Training Report on Bsp

8/10/2019 Training Report on Bsp

1/14

TRAINING REPORT ON

BHILAI STEEL PLANT

DURATION26.05.2014 - 07.06.2014

REPORT SUBMITTED BY: -

KUNAL SINGH (12119037)

INSTITUTION:- NATIONAL INSTITUTE OF TECHNOLOGY RAIPUR

DEPARTMENT OF MECHANICAL ENGINEERING


2/14

A Brief Introduction To Bhilai Steel Plant

Bhilai Steel Plant, a unit of Steel Authority of India Ltd. is a

public sector undertaking and was conceived under Indo-USSRTreaty in the 2nd Five year plan. This was in accordance with

erstwhile government policy for strengthening economy and self

reliance through development of core sector. The plant is located

at the central position of India, which is one of the major iron belt

of India, and it is about 40 kilometer from Raipur, capital of

Chattisgarh. The captive mines of the plant located at Dalli-

Rajahara supplies iron ore and lime stone used to be availablefrom Nandini captive mines. At present lime stone is procured

from outside. The other major raw material, coal is purchased

from outside either through import or from indigenous market.

Bhilai Steel Plant, an integrated steel works, was commissioned

in 1959 with production capacity of 1.0 million tonne of steel. Insuccessive phases, capacity was enhanced to 2.5 and 4.0 million

tonne in the year 1962 and 1984 respectively. Figure depicts

facilities available with Bhilai Steel Plant for 4.0 mt production.

As of now this is the largest steel plant in India with present

capacity utilisation more than 100% for three consecutive years.

Bhilai Steel Plant, an integrated steel works, was commissioned

in 1959 with production capacity of 1.0 million tonne of steel. In

successive phases, capacity was enhanced to 2.5 and 4.0 million

tonne in the year 1962 and 1984 respectively. Figure depicts

facilities available with Bhilai Steel Plant for 4.0 mt production.

As of now this is the largest steel plant in India with present

capacity utilisation more than 100% for three consecutive years.


3/14

Bhilai Steel Plant - Major Landmarks

Signing of Agreement for setting up of the plant Feb. 02, 1955

Commencement of work at site May 06, 1956

Commissioning of Coke Oven Battery # 1 Jan. 31, 1959

Commissioning of Blast Furnace # 1 Feb. 04, 1959

Commissioning of Power & Blowing Station Jun. 04, 1959

Commissioning of Steel Melting Shop O.H. Fce # 1 Oct. 11, 1959

Commissioning of Blooming Mill 1150 stand Nov. 12, 1959

Commissioning of Billet Mill Dec. 24, 1959

Commissioning of Rail & Structural Mill Oct.27, 1960

Commissioning of Sintering Plant # 1 Jul. 03, 1961

Commissioning of Merchant Mill Feb. 02, 1961

Commissioning of Wire Rod Mill Sep. 01, 1967

Commissioning of Sintering Plant #2 Aug. 01, 1979

Commissioning of Plate Mill Mar. 31, 1983

Commissioning of Converter #1 Jul. 29, 1984

Commissioning of Continuous Casting Shop M/C #1 Mar. 15, 1986

Commissioning of First Twin Hearth (at SMS-1) Sep. 12, 1986

Commissioning of Blast Furnace #7 Aug. 30, 1987

Commissioning of Coke Oven Battery Mar. 31, 1988

Commissioning of Second Twin Hearth Jan. 01, 1990

Commissioning of VAD unit at SMS-2 Jan. 17, 1991

Commissioning of Third Twin Hearth Jun 29, 1992


4/14

Commissioning of Fourth Twin Hearth Jan 21, 1998

Commissioning of Ladle Furnace at SMS-2 Dec 23, 1999

Commissioning of RH Degasser Unit at SMS-2 Mar. 30, 2000

Commissioning of Sintering Plant # 3 Dec. 12, 2001

Only Steel Plant in India to cross 5 MT Mar 31, 2006

Curde Steel Production in the financial year.

Bhilai's expansion & modernisation to 7.5 MT Feb. 09, 2008

capacity inaugurated

Bhilai repeats 5 MT + performance Mar. 31, 2008


5/14

BSP FLOW PROCESS


6/14

PLANT OVERVIEW

No. Department Unit Capacity

Coke Oven 8 Batteries of 65 ovens and 4.3

M high

2 Batteries of 67 ovens and 7.0 M

high

3.3 million ton

of BF Coke

BLAST

FURNACE

3 Furnaces of 1033 Cum

3 Furnaces of 1719 Cum1 Furnace of 2000 Cum

4.71 mt of hot

metal

SMS-1 4 Twin Hearth Furnaces 2.5 mt of steel

SMS-2 3 BOF of 100/130 T capacity 1.425 mt of steel

CONCAST 1000/700/500 mm Cont. Billet

Mill

1.425 mt of steel

BBM 3 BOF of 100/130 T capacity

1000/700/500 mm Cont. Billet

Mill

2.15 mt of bloom

RAIL ANDSTRUCTURAL

MILL

950/800 2 high reverseing Mill .75 mt of product

WIRE ROD

MILL

4 strand continious Mill .4 mt of product

MERCHANT

MILL

350 mm Cross Country Mill .5 mt of product


7/14

0 SINTERED

PLANT

1) 4 Machine of 50 Sq M hearth

area

2) 3 machine of 75 Sq M and 1

Machine and 1 Machine of 80 Sq

M hearth area3) 1 Machine of 320 Sq M hearth

area

8.3 mt of sinter


8/14

BLAST FURNACES

What is a Blast Furnace? BF is a counter current heat and mass

exchanger, inwhich solid raw materials are charged from the

top of the furnace and hot blast is sent through the bottom via

tuyeres. The heat is transferred from the gas to theburden and

oxygen from the burden to the gas. Gas ascends up the furnace

while burden and coke descend down through the furnace. The

counter current nature of the reactions makes the overall

process an extremely efficient one.

In the blast furnace process iron ore and reducingagents (coke, coal) are transformed to hot metal, and slag is

formed from the gangue of the ore burden and the ash of coke

and coal. Hot metal and liquid slag do not mix and remain

separate from each other with the slag floating on top of the

denser iron. The iron can then be separated from the slag in the

cast house. The other product from the Blast Furnace is dust

laden blast furnace gas, which is further cleaned in the gas

cleaning plant and is used as a fuel all over the plant.

Blast Furnace constructional features:

A blast furnace has a typical conical shape. The sections from top down are:

> Throat, where the burden surface is.

> The shaft or stack, where the ores are heated and reduction starts.

> The bosh parallel or belly and

> The bosh, where the reduction is completed and the ores are melted down. The

hearth, where the molten material is collected and is cast via the tap hole


9/14

MACHINING ASSEMBLY & RE-ENGINEERING SERVICES-1

( MARS-1).

MARS-1 has a vital role to play in maintaining the plant equipment so

for as it supplies the bulk of spare parts required by the various units. It

acquires an added significance by virtue of the finishing line of

manufacturing activities of engineering shop . The product mix so

arranged so as to meet the demand of both heavy and small spares. The

shop is housed in three machining bays, 21 meters x182 meters each

with an assembly bay of 24 meters x 96 meters .A total of 196 machine

tools are engaged in direct production of spares, whereas the

remaining contribute indi- rectly towards shop production. Apart from

these, there are 12 Heat Treatment / Heating furnaces 22 material

handling equipment (cranes,jib cranes transfer cars). The Annual

production plan for MARS-1 during 2007-2008 is 6,40,000 credit

hours.

MAIN ACTIVITIES:-

Function wise MARS-1 carries out the following activities:

1. Manufacture of spares, changables, tools, tackles etc. Required for

maintenance and operation of various departments.

2. Overhauling and repair of equipment sub - assemblies to the extent

of those that can be transported to MARS-1.

3. Reclamation of worn-out spares .

4. Repair of certain equipment at site-especially where machining atsite is required.

5. Manufacturing and modification of equipment / spares for

development work from the point of view of import substitution,cost

reduction ,etc.


10/14

BLOOMING & BILLET MILL

Blooming & Billet Mill popularly known as "Mother Mill", is a

primary mill designed to roll 2.5 MT/ Annum of ingots into semies in

the form of blooms & billets. A two high reversing blooming mill and

12 stands continuous billet mill are part of this department. The

1150mm two high reversing Blooming Mill is designed to roll steel

ingots into blooms for Continuous Billet Mill and Rail & Structural

Mill. Average weight of steel ingots which are used for rolling is 8 to 9

Ton.

BLOOMING MILL

The heated ingot are placed on the ingot buggy (two ingots at a time)by means of tongs crane which delivers it on to the receiving roller

table of Blooming Mill.The Blooming Mill is a 2-High horizontal

stand, equipped with individually driven rolls. Each roll of the

Blooming Mill is driven by 930 V, 8000 KW, 0-20-80 rpm motor.

Length of Roll - 2800 mm

Dia. of Roll - 1150 mm (Min.1100mm & Max.1180mm)

The Mill can roll square and rectangular blooms and also narrow width

slab. Common Sizes of Blooms and Narrow Width Slabs

i) 320 x 320 mm

ii) 265 x 340 mm

iii) 260 x 300 mm

iv) Shaped blooms for Beam-450mm & Beam-600mm

v) Narrow Width Slab 200 x 320 mm

vi) Narrow Width Slab 200 x 420 mm


11/14

BILLET MILL

The Billet Mill has been designed to roll billets from blooms of cross

section 325x325 sq.mm in 6 to 12 passes depending on cross section of

billets to be produced in the Mill. The capacity of the Mill was

designed to roll 15,01,000 Tonns/Year. But with modified output sizeof billets the mill is now capable of rolling to million tones per year.

The Mill consists of 12 working stands arranged in three groups.

a. The First group contains Two 2-High Horizontal stands with a 90

deg. tilter in between. These stands are equipped with rolls of diameter

1000mm and length 1200mm.

b. The Second group called the roughing group contains 4 stand - 2

each of Horizontal and Vertical stands arranged alternately. These

stands are equipped with rolls of diameter 700mm.

c. The Third group called the finishing group located after the transfer

table contains 6 stands - 3 horizontal and 3 vertical stands arranged

alternately. These stands are equipped with rolls of diameter 500mm.

SECTION OF BILLETS ROLLED ARE

1. 150 x 150 mm 2. 110 x 110 mm

3. 105 x 105 mm 4. 100 x 100 mm

5. 90 x 90 mm


12/14

WIRE ROD MILL

The 4 strand 250mm continuous Wire Rod Mill, commissioned on

September 1 1967, was designed to roll 6, 7, 8, 10mm diameter wire

rods from square billets of 80mm x 80mm cross section (of length 11

to 11.8 meters) with rated capacity of 4,00,000 T per annum. The billet

size was further enhanced to 85 mm2, 90 mm2, 100 mm2, 105 mm2 to

improve in coil weight from 540 Kgs. to 930 Kgs. After the revamping

of Right Side, sections 5.5 - 12 mm dia. wire rods are rolled in B ,

C&D strands, whereas 8mm & 10mm are rolled on left side (A strand).

BRIEF DESCRIPTION OF THE MILL

Inspected billets are fed on the charging grate of the furnace bymagnetic finger cranes. The billets are fed one by one to the furnace,

through roll table and draw-in- roller mechanism. Billets are moved

into the furnace by means of pushers at the charging end. Soaked

billets are ejected out by means of Ejector Ram from the discharging

end.

The reheating furnace of the size 18Mx 12M is having 28

burners, which includes 14 in the heating zone and 14 in the soaking

zone. Mixed (Coke Oven & Blast Furnace) gas with calorific value of

1800 K Cal/Cum is used in the furnace as fuel. Capacity of the furnace

is 120T/Hr. Gas and air is preheated to 250c and 450c in metallic and

ceramic recuperators respectively.

The roughing group consists of nine horizontal stands in

which combined drive is provided for stands 2-3 and 4-5; whereasstands 1, 6, 7, 8 and 9 are individually driven. All the drives are

controlled by thyristor converter.

Flying Shear is provided after stand no. 9 for front-end cutting

& cobble cutting. First intermediate group has 6 horizontal stands, out

of which stand No. 12 & 13 are not being used. Stand No. 10 & 11/14

& 15 are used for rolling on all the strands. After stand No. 15, the Mill

is divided in four strands, old line (A) and Modernised line (B,C&D).


13/14


14/14

Date post:	02-Jun-2018
Category:	Documents
Upload:	sanchay3090
View:	226 times
Download:	0 times

Training Report on Bsp

Documents