Internship Report

Submitted to:

Submitted by:

H.P.KUSHAL , 13BEM0056

B.TECH III year

MECHANICAL WITH SPECIALISATION IN ENERGY ENGINEERING

SUPERVISOR: S.L.DAS, A.G.M, SAIL R.S.P

START DATE: 5TH DECEMBER 2015

END DATE: 5TH JANUARY 2016

Report Date: 5TH JANUARY 2016

Preface

This report documents the work done during the internship at ROURKELA STEEL

PLANT, Rourkela, Orrisa under the supervision Mr.S.L.DAS, A.G.M, SAIL R.S.P. The

report shall give an overview of the tasks completed during the period of internship

with technical details. I have tried my best to keep report simple yet technically

correct. I hope I succeed in my attempt.

The document contains information about the organization and the responsibilities

performed throughout the period of internship.

The first part of the report offers an overview of the organization, followed by the

working plan initially agreed upon with the SAIL, R.S.P as a suitable internship.

Following, it proceeds to describe in some detail the most relevant activities carried

out and their respective analysis. Finally, the report wraps-up with a few closing

remarks and conclusions from the experience.

More than a plain account of tasks, the objective of this text is to reflect upon the

experiences collected during the internship from the perspective of a B.Tech

student.

About Rourkela Steel Plant

Rourkela Steel Plant (RSP), the first integrated steel plant in the public sector in India, was set up with German collaboration with an installed capacity of 1 million tons. Subsequently, its capacity was enhanced to 2 million tons of hot metal, 1.9 million tons of crude steel and 1.67 million tons of saleable steel. After implementing a massive modernization and expansion that is in the last leg of completion, Rourkela Steel Plant has enhanced its capacity to 4.5 million tons of Hot Metal and 4.2 Million Tons of Crude Steel.

RSP was the first plant in India to incorporate LD technology of steel

making. It is also the first steel plant in SAIL and the only one presently

where 100% of slabs are produced through the cost-effective and quality-

centric continuous casting route. It is SAIL’s only plant that produce silicon

steels for the power sector and high quality pipes for the oil & gas sector. Its

wide and sophisticated product range includes various flat, tubular and

coated products.

Modernization and Expansion of Rourkela Steel Plant

Rourkela Steel Plant is on the verge of completing a massive modernization and expansion programme that is truly historic. With this the Steel Plant has doubled its capacity and augmented it to the level of 4.5 MTPA (Million Ton per Annum) of Hot Metal from the previous level of 2 MTPA. The Crude Steel making capacity has simultaneously increased from the level of 1.9 MTPA to 4.2 MTPA and production of Saleable Steel is all set to zoom from the level of 1.671 MTPA to 3.99 MTPA. It is worth mentioning here that, apart from increasing the volume the other benefits envisaged from this phase of modernization and expansion are increased economy of scale, enlarged customer base, enhanced quality, reduced cost of production, better market compatibility, improved labor productivity, stricter adherence to environment norms and superior Techno-economics.

Products

PRODUCT-MIX TONNES/ANNUM

Plate Mill Plates 2,99,000 from old Plate Mill 10,00,000 from New Plate Mill

HR Plates 92,500

HR Coils 3,98,000

ERW Pipes 75,000

SW Pipes 55,000

CR Sheets & Coils 4,33,000

Galvanized Sheets (GP& GC) 1,60,000

Silicon Steel Sheets 73,500

Products Applications

HR Coils

LPG cylinders, automobile, railway wagon chasis and all types of

high strength needs.

Plates Pressure vessels, ship building and engineering structures

Chequered

Plates

Flooring & staircases in the industrial installations, railway

platforms, etc.

CR Sheets &

Coils

Steel furniture, white goods like refrigerators, washing machines,

automobile bodies, railway coach panelling, drums, barrels, deep

drawing and extra deep drawing, etc.

Galvanised

Sheets

Roofing, panelling, industrial sheeting, air conditioner ducting and

structural

Electrolytic Tin

Plates

Containers for packaging of various products including edible oils,

vegetables and confectionary items.

Silicon Steel

sheets & Coils

Small generators, stators for high efficiency rotating equipment

and relays, etc.

Spiral Weld

pipes

High pressure transportation of crude oil, natural gas and slurry

transportation, water supply, sewage disposals, grain silos, civil

engineering pilings, etc.

ERW Pipes

High pressure transportation of oil & water, sewage disposal, tube

wells, etc.

A captive power plant is a facility that is dedicated to providing a localised

source of power to an energy user. These are typically industrial facilities or

large offices. The plants may operate in grid parallel mode with the ability to

export surplus power to the local electricity distribution network. Alternatively

they may have the ability to operate in island mode; i.e. independently of the

local electricity distribution system./

Captive power plants are a form of distributed generation, generating power close to the source of use. Distributed generation facilitates the high fuel efficiency along with minimising losses associated with the transmission of electricity from centralised power plants.

Gas-fuelled captive power plants are most fuel efficient when used in a combined heat and power (CHP) configuration. Here a facility can generate not only electricity, but also heat which can be off-set.

Benefits of captive power plants

Security of power supply through self-generation Reduced costs through high fuel efficiency, particularly when in CHP

configuration Improved environmental performance resulting from fuel efficiency

Captive power plant

BLOCK DIAGRAM OF CPP 1

COMPONENTS INVOLVED

BOILER COMPONENTS, FUNDAMENTALS & OPERATIONAL EFFICIENCY

BOILER AS PER IBR:

Any closed vessel exceeding 22.75 litres (5 gallons) in capacity explicitly used for

generating steam or vapour under pressure by application of heat includes any

mounting or other fittings attached to such vessel, which is wholly or partly under

pressure when steam/ vapour is shut off.

SECTIONAL DRAWING SHOWING DIFFERENT PARTS OF A BOILER AND

PROCESS FLOW CHART:

BOILER DRUM INTERNALS:

-

COMMON BOILER OPERATIONAL PROBLEM

IMPROPER FUEL STORAGE, HANDLING AND PREPARATION [ Wet Coal, Size, Poor Pulveriser/ Classifier, Less inventory/ More Inventory]

OPERATION AT NON-OPTIMUM EXCESS AIR LEVEL

Unavailability of O2 Analyser

Air In-Leakage Upstream of the Plant O2 Analyser

Incorrect O2 Analyser Calibration Improper Location of O2 Analyser

IMPROPER COMBUSTION CONTROL

Poor Control of Mixture of Fuel and Air

Excessive Air-Rich Combustion for Safety and Stability

Improper Combustion Because Of Less Air i.e. Combustible Loss

Basic Ingredients[Change in Viscosity, Temperature, Pressure Or Calorific Value of Fuel ] and Ambient Conditions

Worn, Damaged and Dirty Burner

Sooting Up of the Boiler Tubes.

LACK OF COMBUSTION UNIFORMITY

Maladjustment of Air Dampers

Partially Plugged Air Heater

Poor Windbox Design

Uneven Coal Flow From the Pulveriser

Partially Plugged/Cracked Oil Gun Atomiser Tip

Broken/Poorly Positioned Oil Gun Diffuser

Different common abnormality that requires maintenance:

Malfunctioning of steam Trap

Poor Insulation

Poor sealing in APH

Erratic behaviour of combustion air fans

Steam leak

Abnormal power consumption by auxiliaries

COKE OVEN BATTERY

The Coke Oven Complex converts prime coking coal from Jharia, Dugda and Moonidih and

medium coking coal form Kargali, Kathara and Mahuda, blended with imported coal, into

high quality coke for the Blast Furnaces, recovering valuable by-products like Anthracene

Oil, Benzene, Toluene, Xylene, Light Solvent Naphtha, Ammonium Sulphate and Extra-

hard Pitch in the process.

The Coke Oven battery has 8 batteries with 69 ovens each, maintained meticulously in terms

of fugitive emission control, use of phenolic water and other pollution control measures.

Coke ovens

• 8 Batteries of 5 meter height, 69 Ovens each

• The process of coke making consists of destructive distillation of coal in absence of air.

The phenomenon is called high temperature (above 12000c -13000c carbonisation of

coal

• Volatile matters are driven out leaving behind the residue called COKE

• By-Product Plant:

- Gas Condensate Section

- Ammonium Sulphate Plant

- Benzol Recovery Plant

- Tar Distillation Plant

- Sulphuric Acid Plant

Desired Analysis vs Indian Coals

Quenching of Coke

Desired Analysis Indian Coals Imported Coals

Ash% < 16 19-24 3-12 (Av 9)

Volatile Matters% > 25 24-26 19-28 (Av 23)

Moisture% 7-9 7-8 8-11 (Av 9)

Sulphur% < 0.05 0.56 < 0.05

Phosphorus% < 0.05 0.09 < 0.05

Material Flow Diagram : Coal & Coke

Coking Coal From

Various Source Wagons Coal Handling Plant

Coke Sorting Plant Coke Battery

( 8 Nos.)

Blast Furnace

Coke

+ 25 -80 mm

Nut

Coke

Coke

Breeze

-15 mmBlast Furnace

Coke Oven

Gas

By Product Plant

Sinter Plant Sold

By-Product Plant

It consists of : • Gas Condensate Section • Ammonium Sulphate Plant • Benzol Recovery Plant • Tar Distillation Plant • Sulphuric Acid Plant

Products produced from by product plant. • N G Benzol • N G Toluene • Xylene • L S Naptha • S B Oil • PCM • Road Tar • Coal tar wash oil • Extra hard pitch • Hard medium pitch • Hot Pressed naphthalene

All by products of By Product Plant are sold through e- auction.

Tech-economic factors

SINTERING PLANT

SINTERING PLANT

Sintering is the process for agglomeration of fines mineral particles in to a compact porous and lumpy mass by incipience fusion caused by heat produced by combustion of solid fuel within the mass it self.

• 3- Sinter machine , capacity 6.25 Mt./annum • Production of sinter per day 1800T(with 3 M/C) • Capacity 300to 450 T/hrs

• Sintering area – 252 M2

• No. of pallets – 130 • Speed of pallets – 0 to 7.5 • Sinter Size for B./ F./ Use – 5, -40 mm

Blast Furnace

* Iron oxide of ore and Sinter is reduced to iron with the help of CO & Coke

• B.F is a counter current heat and mass exchanger in which solid raw materials are charged from the top of the furnace and hot blast at about 1100 Degree Celsius is sent from the bottom via Tuyers.

• 5 Furnaces each 2000 M3 useful volume and 2640 T/day HM capacity.

• All furnaces have bell-less Top charging system for continuous charging and better distribution of charge

• CDI is working in BF No. 4 & 5 • CHSGP in BF 4 & 5 • Capacity of BF -4.585 MT/annum • Hot Metal Temperature 1460-1480 degree celcious • Coke rate 520 Kg/THM

Blast Furnace

• The iron oxide of ore and sinter is reduced to iron with the help of carbon monoxide & Coke

• Functions of coke in BF are manifold. It provides strong porous bed to burden and supplies the heat load. Part of the heat load is supplied by the hot air blast

• 5 Furnaces each of 2000 cubic meter useful volume and 2640T/day HM capacity

• All furnaces have Bell-less Top charging System for continuous charging & better distribution of charge

• Coal Dust Injection in Fce.# 4 & 5 • CHSGP in Fce. # 4 & 5 • Capacity of B F 4.585 MT of Hot Metal per annum

• Hot Metal Temperature 1460-14800C

• BF Productivity: 1.4 T/m3/Day

• Coke Rate 520 Kg/THM

Steel Melting Shops

Hot Metal from the Blast Furnaces is converted into steel by blowing 99.5% pure

Oxygen through it in the LD converter. Suitable alloying elements are added to

produce different grades of steel.

we have two Steel Melting Shops - SMS-I and SMS-II. SMS-I has 5 LD converters

of 130T capacity each. It is capable of producing Rimming steel through the ingot

route. SMS-II has 2 LD converters, each of 300 T capacities, with suppressed

combustion system and Continuous Casting facility. It produces various Killed and

Semi-Killed steels

FACILITIES

SMS-I SMS-II

MIXER 2/1300T 2/2500T

Converter 5(100T/130T) 2(300 T)

Capacity 2.5 MT 2.25MT

Steel Melting Shop

• SMS-I: 5 Converters each of 100/130T capacity, 2 Mixers each of 1300 T capacity

(Rated Capacity 2.5 MT/Yr)

• SMS-II: 2 Converters each of 300 T capacity, 2 Mixers each of 2500 T capacity

(Rated Capacity 2.25 MT/Yr)

• Total capacity 4.5 MT of liquid steel

• Oxygen of high purity(99.9 %) is blown into the converter from the top through

water cooled lance so as to remove the impurity of hot metal through oxidation

• Impurities of Si, C & P are oxidised and Forms slag with lime

• Killed, Semi-killed and Rimming steels are made

• SMS-II has got suppresed consumption system

• Lining life :

SMS-I = 800 – 1000 heats

SMS-II = 2000 – 2500 heats

STEEL MAKING

Lime addition in converter

Scrap charging

Hot metal charging

Oxygen blowing

Addition of fluxes in batches during blow

At blow end sampling & temp recording

Tapping in ladle

Addition of de-oxidizer in ladle

SLABBING MILL

Slabbing Mill transforms ingots into slabs by rolling them in its 1250 mm

Universal Four-High Mill. The rolling capacity of the Mill is 4 MT per annum.

The shop has Hot and Cold Scarfing. Machines and 2800 T Shearing Machine.

Controlled heating in Soaking Pits, close dimensional accuracy during rolling

and hot and cold scarfing help produce defect-free slabs.

Slabbing Mill transform Ingot into Slab by rolling. The ingot of various sizes and weights are received from SMS and rolling is done. Rolling is a plastic deformation of the metal by passing between rolls to give the desired shape.

Slab dimensions.

Thickness-170 to 230 mm, Width- 910 to 1,850mm Length – 7.7 to 10.5 m

Rolling Temperature 1300 degree celcious.

Soaking pits 12 groups and each group has 4 pits

Soaker crane – 4 No. of capacity 50/40 Tons

Re-heating furnace-5

HSM

Coil dimension.

Strip Th. 1.5 to 16 mm , Width 910 to 1,850 mm, I.D- 850, O.D-2300 mm , Wt- 32T

Slabbing Mill

• 12 groups of Soaking pits with each group having 4 pits ; total 48 pits wherein ingot are heated to a temperature above

13000C

• On line hot & cold scarfing M/c for surface scale/defect removal

• One 1250 mm Roll dia 2-high Reversible Universal Mill to produce slabs of thickness 150-300 mm, width 950-1850 mm and length 2.5 – 10.5 mtr.

• 2800 Ton Hydraulic Shear (6 cuts/min) • 4MT Capacity (Rolling Rate 600-800T/Hr) • Main Sections a) Ingot Storage Yard b) Soaking Pit

C) Mill Proper d) Slab Storage Yard

CRM-1 CRM-2

Tandem Mill-4 Stand,4-high mill 5-Stand 4-high

• The DCR mill can produce Tin Mill block plate, which is tinned for use by the canning industry.

• The hot dip Galvanizing line produces Zinc Coated CR strips resistance to atmospheric, liquid & soil corrosion & its continuous coil corrugation line produces corrugated sheet.

• Hood Annealing-Purpose of annealing after thickness reduction in Tandem

Mill, the grain structure of the steel gets elongated and heavy internal stress

are developed. To regain the mechanical properties the material is heated

upto tempr 600-720 ded and allow to cool slowly. • Heating is done by Protective gas 96% N2 4 % H2.

• SKIN PASS MILL –To develop the required mechanical properties to impart

desired mechanical finish

HOT STRIP MILL

Slabs from CCS and Slabbing Mill are processed in the state-of-the-art Hot

Strip Mill. The fully automatic Hot Strip Mill with an annual capacity of 3.363

million tonnes has a wide range of products - thickness varying from 1.2 mm to

20 mm and width from 750 mm to 1850 mm. The mill is equipped with state-

of-the-art automation and controls, using advanced systems for process

optimization with on-line real time computer control, PLCs and technological

control systems.

Hot Rolled Coil Finishing

All the Hot Rolled coils from the Hot Strip Mill are received in HRCF for further

distribution or dispatch. HR Coils rolled against direct shipment orders are

sheared and finished to customer-required sizes and dispatched to customers.

The material is supplied as per Indian specifications and many international/

foreign specifications. The shop has two shearing lines with capacities of 6,

45,000 Tonnes/ year and 4, 75,000 Tonnes/ year respectively.

Cold Rolling Mills

• Cold rolling is done to produce thinner gauge strip of smooth finish with better mechanical properties than those obtained by Hot Rolling

• Uses : Automobile Bodies, Steel Furniture, Drum & Barrels, bending and shaping applications.

• Capacity: 1.66 MT of CR saleable • CRM I: H

2So

4 Pickling Line, 4-Stand Tandem Mill (2-4.5mm thick into 0.63-

2mm thick) Annealing Furnaces, SPM-I & SPM-II, Shearing Line I & II, Slitting Line and Shipping-I

• CRM II: HCl Pickling Line, 5-stand Tandem Mill (1.4-2mm thick into 0.63-1.6mm thick) , ECL, CAL, DCR Mill, HDGL and Shipping-II

• Besides Continuous Annealing furnace103 Annealing Furnaces and 230

Bases are available in three areas. Annealing is done at 680-7200C in inert

atmosphere (95% N2+5%H

2) with the help of mixed Gas of 1550-1600 CV

Hot Strip Mill

• Hot Rolling involves plastic deformation of a metal under squeezing force (a

pair of Rolls) above its re-crystallization temperature.

• This mill is designed to roll thin & wide strips for use in various industries

such as wagon building, tube & pipe industry, drum & furniture

manufacturing and further rolling in Cold Rolling Mill

• 3 Walking Beam Reheating Furnaces & 1 Pusher type furnace

• Vertical Scale Breaker

• 5 Roughing Stands, 7 Finishing Stands

• Hydraulic AGC in last four Strands

• 4 Hydraulic Coilers with automatic strapping & Robot marking

• Capacity: 3.955 MT of HR Coils • Coil Dimensions

– Strip thickness 1.6 to 16.0 mm – Strip Width 910 to 1,850 mm – Coil inside dia 650 mm – Max Coil outside dia 2,300 mm – Max coil weight 32 T

• Rolling Speed: 20 m/sec Max.

Hot Strip Mill

SAIL Today

SAIL today is one of the largest industrial entities in India. Its strength has been the diversified range of

quality steel products catering to the domestic, as well as the export markets and a large pool of technical

and professional expertise.

SAIL produces iron and steel at five integrated plants and three special steel plants, located principally in

the eastern and central regions of India. The company also owns iron ore, limestone and dolomite mines:

domestic sources of raw materials. These mines are situated close to the eastern and central regions of

India giving company competitive advantages. The company has the distinction of being India’s second

largest producer of iron ore and of having the country’s second largest mines network.

Major Units

Major units of SAIL consist of integrated Steel plant, special steel plant & subsidiary units.

Integrated Steel Plants

Bhilai Steel Plant (BSP) in Chhattisgarh

Durgapur Steel Plant (DSP) in West Bengal

Rourkela Steel Plant (RSP) in Orissa

Bokaro Steel Plant (BSL) in Jharkhand

IISCO Steel Plant (ISP) in West Bengal

Special Steel Plants

Alloy Steels Plants (ASP) in West Bengal

Salem Steel Plant (SSP) in Tamil Nadu

Visvesvaraya Iron and Steel Plant (VISL) in Karnataka

Subsidiary

Maharashtra Elektrosmelt Limited (MEL) in Maharashtra

Joint Ventures

NTPC SAIL Power Company Pvt. Limited (NSPCL)

Bokaro Power Supply Company Pvt. Limited (BPSCL)

Mjunction Services Limited

SAIL SCL Limited

SAIL-Bansal Service Centre Limited

Bhilai JP Cement Limited

Bokaro JP Cement Limited

SAIL & MOIL Ferro Alloys (Pvt.) Limited

S & T Mining Company Pvt. Limited

International Coal Ventures Private Limited

SAIL SCI Shipping Pvt. Limited

SAIL RITES Bengal Wagon Industry Pvt. Limited

PRODUCT DETAILS

Today, the accent in SAIL is to continuously adapt to the competitive business environment and

excel as a business organization, both within and outside India

PRODUCTS DETAILS: Products by SAIL can be segregated into different categories-

(1) Long Products

(i) Crane Rails

(ii) Z-Section Center Sill

(iii) Z-Type Sheet- Piling Section

(iv) MS Arch

(v) Bars, Rods & rebars: SAIL TMT

(vi) Wire Rods

(2) Flats Products

(i) Hr Coils ,Sheets & Skelp

(ii) CR Coils & Sheets

(iii) Plates GP Sheets Coils, GC Sheets: Sail Jyoti

(iv) Tin Plates

(v) Electrical Steels

(3) Pipes

(4) Railway Products

(i) Rails

(ii) Wheels, Axles & wheel Sets

(5) Semis: Blooms, Billets, Slabs

(6) Pig Iron

CONCLUSION:

The opportunity of getting vocational training at such a famous and prestige

organization is an opportunity of lifetime. The training at RSP was very helpful. It

has improved my theoretical concepts of air separation process, mass transfer

operations like absorption, mechanical operations like crushing and sieving. It also

let me to watch and understand machines working on the principles I use to study in

my course. It helped me in understanding that despite of technology advancement

and modern machinery, proper co-ordination between employees and their

experiences is the key to a proper functioning and growing plant.

From doing the project we have got a great experience of real situation of an

organization. It helped to know about Indian steel industries and Rourkela’s Steel

Plant’s process of operation and its technical department operations. That is very

similar to our theory but very complicated and sensitive in practical part. Through

this project I came to know about the strength, weakness, opportunities, and threats

of the steel Industries, and the future expansion of company

I had a chance to see the blast furnace and steel melting shop where the main

working of steel plant is being done and also I saw the working of various shops of

the plant, which was very interesting. So the training was more than expected to me

and helped me to understand about the purpose of employing a chemical engineer in

steel plant more. The most important thing for this organization is individual’s

safety, not only for its employ but for every individual related to this organization

any way.

RSP promises a glowing future for itself and the country’s development in order to

harness the benefit and standard of living of the people of the state and the country.