failure of the of captive power plant due to break
down or under maintenance there is an agreement with APSEB to
supply the power. At VSP power is generated through steam
turbines. Steam is produced for power generation by burning coal
in four boilers boilers. Superheated steam at a pressure 107
kg/cm2 is supplied to steam turbines for generation. There are 3
turbines of 60 megawatts and one of 67.5 mw. Power generated at
6.6 kv is stepped up to 220KV.through outdoor transformers in
switch yard. Power is received from Andhra Pradesh Electricity
Board at 220 KV from 2 lines fed to 220 kv bus. Power is also
generated by waste heat recovery in CO & CCP plant & BF plant.
Thermal Power Plant(TPP) 3x60 MW
- 1x67.5 MW
Back pressure turbine(CO &CCP) -2x7.5 MW
Gas expansion turbine (BF plant) 2x12 MW

The entire plant load of plant is divided in five blocks (LBSS 1 to 5).
In each LBSS, power is stepped down to 33/11/3.3 kV
Power is supplied to the various department and machinery at
230V, 440V, 6.6KV and DC supply. Most of the transformers are
indoor in separate cubicles. Transformer has its outdoor baffle wall
is constructed between the transformers. There is a separate
central maintenance department to look after maintenance of H.T.
motors, L.T. motors and D.C. motors above 200 kW.
b. Fuel
There are 3 major fuels used in the manufacturing process
namely Blast Furnace Gas(BF gas),
Coke Oven Gas (C.O. Gas) and
L.D. Gas.
All the three fuels are generated inhouse and are used as heating
medium at various points in the plant.
Fuel
BF Gas
L.D. Gas
C.O. Gas

Generating Source
1 and 2 blast Furnaces
L.D. Shops
Coke Plant

c. Water
The water is received from Yelluru reservxoir about 150kms from
the plant site through gravity channel. There is a reservoir inside
the plant that has 45 days storage capacity. Daily water
requirement is 3000 metric tonnes.

d. Air
There is adequate generation of Instrument Air in the works with
redundancy and storage to cater to the requirement of the works.
e. Industrial Gases
There is an air separation plant at VSP for generating Oxygen,
Nitrogen and Argon. The air is compressed and chilled. Various
gasses are then separated out. Oxygen requirement is 3000 tonnes
per day. Oxygen is stored in tanks and supplied. Nitrogen is used
for cooling in COCP and SMS plant. It is supplied via pipeline. Argon
is used in the Steel Making process. Acetylene is generated by
reacting calcium carbide with water. Acetylene is required for gas
cutting of steel.

INDUSTRY-RELATED HINDRANCES TO
PRODUCTION IN RINL
Foregoing analysis shows that India has made sufficient
achievement in industrial development during the last five decades
and has emerged as the tenth largest industrialized country of the
world. But considering the size of the country this development is
far from satisfactory.
Visakhapatnam Steel Plant (VSP) is the only shore-based Indian
integrated Steel Plant, with a rated capacity of 3.4 Mt Hot Metal,
3.0 Mt Liquid Steel and 2.656 Mt Saleable Steel. The plant was
commissioned in the year 1990. VSP has 7 M tall Coke Ovens with
Dry Quenching facility, the 3,200 cu.m Blast Furnace and the 100%
Bloom Casting technology and fully computerized Rolling Mill.
Presently the Plant is operating at higher efficiency levels
surpassing the rated capacities.
Current capacity is as below:
Hot Metal 4.15 Mtpa
Liquid Steel 3.6 Mtpa
Saleable Steel 3.2 Mtpa
RINL is a Navratna company
MOU performance over the decade:
Excellent
: 7 years
Very Good : 3 years
ONLY INTEGRATED STEEL PLANT AMONG PSEs HAVING NO
CAPTIVE IRON ORE AND COAL MINES.
Long products manufacturer Market leader in Bars & Rods

 The most modern plant Expansion has latest technological

features
Over 100% capacity utilisation since 2001, consistently i.e.,
for 12 years despite ageing plant
Producer of highest percentage of value added steel ,
percentage of which has been continuously improving
First Integrated Steel Plant to be triple certified for Quality,
Health & Safety and Environment ISO 9001, OHSAS 18001
& ISO 14001
First PSE & First in Steel sector to get BS EN 16001 (Energy
Management system) certification in India in Dec. 2010.
Recipient of coveted Prime Ministers Trophy for best
integrated steel plant TWICE
Recipient of Steel Ministers Trophy twice
Recipient of several national & international awards for Quality
& Innovation including several Viswakarma Rashtriya Puraskar
for individuals
Winner of 7 consecutive energy conservation awards
Lowest water consumption rate in India and perhaps in the
world
RINL-VSP recognised as Indias Best companies to work for
by Great Place to Work Institute & Economic Times for the
years 2009 , 2010 and 2011 in a row.

Product

DPR
Capacity

As
Achieved

Hot
Metal

3.4

4.0

Liquid
Steel

3.0

3.5

Saleable
steel

2.6

----

However RINL faces various problems due to industry-related

problems in its production processes.The various problems faced in
the production processes of RINL are1. Unbalanced Industrial Structure
Despite all efforts India has not been able to attain self sufficiency
in respect of industrial material. India is still dependent on foreign
imports for transport equipments, machineries (electrical and nonelectrical), iron and steel, paper, chemicals and fertilisers, plastic
material etc. In the total industrial production consumer goods
contribute 38 per cent. In newly industrialised countries like
Singapore, South Korea and Malaysia this percentage is 52, 29 and
28 respectively. This shows that import substitution is still a distant
goal for the country .
2. Low Demand
There is low demand for industrial products in the country due to
low consumption level, weak purchasing power and poor standard
of living. The domestic market is chronically underdeveloped
through lack of enthusiasm generated by the middle and upper
class segment who do not wish to raise their standard and improve
their living conditions.
3. LACK OF INFRASTRUCTURE
An inadequate infrastructural facility is another major problem
faced by the Indian industries. Energy crisis has a great bearing on
the industrial development and production. Although the installed

capacity of electricity increased from 66.08 million km in 1990-91

to 85.79 million km in 1996-97 but it is much short of the actual
demand.
It leads to power cut and rostering which hampers the industrial
production. Most of the State Electricity Boards are running in loss
and are in deplorable condition. Rail transport is overburdened
while road transport is plagued with many problems. Even national
highways in many places are in bad shape. Telecommunication
facilities are mainly confined to big cities.
4.Shortage of Industrial Raw Material
Most of the raw material(i.e iron ore) is imported from Australia via
the Vishakhapatnam port. Other raw materials like coal, limestone.
dolomite are obtained locally.
5. Lack of Institutional Organization
A major development thrust during the Five Year Plans was toward
the establishment of a vigorous public sector developed hastily
without the creation of a base of administrative machinery capable
of undertaking this enormous task. Preparatory work for such
tremendous institutional reorganization was poor. High performance
was rarely insisted on even after the construction of an
administrative base. The result was non-achievement of targets.
During the Fourth, Fifth and Sixth Plans, achievement levels fell
short of targets by 15-18 per cent. This malady is still persisting
even after liberalization. There is no clear-cut planning at state
level to attract foreign capital and promote industrialization.
Industrialization started in India roughly a century later than in the
developed countries. That is why, when it was in mature stage in
the Western countries it was in infantile stage in India. Hence, India

had to perform dual task of promoting industrialization as well as to

equip herself with latest technology in the field of electronics,
nuclear science, space research etc.
This slowed down the pace of industrial progress. Frequent change
in the approach-sometimes emphasis on rural industrialisation,
sometimes on urban-nucleated industrialisation or rural led
employment-oriented strategy or creation of employment-oriented
agro-based industries-confuse the situation. Indian industrialisation
has passed through great odds. Besides being victim of 'economics
of scarcity' it has been mauled by political indecision, prejudices
and confusion.
6. Industrial Sickness
In the industrial sector a growing number of industrial units are
becoming sick. Widespread sickness has, indeed, become a major
problem of this sector. The causal factors for this sickness are: (i)
deficient management, (ii) under-utilisation of capacity due to
shortage of raw materials, coal and power and transport, (iii)
obsolete machinery, equipment and production techniques, (iv)
uneconomical scale of production, (v) faulty choice of products and
processes, (vi) difficulties in selling the products, (vii) diversion of
funds to new units under same ownership, and (viii) conflict
between different interest groups among the owners. At the end of
March 1999 there were 3, 09,013 sick/weak units (3, 06,221 in SSI
and 2,792 in non-SSI sectors). A total of Rs. 19,464 crores of bank
credit was locked up in these sick units. Sometimes, the
government takes over sick units which further worsen the problem.
In order to provide a focal point for the revival of sick units, the
Industrial Reconstruction Corporation was reconstituted in 1985 as

the Industrial Reconstruction Bank. It is now the principal agency

for reconstruction and rehabilitation of sick units.

GOVERNMENT RELATED HINDRANCES IN

PRODUCTION IN RINL
RINL is a Navratna Company, as been conferred by the Govt. of
India. However it faces various problems related to inefficiency in
government administration and redtops. The various problems
faced by RINL due to government inefficiency are1. Loss in Public Sector Industries
Owing to focus on socialistic pattern of development investment
under public sector industries increased phenomenally during early
five year plans. But due to defective policy of the government characterised by redtops and inefficiency and strained labourmanagement relations most of these public sector enterprises are
running in loss. Every year the government has to incur huge
expenditure to cover up this loss and meet obligations of paying
wages to the employees.
This hardly leaves surplus money to go for new industrial ventures
and launch schemes for social development. To avoid this burden
on exchequer the government is promoting privatisation and
disinvestment of shares of public sector undertakings. This goes
against the Peruvian model of development initiated during the
fifties of the last century.
2. Lack of Capital
Indian industrial development is facing acute shortage of capital.
The short-term and long-term loans from international agencies like
World Bank and Asian Development Bank etc. have done more
harm to the economy than taking it out from the crisis. A lot of
foreign exchange is being utilized in the payment of these loans.

The situation becomes acute when fresh loans are taken to pay the
installments of the old loans. Due to liberalization, the foreign
exchange reserve position has improved in recent years and flow of
foreign capital has started in industrial sector. These foreign
investors also do not like to invest in such industries which require
large capital, need long gestation period and where recovery is slow
or more risk is involved. Instead of depending on foreign capital we
have to place more reliance on indigenous capital with greater
emphasis on the development of priority industries.
3. License Policy
The license policy approving the site, capacity, type and expansion
of industries is a typical example of excessive state interference
and red tapes which hinder the industrial development. Recently
some examples of political vendetta have come to surface whereby
central government over delayed the approval of industries from
such states where hostile political party is in power. Ministers and
influential political leaders are pressurizing industrialists to install
industries in their electoral area so as to approve their licenses.
With the introduction of liberalization policy many of the
shortcomings of the license policy have been removed.

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