BY-

PRABHAV MITTAL (1171110156)

JINDAL STEEL AND POWER ,ANGUL This plant was built few years back. The company have invested US $ 6 billion (36,200 crores

INR) in the state of Odisha for steel production and power generation.

The proposed steel plant to be set up in Odisha will produce 12.5 MTPA (million metric tonnes per annum) steel and generate 2600 MW of power in phases.

In the first phase, the company is setting up a 6 MTPA integrated steel plant at Angul.

A 2.5 MTPA steel melting shop (SMS) has been commissioned.

The project is in a fast-track mode, with the 1.5 MTPA plate mill and an 810 MW captive power plant already commissioned.

The plate mill is capable of producing 5 meter wide plates, making it the widest to be ever produced in the country.

The major facilities at the plant include:

Coal washery

Sinter plant

Pellet plant

Coke oven and by-product plant

Coal gasification plant

DRI plant and blast furnace

Steel melting shop

Slab caster

Plate mill Oxygen plant

Lime and dolomite plant

Power plant

Technology The DRI-BF-EAF route technology would be adopted for

steel production.  The DRI (Direct reduced iron) plant has a unique feature

of using syn gas from the coal gasification plants as reductant.

It is being used for the first time in the world and has the advantage of using high ash coal which is predominantly available in the vicinity of the project site.

The company has signed an agreement with Lurgi Technology Company- South Africa, for providing technology for coal gasification.

DRI (Direct reduced coal) plant

Direct-reduced iron (DRI), also called sponge iron.

It is produced from direct reduction of iron ore (in the form of lumps, pellets or fines) by a reducing gas produced from natural gas or coal.

The reducing gas is a mixture, the majority of which is hydrogen (H2) and carbon monoxide (CO) which act as reducing agents.

This process of reducing the iron ore in solid form by reducing gases is called direct reduction.

Advantages- Economical

Higher grade of steel

Energy efficient

Steel melting shop (SMS) Steel is made in steel melting shop in the refractory lined vessels

called LD Converters by blowing oxygen through the hot metal bath.

While iron making is a reduction process, steel making is an oxidation process.

The oxygen reacts with the carbon in the hot metal and this reaction releases large quantities of gas rich in carbon monoxide along with huge amount of dust.

The gases released from the converter are collected, cooled, cleaned and recovered for use as fuel in the steel plant.

The entire molten steel is continuously cast at the radial type continuous casting machines resulting in significant energy conservation and better quality steel.

Steel manufacturing process:-

Untreated ore cannot be used to make steel as it reduces the quality of the metal.

Therefore, the raw iron ore is processed at the DRI plant (or processed iron ore) plant.

The coal used in the plant is cleansed of impurities in coke ovens.

Conveyor belts carry metallics — pellets and sinters — The the heart of the steel plant, the blast furnace.

The blast furnace is a six-storey tall reactor where heating of dark iron ore into glowing hot liquid iron takes place.

The ore is charged into the blast furnace along with fluxes and limestone.

Temperatures in the blast furnace reach up to 1,500*C and the resulting metallurgical reaction converts iron oxide into molten iron.

The blast furnace works round the clock.

Liquid steel being tapped into a ladle car

The red hot liquid metal produced in the blast furnace is collected in the hearth and ‘tapped’ on a near continuous basis through day and night.

The process is called casting.

Molten iron being poured into the furnace

Hot metal or molten iron from the blast furnace is transferred into vessels called torpedoes and transported on rail tracks to the LD, or Linz Donawitz.

Here the molten iron is refined into steel using the ‘basic oxygen furnace’ method.

At the LD shop the process begins with charging scrap into the furnace, where temperatures reach 1,700°C.

Large ladles, capable of holding 170 tonnes of liquid metal, pour the molten iron into the furnace.

A water-cooled lance is lowered into the furnace to blow in pure oxygen.

Furnace (Bottom view)

THERMISTORS ARE USED TO MEASURE THE TEMPERATURE

Iron ore (as coolant) and burnt lime and raw dolomite (as flux) are added from the top.

The oxygen removes carbon, silicon , sulphur and phosphorus content from molten iron and converts it to steel, an alloy that is tougher than iron.

One ‘heat’ (a cycle of steelmaking) takes 45-50nminutes and produces an average of 250 tonnes of molten steel.

This steel goes through further refining, depending on requirement, at the online purging station, ladle furnace station or RH degasser.

Ladles with a holding capacity of 160 tonnes carry the liquid steel to the continuous caster machines.

Here the liquid steel finally takes solid form and is shaped into what are called long products or flat products.

The continuous slab caster,

from which emerge flat-steel products.

PLATE MILL

CONVEYORS GREASE SYSTEM

ROLLERS CRANE

SENSORS

PROXIMITY SENSOR TEMPERATURE DETECTING SENSOR

Environment Protection Measures

The company is very much concerned about the impact on environment and has therefore taken adequate measures and adopted the best pollution control norms available in the world.

One of the major steps taken towards protecting the environment and reducing soil degradation is the usage of fly ash bricks in place of conventionally used red bricks in all construction activities at the project sites.