MALAVIYA NATIONAL INSTITUTE OF

TECHNOLOGY, JAIPUR

SUMMER TRAINING ( 22nd May

2017 to 8th July 2017

STEEL AUTHORITY OF INDIA LIMITED

( SAIL), BHILAI

Presentation By:
Prachanda Poudel
2014UME1017
M1

Guided by:
Mr. Jainendra Verma
Training Engineer, CCS, SMS-II
 CONTENT

About SAIL
About Bhilai Steel Plant (BSP)
Different Department of BSP
Steel Melting Shop II (SMS-II)
Processes in SMS II
About Project
Learnings from Industrial Training
 STEEL AUTHORITY OF INDIA LIMITED (SAIL)

One of the largest state owned steel

producers in India
24th largest steel producer in the world
5 integrated plants in India (Bhilai,
Rourkela, Durgapur,Bokaro and Burnpur)
Annual turnover of US$6.7 billion
Annual production of 13.5 million metric
Ton of steel
Leading supplier of Rail tracks to Indian
Railway.
 BHILAI STEEL PLANT (BSP)

Located in Bhilai, Chhattisgarh, a symbol of Indo-Soviet Techno-economic

collab.
One of the first three integrated Steel plants set up by Govt. of India
Agreement to set up was done on 2nd February, 1955 between India & U.S.S.R.
First Blast furnace inaugurated on 4th February, 1959 by the then President of
India.
 BHILAI STEEL PLANT (BSP)

Expanded in an area of 25 KM2.

Commissioning of all the units of 1 MT capacity was completed by 1961.
Thereafter plant was expanded to 2.5 MT per annum on sept. 1967 , then 4MT per annum on 1988. Now
nearly produces 7MT
It has won Prime ministers trophy 11 times being the best integrated steel plant and was a most profitable
plant in fiscal year 2004-2005.
It is the only producer of longest Rail tracks(260 meters) for Indian Railway.

Captive mines of BSP

Iron ore Dalli-Rajhara Iron Ore complex, 80kms from Bhilai
Lime Stone Nandini, 23kms from Bhilai
Dolomite Hirri, 150kms from Bhilai
 DIFFERENT DEPARTMENTS IN BSP
Coke Ovens Batteries: 8 batteries of 4.35m height consisting of 65 ovens each
11 Nos. 3 batteries of 7m height consisting of 67 ovens each

Blast Furnaces : 3 Blast furnaces each of 1033 cu.m volume

7 Nos. 3 Blast furnaces each of 1719 cu.m volume
1 Blast furnace of 2355 cu.m volume

Sintering Plants : SP-1 : 4x50sq.m hearth area

2 Nos. SP-2 : 3x75sq.m hearth (3 M/cs) and 1x80sq.m hearth area (1 M/c)
SP-3 : 1x320sq.m area and 1x360 sq.m hearth area

Steel Melting Shop-I 4 Twin Hearth Furnaces

Steel Melting Shop-II Convertor Shop :

3 BOF 110/130 T Convertors
Secondary Refining facilities : 1 VAD unit, 2 RH degassers, 2 Ladle furnaces
Continuous Casting Shop:
4 Slab Casters, 2bloom caster

Mills Blooming & Billet Mill

Rail & Structural Mill
Plate Mill
Merchant Mill
Wire Rod Mill
 STAGES OF PRODUCTION OF STEEL IN
INTEGRATED PLANT
Irons extracted from iron ores
Smelting is done in Blast Furnaces
Refining procedure is carried out in Steel Melting Shop
Casting process is carried out in Steel Melting Shop
Rolling and rerolling of the Blooms/Slabs is done in Mills
 PRODUCTS OF STEEL MELTING SHOP

BLOOMS
Taken to the rail mills to manufacture rails.
After the manufacturing of Rails, exported to the customers (i.e. Indian
Railways)
SLABS
Taken to the plate mills to manufacture plates
After the manufacturing of Plates, exported to the customers (i.e. DRDO, ATM
manufacturers, Indian Army, etc.)
 PROJECT 1: STUDY OF STEEL MELTING SHOP II
Sections of Steel Melting Shop II
Converter Shop: Converts Hot metal to Steel

Slag Yard & Scrap Yard: Slag produced after conversion is handled in slag yard by remote control overhead
crane. Scrap yard stores scrap as per the requirement of shop (scraps are used as coolant)

Ladle preparation Bay: Used to prepare ladle for taping and making of new ladles. (5 burners used for
preheating the ladle before taping.

Tundish Preparation Bay: Reservoir of hot metal until molten metal is charged again is prepared and
relined (40 ton capacity).

Ladle Heating Furnace: Steel in Ladle is heated over 1650 C temp using arcing facility.

Argon Rinsing: This is used in case of LHF shut down, heating is done without the use of arcing(vacuum
argon rinsing wasnt in use)

RH Degasser: Vacuum degassing is done for the removal of hydrogen gas for high quality steels.

Casting Bay: Continuous casting of blooms were done and cooled for storing in storage yard
 Desulphurization/ Removal of slag Scrap charging Hot metal Oxygen blowing
Blast Furnace Mixer charging converter

Ladle furnace Argon rinsing

RH Vacuum
station Tapping
degasser

caster

Slab & Bloom Storage

Yard
Slab cut up

Fig. Process diagram of SMS II

 CONVERTING IN LD CONVERTOR
Sequence of operation:

Scrap charging HM Pouring

Oxygen blown Tapping of steel

 STEEL PREPARATION

Ladle Heating Furnace

Objectives:
Heating molten steel by arcing method, with argon purging
from bottom.
Modification of steel as per the requirement.
Adjustment of temperature and chemical analyzing before
sending to casting.

RH Degassing
Objective:
To reduce hydrogen gas content <1.6 ppm
Improving the cleanliness of steel
Improve the quality of steel by reducing the
unwanted dissolved gases.
 CONTINUOUS CASTING

Fig: Schematic Diagram of Continuous casting

PROJECT 2: STUDY OF WHEEL FLANGE LUBRICATION SYSTEM IN
OVERHEAD CRANE

Root cause of Wheel Flange Wear is friction due to continuous rubbing of two metal
surfaces.

Fig. Wheel flanges and effect of friction on them

 SOLUTION: LUBRICATING THE SURFACE TO REDUCE
FRICTION

Dry Lubrication
Using lube sticks as a lubricant.
Using graphite powder as a
lubricant on wheel flanges.
Using graphite powder on rail line.

Liquid Lubrication
Using liquid lubricants like Mobil, Fig: Dry Lubrication(use of lube sticks)
grease etc. on the wheel flanges.
Using the liquid lubricants in rail line.
MEAN OF LUBRICATION IN CCS, SAIL

Fig: Rail Line Lubricator

Fig: Inner view of rail line lubricator
LEARNINGS FROM THE INDUSTRIAL TRAINING
Different processes involved in steel manufacturing.
How is continuous casting process carried out.
Importance of Lubrication in wheel flanges and rail line.
Types of Lubrications done in wheel flanges & rail line.
Working of rail line lubricator.
Most importantly, manufacturing process and challenges faced in manufacturing a
product in an Industry.