Durgapur Steel Plant

Operation Department Manual

Contents:

1. Steel Authority of India Limited

2. Brief Description of Durgapur Steel Plant

3. Durgapur Steel Plant

4. Process Flow Chart of DSP

5. Coke Ovens and Coal Chemicals

6. Row Materials Handling Plant

7. Sinter Plant

8. Blast Furnace

9. SMS Complex

10. Blooming and Billet Mill

11. Section Mill

12. Skelp Mill

13. Merchant Mill

14. Wheel and Axle Plant

Steel Authority of India Limited
Hindustan Steel Limited (HSL) was set up on 19th January 1954 for managing a steel plant that was coming up at Rourkela
in Orissa. Thereafter other three integrated steel plants came under HCL. Steel Authority of India Limited (SAIL) was
formed on 24th January 1973 as a holding company for the plants replacing HSL.
SAIL is now (2003) India’s largest and the world’s 15th largest steel producer with an annual turnover of over Rs. 19000
cores. It has five integrated steel plants at Durgapur, Bhilai, Rourkela, Bokaro and Burnpur, with a total production
capacity of more than 12.4 million tonnes of crude steel per annum. In addition, there are three steel plants at Salem,
Durgapur and Bhadravati, which produce special steels and alloy steels and a plant at Chandrapur producing ferro-alloys.

Rourkela Steel Plant:Sutuated in Orissa this plant was set up with a 1 million tonne per annum ingot capacity with
German assistance. Pig iron production began in the plant on 3rd February 1959. The capacity was later expended to 1.8
million tonne per annum. This was the first plant in Asia to introduce Basic Oxygen Furnace (BOF) process at a time when
this process was yet to receive recognition from the established steel producers at home and abroad. The plant produces
a wide range of flat steel products like hot and clod rolled sheets, strips and narrow plates, galvanized plain and
corrugated sheets, electrical steel sheets, tin plates and large diameters ERW and SW pipes.
After modernization in early 90s the capacity of the plants is 2 million tons of hot metal per annum, 1.9 million tonne of
liquid steel and 1.671 million tonnes of salable steel. New units for producing Cold Rolled Grain Oriented (CRGO) and Cold
Rolled Grain Not-Oriented (CRGNO) electrical sheets have come up.

Bhilai Steel Plant: This plant come up with Russian assistance in the state of Chhatisgarh. Commissioning of Blast Furnace
was done on 4th February 1959. Present capacity of the plant is 4 million tonne per annum. This plants (mainly for long
products) has huge Rail and Structural Mill, one of the biggest of its type in the world producing heavy rails to Indian and
International specification. This plant also has Wire & Rod Mill, Heavy Plates are also produced here. The plant was the
first in India to produce 3600 mm wide heavy plates. The Plate Mill, DalliMechanised Mines and Rail Mill of the plant have
ISO 14001 certification for the environment management system. All salable products of the plant have ISO certified.

Durgapur Steel Plant: This plant was built up with British assistance in West Bengal. The Plant started iron production on
26th December 1959. The plant produces Wheel and Axles mainly for Indian Railways. The other products being Light and
Medium Sections, Merchant products, Shleps, Blooms and Billets. The present capacity of the plant is 2 million tonne of
hot metal per annum. All the production units of the plant are covered by ISO 9001:2000 certification.

Bokaro Steel Plant: Situated in the coal belt of Jharkhand, this plant also was set up with Russian collaboration.
Commissioning of the first Blast Furnace was done on 2nd October 1972. Present capacity of the plant is 4 million tonne
per annum. This plant is mainly for the flat products like hot and cold rolled sheets and coils, Slit coils and galvanized
sheets. The special features of the plant is its Universal Slabbing Mill and 2000 mm continuous Hot Strip Mill, one of the
fastest of its type in the world. Some of the special steel products of the plant are SAILCOR, SAILMEDS, SAILRIM, HRNO,
SAILMA, WTCP, BSL-46 etc.

Durgapur Steel Plant

This is the third integrated Steel Plant of the then Hindustan Steel Limited to come up under public sector in India. The
first two being Rourkela Steel Plant and Bhilai Steel Plant in that order, Durgapur as location was selected because of its
proximity to coal fields, the Grand Trunk Road, Calcutta Delhi main railway track, Calcutta Port, Power from DVC
(Damodar Valley Corporation) and water from Durgapur Barrage on river Damodar.

The plant, covering an area by a group of British Companies in late fifties, With an investment of Rs. 189.6 Crores
including Rs. 17.36 Crores for township development. The plant operated almost at the rated capacity during the years
1963, 1964-65 and 1965-66. The capacity was expanded to 1.6 MTPA in late sixties with an additional investment of Rs.
67.83 Crores out of which Rs. 6.31 crores was paid for the Township.

The performance of the plant after expension was much below the rated capacity which called for setting up of a number
of committees to investigate into and suggest remedial measures. The constraints as identified by almost all the
committees are as follows –
 Deterioration in raw materials quality to a great extent
 Aging of the Plant
 Obsolete technology
 High energy consumption

Later in early eighties, British Steel Corporation (a British firm), MECON(an Indian consultancy firm) and the Japanese Iron
& Steel Federation were entrusted with the job of making a developmental plan for DSP after studing the problems of the
Plant in detail.
Based on their findings SAIL decided to modernize DSP with a final Government approved definitive cost of RS. 2668
crores in 1989, which later escalated to more than 4500 crores. After modernization the present capacity of the plant is
2MTPA of hot metal.
 Process Flow chart of D.S.P

LS, Dolo, Iron ore,

Ferro Mn, Ferro Si,
Silico Mn
Raw Material Coal Handling
Handling Plant Plant

LS Iron Sinter Mix

Ore GAS
Coke Coal
Lump Sinter Plant Clean Gas
Oven Chemicals
NLCP Oven Benzene
Toluene
Sinter
LSN
FeSi Napthalene
Coke
FeMn Lime Creosote Oil
Blast Furnace Crude Tar
Dolo Slag Granulated
SGP Slag AS
I/Ore Hot Metal Light Oil
Lump Return &
Scrap Pig Iron
Scrap Yard Process PCM
Scrap
Steel Melting Shop (BOF) O2,Ar, N2 O2& N2 for sale
Oxygen
Plant
Liquid Steel

Wheel
Teeming Stage Special Casting Bay
Ingots
CCP

CC Billets
and Blooms Wheels & Axles for
Wheel & Axle Railway Carriages
For
Plant Legend:
Sale
AS – Ammonium Sulphate
BOF – Basic Oxygen Furnace
CC – Continuous Cast
CCP – Continuous Casting Plant
Dolo – Dolomite
I/Ore – Iron Ore
LS – Lime Stone
LNS – Light Solvent Naptha
NLCP – New Lime Calcination
Merchant Mill MSM Section Mill
Plant
PCM – Pig Casting Machine
SGP – Slag Granulation Plant
Plain Rounds & Ribbed Angles, Channels, Joists Angles, Channels, Joists TMT – Thermo Mechanically
Rounds (TMT Bars) Treated
Coke Ovens & Coal Chemicals

Introduction: Coke Oven is an important department in an integrated steel plant. In this department, coal is carbonized
into coke which is an essential raw material for the production of hot metal in Blast Furnaces.
While carbonizing coal into coke, a number of valuable coal chemicals are obtained. These coal chemicals are also
recovered and processed in this department.
Major sections of this department are:
1. Coal Handling
2. Coke Oven Battery, Heating and Coke Handling
3. Coal Chemicals

Coal Chemicals Plant has following sections:

 Gas Condensation Section
 Benzol Rectification Plant
 Tar Distillation Plant
 Ammonium Sulphate Plant
 BOD Plant
 MNCP (Mechanised Naphthalene Crystallisation Plant
 Benzol Absorption
 Naphthalene Absorption

Benzene
Toluene
Coal Coke Ovens Coal Chemicals LSN
Handling Light Oil
Plant Naphthalene
Creosote Oil
Crude Tar
Amm. Sulphate
B.F. Coke (+20 -80 mm)
Coke Handling Nut Coke (+10 -20 mm)
Plant Coke Breeze (0 -10 mm)

Flow Chart of Coke Ovens

Coal Handling Plant:

The Coal Handling Plant’s aim is to supply coal of required quality and quantity to Service Bunkers for BF coke making. In
Coal Handling Plant (CHP), washed coal and imported coal are received in coal wagons (BOX-N and BOX-C type) and are
unloaded by means of a machine called Box Tippler. Then the tippled coal is conveyed and tracked in Beds/ Silos as per
their quality and grade. Coal of different quality are down from Blending Silos as per-determined blending ratios and
selectively crushed and blended in the Selective Crushing Unit (SCU). Thus Blended quality coal is sent to Service Bunkers
for BF coke making.
Coal handling plant has three major sections. These are 1. Tippling Section 2. Reclaiming Section and 3 Selective
Crushing Section. Brief description of these section are given bellow:

1. Tippling Section:

Major equipments:
Box tipplers - 3 nos
Wing Trippers - 6 nos
Stacking Beds - 12 nos
Conveyors - 10 km long (approx.)

IN CHP Prime Coking Coal (PCC) and Medium Coking Coal (MCC) are received as indigenous coal form different
washery e.g.
Patherdih - PCC
Bhojudih - PCC
Munidih - PCC
Dugdha - PCC
Mahuda - PCC
Swang - MCC
Rajarappa - MCC
Kedla - MCC
Kathara - MCC

Important coal from Australia and New Zealand is also received here. All types of PCC, MCC, Imported (New
Zealand) and Imported (Soft) are sent to stacking Beds as per stacking plan and availability and Imported (Hard) is
normally sent to earmarked Blending Silos. Layer by layer stacking in bed is done by means of Wing Tripplers.
During stacking in beds special care is taken so that best possible average coal blend is prepared; otherwise coke
quality will suffer.

2. Reclaiming Section:

Major equipments in this section are:

Old Reclaimers - 4 nos
New Reclaimers - 3 nos
Blending silos - 14 nos
New Blending Silos - 15 nos.
Conveyors - 12 km long (approx.)

3. Selective Crushing Unit (SCU):

Major equipments of this section are:

Blending Silos - 14 nos
Primary Crusher - 4 nos
Secondary Crusher - 2 nos
Pneumatic Classifiers - 4 nos
Conveyors - 12 km long (approx.)
 Bradford
-3 Inch Coal Washery
Breaker for
Crushing

Raw Coal -125 mm size

Wagon Tipplers Wing Bed Reclaimer
(Total 3 nos.) Tripper (12 nos) (7 Nos)
Washed Coal (-25 mm) (6 Nos)

Blending Silos
(14 Nos)
Cap.: 1200 T/TSilo

SRU

Primary Crusher
(4 Nos)

Service Bunkers
No of Bunkers : 4 Pneumatic Classifier
Cap: 4000 T each (4 Nos)

Secondary Crusher
(4 Nos)
Coal for BF Coke
making

SCU – Selective Crushing Unit

To Battery

Coal Handling Plant (Schematic)

Coal of different quality is down from different earmarked silos as per pre-determined blending ratios to get desired coal
ash and other petrographic properties. This coal is then selectively crushed in Primary Crusher to avoid over crushing of
softer part of the coal charged and then classified in the Pneumatic Classifiers as per coal particles’ size and density.
During classification of crushed coal harder and bigger part of the coal is separated and dragged to Secondary Crusher for
further crushing and the final product directly goes to Service Bunkers. Output of the Secondary Crusher is recycled to the
conveyer where the Crusher’s output is sent for classification. Quality of coal which is coming out from classifiers as final
product should meet the following targets:

+ ½ inch = nil
+ ¼ inch = 3% max
+ 1/8 inch = 10 – 14.5%
+ 36 mesh = > 70%
+ 60 mesh = > 80%
Ash = 14.5 + 0.5%
Moisture = 8%

Coal Washery
Raw coal is washed to reduce its ash content before using it for blend preparation. Raw coal received in CHP is sent to
washery after sizing it to -75 mm. According to its size fraction this coal is beneficiated through three different
procedures.Size fraction ranging -75 mm to + 0.5 mm is washed, fraction below -0.5 mm is recovered through thickener
and filter and mixed with washed coal. Different size fraction, types of corresponding washers and their capacities are
given bellow:

Size fraction Washer Capacity

75 mm to 20 mm Heavy Media Bath 120 T / Hr.
20 mm to 1.4 mm BATAC Jig 143 T / Hr.
1.4 mm to 0.5 mm Spiral Washer 23 T / Hr.
< 0.5 mm Thickener & Filter 14 T / Hr.

The capacity of the washery is 300 T / Hr., 0.9 mt per year.

Heavy Media Bath

Magnetite ore slurry (Partical size 300 mesh) is used as heavy media. Specific gravity id kept in between 1.32 to 1.42
depending upon types of coal. Stipulated consumption of magnetite is 0.65 kg / ton of raw coal.
When coal is subjected to this media coal having lower specific gravity floats and is collected as clean coal and is used for
coke making. The coal, which sinks is collected as middling and is used in power plants for steam raising purpose.

BATAC Jig
It is a electronically controlled pneumatic Jig, Where coal is subjected to periodic pneumatic pulse. It leads to
stratification of coal bed where heavier coal particles settle in bottom layer and lighter particles at the top. The bed can
be divided according to bed height. Hence clean coal is separated from middlings.
Spiral Washer
Slurry containing 1.4 mm to 0.5 mm coal is allowed to fall through a spiral down comer tray suitably inclined towards the
center of the spiral. Adjustable cutting knife divides the slurry into two streams, one stream containing tray peripheral
flow, and other contains tray center flow. While former contains clean coal the letter middlings

Thickener and Filter

Slurry containing less than 0.5 mm size of coal is thickened in a thickener. Solids form thickened slurry is recovered and
mixed with clean coal. There is provision for dosing of flocculation agent.

Coke Oven Battery

There are 6 batteries of 78 ovens each. Of these only 4 batteries are operational ( No. 1, 2, 5 and 6). Battery No.4 is sold
off. COB#3 is in Cold repair. Thus now there are a total of 312 ovens in the four batteries. Each oven has a capacity of
16.6 tonnes on dry basis (23.8 m3 of dry coal). The minimum coking time is 18 hours. Working coking time is 19.5 to 20
hours. The flue temperature is 1230°C. Oven height is 4.45m, length is 13.59m and average width is 450 mm. Coke of size
range +20 to -80 mm is sent to Blast Furnace. The undersize coke is further screened to different sizes as Nut Coke (+10
mm to -20 mm) and Coke Breeze (-10 mm) which is sent to RMHP.

Coal is charged into the oven and is heated in absence of air to produce coke. All the volatile material is removed from
the coal as raw gas and the mass which is left behind is coke. When coke formation is complete, it is pushed out of the
oven and quenched with water.
There are four special cars. One takes coal from the service bunkers and charge in individual ovens is called Changing Car,
The second one pushes the coke out of individual oven is known as Ram/Pusher Car, the third one guides the coke during
pushing operation is known as Guide Car and the fourth one which receives the hot coke for quenching is called Hot Coke
Car, which is driven by Electric Loco. Coal tower capacity is 4000 tonnes.
Normal working pushing potential for all batteries is 96 ovens/day.

The quality parameters of the cleaned coal are:

Blend coal ash (average) 11.2±0.5%

Ash in BF Coke 15±0.5%
Fineness of crushing 82% max.(-1/8”)
Coal Blend
Prime 15%
Medium 5%
Imported 80%

Coal Chemicals Plant

The gas evolved during the carbonisation of coal contains various chemicals, and for the economy of the carbonization
process and also for using this gas as fuel, the recovery of these chemicals from the gas is essential. The by-product plant
recovers the chemicals from the gas and allows the clean gas to be used in coke ovens and other plants as fuel.
There are four gas streams in operation, each has a capacity of 33000 m3 / Hr. So coal chemicals section can handle
4X33000 = 132000 m3 of gas per hour.
Hot gas coming out of the oven through Ascension Pipe is cooled in the Gooseneck by direct contact with the spray od dilute
ammoniacal liquor called flashing liquor to a temperature of about 80°C. Most of the tar is condensed from the gas and is collected in
the Hydraulic Mains. Flashing liquor pressure is kept at 4.8 kg/cm2 and flow rate at 250 m3/hr.

From the Hydraulic Mains both gas and liquid phase reach the Down comer where both phases become separated from each other.
Liquid phase enters into Decanter where liquor and tar gets separated. Liquor is pumped to battery again (for cooling the gas) and tar
is pumped to Tar Tank. Gas phase enters into Primary Cooler where it is cooled to 35 - 40°C. There are 12 Primary Coolers in 1.0 mt
side and 11 in expansion side.

Gas from the battery is sucked into Coal Chemicals plant by means of Exhauster. There are 3 Exhausters in each side. It maintains 130
mm Wg of suction before exhauster (for 78 ovens battery). Exhausters suck gas from battery through Hydraulic Main and Primary
Cooler and force it through Detarrer, Ammonia Absorber and Benzol Plant. Back pressure on Exhauster is not allowed to exceed 1100
mm of water column.

In the Detarrer the gas is subjected to the action of a high voltage electrical field. The gas passing through the field is ionized and the
charged tar particles collect on the surface of the grounded positive electrode. Detarrer removes more than 99% of the tar mist from
the gas. Allowable tar mist in the cleaned Coke Oven gas is less than 0.003 gm/Nm 3. There are 8 Detarrers in 1.0 mt side and 6 in the
expansion side.

From Detarrer the gas is delivered to Ammonia Absorbers. Ammonia generated from steam stripping of Ammoniacal liquor (after
caustic dosing) is mixed with the gas. The ammonia present in the gas is absorbed by spraying dilute sulphuric acid (0.8 – 1.5%) in low
acid zone and 8-10% in high acid zone). Ammonium Sulphate liquor thus generated is evaporated in calendria type evaporator;
thereafter salt is generated through Centrifuge. There are 4 Evaporators and Centrifuge. Capacity of ammonium sulphate production
is 100 T/day. Ammonia in the cleaned Coke Oven gas should not exceed 0.05 gm/m 3.

The gas leaving the Absorber at 45°C is cooled to 35-40°C in secondary Cooler cum Primary Napthalene Washer. Here a portion of the
naphthalene is removed from the gas by Wash Oil. Further naphthalene is removed from the gas by wash oil in Secondary
Naphthalene Washer. The naphthalene rich oil is system stripped in the Stripper Column. The separated naphthalene oil is mixed with
tar. The stripped lean wash oil is used again. Allowable naphthalene content in Coke Oven gas is 0.04 gm/m 3.

After removal of naphthalene the gas is further cooled to 20°C by spraying chilled water (10°C), wash oil is also cooled through spiral
plate type or shell & tube heat exchangers to 20°C. Coolent used is chilled water (10°C) The cold gas is scrubbed by cold wash oil in
Benzol Scrubber to absorb Benzol in wash oil.

The gas coming out of the Benzol Plant is clean and usable as fual. Debenzolised wash oil is used again. Wash oil consumption is ̴ 48
L.KL of crude Benzol.

Benzol Plant:
The benzolised washed oil is stripped in the column by stream and crude Benzol is collected. This crude Benzol is washed with caustic
soda and sulphuric acid in CAW (Continuous Acid Washer) plant. The washed Benzol is then fractionated in the rectification unit to
get pure products e.g. Benzene, Toluene, Heavy and Light Solvent Naphtha (LSN).

Tar Distillation:
The crude tar, which is separated earlier is distilled to get the following products:
Light Oil, Naphthalene Oil, Heavy Creosote Oil, CTPD (Crude Tar Partially Distilled).
Capacity of one unit is 125 T/Day. There are two units.
 Ammonia Gas from Ammonia Still Sulphuric Acid

Raw Gas with Tar &

Ammoniacal Liquor Ammonium Evaporator
Gas Gas Ammonia Ammonium
from Battery Down Gas Gas
Primary Exhauster Detarrer Recovery Cum
comer Sulphate Crystallizer Sulphate
Cooler Unit Soln.
Tar & Ammoniacal Tar
Tar Tar
Liquor Gas
Naphthalene
Liquor to Battery
Decanter Wash Oil rich Oil
Secondary Naphthalene
Water Cooler Stripping Unit
Excess Liquor
Gas Naphthalene Oil
Tar Storage Tank
Storage
Wash Oil Final Gas Tar Storage Tank
Tank
Chilled Water Cooler
Light Oil
Excess Liquor Tar
Plant Heavy Creosote Oil Gas
Wash Oil

Ammonia Still Naphthalene Oil

Benzol Clean Coke Oven Gas
Scrubber
Effluent
MNC Naphthelene Flakes Benzolised Oil
BOD Plant P Crude
Benzol
Benzol
CTPD Distillation
Mixer Storage Tank Column

To our Fall # 5

Acid Washing Unit

To Ammunia
Recovery Unit NG Benzene
Benzol
Rectification
IG & NG Toluene
Plant
LSN

Coal Chemicals Plant Flow Chart (Schematic)

MNCP (Mechanised Naphthalene Crystallisation Plant)
Napthalene oil is farther distilled in Primary and Secondary Naphthalene Distillation Column and the top product of secondary
column is processed in Refiner (controlled by a PLC). Flaking of the final product of the rectifier is done in naphthalene flaker which is
subsequently bagged and sold. Capacity if the MNCP is 1000 kg/hr.

BOD Plant
Liquor and waste water of the plant is treated here before it is allowed to pass OutFall No. 5. Here all waste accumulates in
equalization tank and then it is treated with bacteria to destroy different poisons. The effluent norms are given below:
pH :6–9
NH3 : 50 mg/l
Phenol : 1 mg/l
Cyanide : 0.2 mg/l
MLSS : 100 mg/l

Raw Material Handling Plant

Raw Material Handling Plant is the starting point of the steel making process in Durgapur Steel Plant. RMHP is mainly concerned with
the receiving, loading, storing and processing of all the raw materials viz. iron ore lumps and fines, Limestone and Dolomite. The
preparation of sintermix is also done in RMHP using state of the art automation system.
There are three Wagon Tipplers (Tippler No. 3 came up later in 07.01.95) to unload the raw materials brought in rakes of wagons
from various mines. The materials are conveyed by a series of conveyors from the tippler hoppers to different yards viz. Ore yard and
Flux Yard. They are stacked in the yards at the designated beds by Stacker cum Reclaimers (Capacity 900 TPH) from where they are
reclaimed using same Stacker cum Reclaimers to intermediate surge bunkers for further transportation to customer departments like
Blast Furnace, Sinter Plant, SMS etc.

Iron Ore (Lump &

Fines). Limestone,
Ferro Manganese Dolomite
Ferro Silicon
Sillico Manganese Limestone
Raw Material Handling Plant NLCP

Sentermix
All Ferro Items
Dolo & I/O Lump
Sinter Plant SMS

I/ Ore Lump

Blast Furnace

RMHP Flow Diagram (Schematic)

Sintermix Preparation
Blend mix production started on 7.7.95. Installed capacity is 12051 TPD. The raw materials required for preparation of sintermix is
stored in 15 bunkers of Junction House #25. The main constituents of sintermix are:

Iron Ore Fines 0 – 10 mm

Limestone Fines 0 – 3 mm
Dolomite Fines 0 – 3 mm
Coke Fines 0 – 3 mm

All the waste generated in the plant like Ferro Scrap, Mill Scrap, Flue Dust, BOF Slag and Sinter Fines are also added in the sintermix.
These materials are received in wagons and dumpers, offloaded at the track hoppers and conveyed to the sintermix proportationing
bunkers. These materials are used in a ratio based on the final sinter chemistry requirement e.g.

Ore fines 65%

Coke fines 4%
Limestone fines
Dolomite fines 15%
Mill scale
Flue dust 6%
Return Sinter fines 10%

The sinter mix is then sent to Sinter Plant for preparation of Sinter.

Flux Crushing Plant

The crushing plant consists of 6 impact hammer type crushers (3 primary crushers of 200 TPH and 3 secondary crushers of 200 TPH
each) and six screens of capacity 200 TPH. Limestone and dolomite are reclaimed from the flux yard and fed to the crushers via
intermediate surge bunkers to get the required size of -3 mm by closed loop crushing system. There is a hopper for unloading NLCP
Rejects received in dumpers. The same is conveyed to a bunker and is crushed along with limestone. The crushed limestone and
dolomite are then conveyed to the sintermix proportioning bunkers in Junction House # 25.

Coke Crushing Plant

The crushing plant consists of 6 smooth roll crushers (2 primary of 50 TPH each and 4 secondary of 35 TPH each). The coke breeze
offloaded at the track hoppers is reclaimed by two paddle feeders and conveyed to the storage bunkers of crushers. The coke i s
crushed to -3 mm size and conveyed to the sintermix proportioning bunkers in Junction House # 25.

The Iron Ore fines are reclaimed from the Ore yard by Stacker cum reclaimers and conveyed to the sintermix proportioning bunkers.

Based on the analysis of these raw materials the rate at which these materials are to be drawn from the bunkers are fixed. There are
weigh feeders below the bunkers which control the rate of feeding the materials.

All the materials are simultaneously withdrawn from the bunkers at the pre determined rate on a common conveyer and stacked on
the sintermix beds in sintermix yard by slewable stacker of capacity 900 TPH. It is reclaimed from the beds by Blender Reclaimer or
Barrel Reclaimer (900TPH) and conveyed to the Sinter Plant.
Material dispatch to Customer Departments

Blast Furnace
There are two screens of capacity 300 TPH in Ore yard for screening the Iron Ore lumps. Screened Iron Ore lumps are stacked on 4
beds in Lump Ore yard using wing Trippers. It is conveyed to Blast Furnace highline after reclaiming from the beds using one of the 5
scrapper reclaimers of capacity 450 TPH each.

Sinter Plant
Sintermix is reclaimed by scrapper reclaimers from the beds in Old Sinter Plant and conveyed to Sinter Plant I. Blender reclaimer or
Barrel Reclaimer is used to reclaim sintermix from sintermix yard and conveyed to Sinter Plant II. There is also a route for sending
limestone fines, dolomite fines and coke fines separately for final trimming addition at the Sinter Plants to compensate for any
variation in sinter quality.

New Lime Calcination Plant

Limestone of BOF grade is conveyed to NLCP and BOF grade Iron Ore and Dolomite is conveyed to BOF from flux yard storage
bunkers.

Ferro Alloys Store

The Ferro Alloys e.g. Ferro Manganese, Ferro Silicon and Silico Manganese are stored separately in Ferror Alloy Store since it is a very
costly material. The Ferro Alloys are brought in wagons / trucks and offloaded manually into pits in Ferro Alloy Store. A grab bucket
crane of 10 T capacity is used to load the Ferro Alloys into the containers. A 20T / 5T EOT crane is used to load the container on trucks
for transport by road of BOF. Coke breeze is also stored in Ferro Alloys Store for transporting by road to BOF.

Pollution Control
There are 2 dust suppression systems at Flux and Coke Crushing Unit for pollution control.
Sinter Plant

Sintering as applied to steel industries can be defined as agglomeration of iron bearing fines, as a suitable feed to the Blast furnace by
incipient fusion within the mass, effected by burning coke fines in the prepared burden on a moving grate by draughting of air from
top to bottom. Sintering is carried out by putting mix of iron ore fines, Lime stone, Dolomite fines and Coke fines on a moving grate
machine. Top layer is ignited in the ignition furnace and air is drawn downwards through exhauster. The cold blast drawn through the
bed cools the already sintered layer (at temp. between 1000 –1200 0 C) and thereby gets it self heated. This heat is utilized to burn
the coke in subsequent layers. Due to burning of the coke particles bonding takes place between the grains and a strong and porous
aggregate is formed known as ‘SINTER’. This sintering process is over when bottom layer coke fine burning is completed. The sinter
cake is then crushed and screened and dispatched to Blast Furnace

Usage of sinter is Blast Furnace offers many advantages like:

 To utilize Iron Ore fines and Coke breeze (which otherwise cannot be used directly in Blast Furnace as it will choke the
furnace due to its fineness)
 To utilize Metallurgical wastes of fines nature like Mill scale, Ferro scrap, LD slag LD Sludge etc.
 Reduction of Coke Rate in Blast Furnace
 Productivity Improvement of Blast Furnace
 Smooth Gas Dynamics inside BF stack.
 Better Operation of Blast Furnaces as Sinter is Engineered Product

At the beginning (i.e. under 1.0 MTPA capacity) DSP did not have any Sinter Plant. Two sintering machines were installed with a
capacity of 2500 TPD each during 1.6 MTPA expansion of DSP in 1968. Then the target was to use 40% sinter in Blast Furnace. Later
During modernization of DSP to 1.876 MTPA capacity another sintering machine with a capacity of 5184 TPD was installed in 1995,
making a total installed capacity of 10,184 TPD of sinter. Now the target of sinter in Blast Furnace burden is 75%.

Plant Data

Unit Commissioned on Hearth area

Sinter Plant-1 M/c-1 15.01.68 142.7 m2
Sinter Plant -1 M/c-2 20.01.68 142.7 m2
Sinter Plant -2 01.02.95 180 m2

The approximate weights of raw materials required for making one tone of sinter are:

Ore Fines 808 Kg

Limestone & Dolomite Fines 200 Kg
Coke Fines 80 Kg
Mill Scale 27 Kg
Ferro Scrap 28 Kg
Return Fines 406 Kg

Typical sinter analysis is as follows:

Total Fe CaO MgO Fe2O3 Al2O3 SiO2 FeO

56 % Min 8.6-8.9 % 2.6-2.8% 70-74 % 2.6-3.0 4.8-5.2 8-11

The raw materials for each machine are stored in 9 bins. The materials are mixed in required proportions and are sent to Primary
Mixer and then to the Conditioning Drum. Calculated amount of moisture is added in Primary Mixer and Conditioning Durm. The
sinter mix Green Mix is sent to Sintering Machine.

A Layer of previous sintered material called the Hearth Layer is first spread on the Grate Bars, over which the green mix is spread. A
cut off plate adjusts the height of the bed and material is ignited under a set of burners (temperature reaching 1200°C). The machine
is kept moving and suction is applied from the bottom of the bed. The heat travels down the bed and sintering continues. By the time
the material reaches the discharge end, the whole mass is sintered.

The sinter passes through a Sinter Breaker, Hot Sinter Screen, Sinter Cooler and Cold Sinter Screens. The various fractions utilized are
as follows:
For Blast Furnace +25 mm and +6 to -16 mm
For Hearth Layer +16 to -25 mm
Return Fines -6 mm (Re-circulated in Sinter Plant itself)
Return Fines -6 mm (From Blast Furnace to RMHP bed)

There is however slight difference between the SP-1 and SP-2as far as fractional sizes are concerned. Return fines are used for
calculating the load.

9 Bunkers* Primary Conditioning Sintermix Drum

Mixing Drum Hopper Feeder
Drum Roller

Return Fines -
6 mm +10 mm to -20 mm for hearth layer

Double Single Sinter Sinter Sinter

Deck Deck Cooler Breaker Machine
Screen Screen

* Storage Details of 9 Bunkers

+6 mm to -10 +20 mm to Blast
Blend Mix 4
mm for Blast Furnace
Furnace Dolomite Fines 1
Lime Fines 1
Coke Fines 2
Return Fines 1
 Sinter Plant

Parameters SP-1 SP-2

No. of Strands Two One

Capacity (MT) 1.35 1.71

Production T/Day 5000 5184

2 0.8 1.2
Productivity (T/M /Hr)

2 143 180
Area of the Machine (M )

Under Grate Suction mm WC 650 1150

Designed By British Russians

Schematic Diagram of Sinter Plant-1
Schematic Diagram of Sinter Plant-2
Blast Furnace
A Blast Furnace is an essential part of an integrated steel plant. Blast Furnace converts the raw materials (viz. iron ore, coke,
limestone, manganese ore etc.) into pig iron. Pig iron turn acts as the source of raw material for steel making by conventional or BOF
route. The coke serves as the heat source and reducing agent while limestone and dolomite is used as a flux, which combines with
unwanted materials in iron ore known as gangue to form slag. A Blast Furnace is called so because it uses air blast as oxygen source
for the process to occur.
The air blown into the Blast Furnaces is preheated in order to increase the efficiency of the furnace. The air is enriched with oxygen
and is preheated in Stoves. There are four Blast Furnaces in DSP and each of them have a set of 3 stoves

I/ Ore Lump

Sinter Coke

Hot Blast BF Gas Clean BF Gas

Blast Furnace GCP

Hot Metal (Liquid Iron)

Slag

PCM
SMS

Material Flow in Blast Furnace (Schematic)

The raw materials are charged into the furnace from top in the required proportions and preheated air from stoves in blown through
a number of symmetrically located openings in the bosh region of the furnace known as Tuyeres. The reducing gases rise up through
the descending burden. The descending raw materials travelling through various temperature zones are heated up and thus get
smelted. The liquid iron and liquid slag formed thus trickles down and accumulates in the hearth which is the bottom most part of the
furnace. The slag separates and floats above liquid metal. Slag is lighter as compared to metal. Whereas the raw materials take about
10-12 hours to descend and get smelted, the ascending gases take a few seconds only to rise through the descending column. This
gas is called BF gas and has high calorific value and is used as fuel at many places inside the plant. Before using this gas as fuel this has
to be cleaned and for this purpose a Gas Cleaning Plant is also located near the Blast Furnace area. The cleaned gas is sent to units
such as Coke Ovens, BF Stoves, Sinter Plant, Soaking Pits and Reheating Furnaces of mills.

Gas Cleaning Plant (GCP):

The gas coming out of the furnace has a calorific value of about 850 Kcal/NM3. It contains 25 – 27 gm/NM3 of dust and unless the gas
is cleaned, it cannot be used for heating purpose. The cleaning is done in stages. On the first stage the gas is subjected to a sudden
expansion in primary dust catcher and in second stage, in the secondary dust catcher the gas is given a cyclonic motion. The gas
coming out contains dust about 5-7 gm 5-7 gm/NM3 of gas.

This is sent to gas washers. The gas is counter currently washed with water. The gas leaving the washers has a dust content of about
0.5 gm / M3 and then enters a set of Electrostatic Precipitators. The gas leaving the precipitators has a dust content of about 9 – 11
mg / M3.
The dust laden water coming out of the gas washer and electrostatic precipitator is taken to Dor Clarifiers, cooled and re-
circulated. The slurry is taken to slag bank.

Number of precipitators 12
Number of Dorr thickeners 6
Number of washers 8

Blast Furnace

Gas with dust 25 – 27 gm / NM3

Primary Dust Catcher

Secondary Dust
Catcher

Washer

ESP

Clean Gas with dust ̴ 10 mg / NM3

Gas Cleaning Plant (Schematic)

He details of the four furnaces in this plant are as follows:

No. 1* No. 2 No. 3 No. 4

Capacity (Tonne/day) 1250 1820 1820 2340
Useful Volume (m3) 1323 1400 1400 1800
No. of Stoves 3 3 3 3
Productivity 1.0 1.3 1.3 1.3

* Blast Furnace No. 1 is down since 06.08.2002

 Various design parameters of the furnaces of the furnaces are given bellow:

Parameters BF # 2 & 3 BF # 4
Blast Temperature (°C) 1100 1150
Blast Moisture (%) 4 to 8 5 to 10
Blast Pr. at Bustle main (Kg/cm2) 1.7 1.8 to 2
High Top Pressure (Kg/cm2) 0.7 0.7
Theoretical Flame Temperature (°C) 1950 – 2050 1950 – 2050
Sinter charges in burden (%) 75 75
Hot Metal composition
Silicon (%) 0.8 0.6
Sulphur (%) 0.04 (max) 0.04 (max)
Manganese 0.15 0.15
Slag composition:
AL2O3 (%) 21-24 21-24
MgO (%) 8-11 8-11
CaO /SiO (%) 0.95 – 0.98 0.95 – 0.98
Main daily production (Tonne) 1820 2340
Overall Plant production 2.088 MTPA
Furnace productivity 1.3 1.3
Burden composition
(Kg/Tonne of Gross Hot metal)
Flux Skip Sinter 1260 1260
Lump Iron Ore 427 427
Coke Dry Skip 550 530
Yield / Tonne of Hot metal
Slag (Kg) 380 380
Top Gas (NM3) 2080 2080
Number of Cast / day / Fce 9 – 10 9 – 10
Number of Tuyeres 18 20
Number of Tap Holes 2 2
Hearth Diameter (mm) 8600 9400
Top Diameter (mm) 6600 6900
Useful Volume above Big Bell (M3) 45.0 45.0
Big Bell Diameter (mm) 4900 5000
Big Bell Stroke (mm) 750 750
Useful Vol of Receiving Hopper (M3) 8.0 10.0
Small Bell Stroke (mm) 900 900
Skip Winch Lifting capacity (T) 19 25
Number of Stoves per furnace 3 3
Blast Volume (NM3 / Hr) 125000 – 130000 140000 – 160000
Dome Temperature (°C) 1250 1250
Waste Gas Temp max (°C) 400 400
Stove Height (M) 45 45
Stove Efficiency (%) 77.85 77.85
Gas Period (minutes) 110 110
Blast Period (minutes) 60 60
Blast furnace # 3 has been provided with Bell less top (BLT) charging system in place of double bell system in
2014.

The slag contains CaO which is used for Cement Manufacturing. This slag is sold outside. Granulated slag fetches better price. There
are two Slag Granulation Plants (SGP) for BF # 3 and # 4. These are modernized furnaces with latest technology.

The details of Slag Granulation Plant for BF # 4 are given below:

Rated Output
Average Rate 2 to 5 T / Min
Maximum Rate 10 T / Min
Glassy Phase Greater than 90 %
Moisture content of Granulated Slag 10 % average
Size range of Granulated Slag 0 – 3 mm

SMS Complex

BOF (Basic Oxygen Furnace)

Here hot metal (liquid iron as obtained from Blast Furnace) is converted into steel by Basic Oxygen process for LD Process*.

* Steel making by Basic Oxygen process or LD process was first used successfully in a place called Linz in Austria in 1952. Next year it
was used at another place called Donawitz also in Astria. From the names of these places (Linz & Donawitz) came the term LD
process. This is a very fast process of steel making. In this process hot metal and scrap is taken in a vessel called Converter. Then
Oxygen is blown at high pressure through the molten metal in converter thereby converting it into steel very quickly. Whereas the
conventional open hearth process takes about 6 – 8 hours to complete the process of steel making, this LD process takes just under
one hour for the same.

Basic Oxygen Furnace (BOF) was added under modernization of DSP. This has a installed capacity of 1.876 MTPA (Million Tonnes Per
Annum) of liquid steel. The shop incorporates all environment protection measures.
Terget activity – To convert hot metal (liquid iron) as received from Blast Furnace into liquid steel. This is done by taking the hot metal
into a vessel called Converter and intense blowing of oxygen through the metal. The liquid steel thus produced is then sent to
secondary refining units like Ladle Furnaces (LRF) / Vacuum arc degassing (VAD) unit for further refining . Refined steel from LRF then
directly cast into Billet / Bloom in CCP . Refined and degassed steel from VAD either cast into bottom pouring ingot moulds for making
ingots for wheel & Axle plant / ASP or directly cast into rounds in Bloom Cum Round caster (BRC) . Rounds from BRC also feed to W &
A Plant for making wheel.

Hot metal which comes out from Blast Furnaces is collected in ladles and poured into the Mixers. There are two inactive Mixers of
1300 T capacity each. These Mixers serve the purpose of storing as well as homogenizing the temperature and composition of the hot
metal. Coke Oven gas is used to maintain the temperature at 1320° C (this is the design value, present reference value being 1260°C).

Normal composition range of Hot Metal obtained from Blast Furnace is as follows:

C Si Mn S P
3.8 – 4.2 % 0.8 – 0.9 % 0.1 – 0.2 % 0.045 – 0.060 % 0.18 – 0.25 %

The converters are commission by Mannessmann Demag of Germany. The first converter was commissioned on 07.06.94, second on
11.09.94 and the third on 21.02.95
The quality of various raw materials for producing one tonne of steel are as follows:

Hot Metal (gross) 1034.29 Kg (2016 – 17 data)

Scrap 100.80 Kg
Iron Ore 18.93 Kg
Calcined Lime 81.87 Kg
Calcined Dolomite 26.87 Kg
Fe-Mn 0.72 Kg
Fe-Si 3.25 Kg
Si-Mn 17.50 Kg
Al 0.05 Kg
Coke Breeze 1.80 Kg
Petroleum Coke 0.72 Kg

There are three converters for steel making in this shop. Each converter has capacity of 110 – 130 T per heat and the average life of a
converter is around 4510 heats(2016 – 17 data). The converter has a tap hole for tapping the slag and steel. Each converter has its
own Lance systems. Lance is used in the converter for blowing oxygen at high pressure so as to form an emulsion on the surface of
metal which increases the surface area to such an extent that the separation of impurities takes place very fast, thus giving this
process a unique distinction i.e. a very fast process for steel making. There are two lances for each converter and these lances are
operated by separate lance carriages. The oxygen blowing rate through the lance is 450 - 650 NM3/min and the blowing pressure is
12.0 to 15.0 bar from top.

BOF shop with 3 Basic Oxygen Furnace (BOF) Converters of capacity 110 – 130 tonne each for steel making by LD process. Converter
tap to tap time is 57 minutes. Installed capacity of the units are as follows.

- Capacity is 1.876 million tonne of Liquid steel per annum

- Mixers 2 X 1300 tonne capacity
- VAD (Vacuum Arc Degassing) unit of capacity 0.34 million tonne per annum to produce special steels
- LRF 3 no. each of 125 t capacity.
- Gas Holder for BOF gas with a capacity of 40,000 m3
 Ladle
Ladle Preparation Bay

Crude Steel LRF 1 LRF 2 LRF3

Hot Metal from BF Mixer Hot Metal Converters
1 2 VAD
Return & For BP
Scrap
Process Scrap Yard Round
Teeming Stage
Scrap
Lime, Dolomite 1 2 3 4
CCP
E P 8
Iron Ore M/C 1 M/C2 M/C 3 M/C4
From
RMHP Cal. Lime Cal Dolo BP Rake
Cal. Dolo BP Ingot
NLCP NDP
From
O2, N2, Ar Special Casting
Oxygen
Plant Bay

BOF Gas

Legend: Gas Holder

GCP
BBM – Blooming & Billet Mill
BF – Blast Furnace
BOF Slag to Slag Bank
BOF – Basic Oxygen Furnace
BP – Bottom Pouring
CCP – Continuous Casting Plant
GCP – Gas Cleaning Plant
NLCP – New Lime Calcination Plant
NDP – New Dolomite Plant
RMHP – Raw Material Handling Plant
VAD – Vacuum Arc Degassing
W&A – Wheel & Axcel SMS Flow Chart (Schematic)
The tap to tap time in BOF has the following components:
Scrap Charging 3 min
Hot metal charging 4 min
Oxygen Blowing 18 min
Initial slag off 5 min
Sapling team measure 6 min
Final slag off 3 min
Tapping of steel 6 min
Reserve delays 12 min

Total 57 min

Tapping temperature at converter : 1650°C (for CCP)

Bottom Pouring temperature : 1580°C – 1600°C
Total blowing time in BOF converter : 18 min

Gas obtained from BOF converter has a calorific value of 2100 Kcal / NM3. At the rate of 80 NM3/T. The slag obtained is around 142
Kg per tonne of crude steel (2016 – 17 data) , dust content is 2% of tap weight.

Oxygen

Oxygen Lance

Tap Hole

Converter Shell

Detechable Bottom
Bottom Blowing Argon Gas
Arrangement

Schematic Diagram of Mannessmann Demag Converter of DSP

Process Automation in BOF
BOF is the only unit in DSP which has an online process automation unit. The level 4 and level 5 computerisation of BOF uses VAX /
VMS system which works on the principal of Virtual Memory. This system is supplied by Digital Electronics (DEC). The whole of the
process has been automated with the help of level 1, level 2 and level 3 computerisation. The higher level computerization caters to
the need of quick retrieval of data about the operation parameters and other activities. Now the systems are connected with SAP
system since 1909 and at present all the computerized systems are undergoing modification for up gradation in 2017 .

CCP (Continuous Casting Plant)

One of the critical features in the modernization of DSP is to produce billets , blooms and rounds by continuous casting. It is the first
billet caster in any integrated steel plant in SAIL. The casting machines are designed and supplied by M/s Concast Standard AG, Zurich,
Switzerland. There are two machines with six stands each capable of producing billets of size varying from 80 mm 2 to 150 mm2.
Presently, however, only 100 mm2 and 125 mm2 billets are produced in Billet casters . Bloom caster have different cross sections
varying from 150 to 350 mm of bloom , BRC can produce Bloom of 350 X 240 mm cross section as well as rounds of 340 mm dia. The
plant is at present under commissioning stage.
Continuous casting means continuous feeding of molten steel into the mould and taking out solid shaped product. Under traditional
route, liquid steel is allowed to solidify into separate moulds and comes out as ingot. These ingots are then rolled to get the billets.
Thus in the CC route the

intermediate step of soaking and rolling in Blooming and Billet Mill is bypassed. Furthermore, from 100 tonnes of molten steel, in
traditional route, one gets only 85-86 tonnes of billets, whereas by continuous casting route, as much as 95 to 98 tonnes can be
obtained.

Some of the technical features of the CCP Billet Caster of DSP

Number of Billet caster machine 2

Number of stands per machine 6
Number of Tundish cars / machine 2
Design Limit 80 – 150 mm2 (square section)
Casting Radius 6m
Heat size 110 T (Nominal), 130 T (Maximum)
Cut off lengths 6m, 9m and 12 m
Capacity : 0.773 million tonne crude steel / annum
Casting time 85 mins.
Casting temperature : 1535 – 1580°C ( depends on grade oF steel casting- preferably 30 – 40 oC superheat)
Casting speed 3.2 m per min
Number of steel ladles 22
Capacity of steel ladle 130 T
Tundish Preparation stands 6
Gas rinsing Ar at 12 - 16 bar
Flow rate of Gas 300 lit / mon (max)
Time of rinsing 8 – 10 min
Shear Up cut pendulum type
No of Bloom Caster machine : 1
Having Design limit : 150 – 350 mm2 (square section).
Number of stands: 4
Cut off lengths: 4 - 12 m ( 4, 9 and 11 Meter)
Cutting: Propen gas cutting torch.
Casting temperature:1545 – 1580°C ( depends on grade of steel casting- preferably 30 – 40 oC superheat)
Capacity: 0.75 million tonne crude steel / No annum
No of Bloom Cum Round Caster ( BRC) : 1
Having Design limit : 350 – 240 mm2 (square section) / 340 mm dia. round
Number of stands : 4
Cut off lengths : Lengths Rectangular : 6 - 12 m (6,8, 10 and 12 m)
Round : 4 - 5.5 mm
Casting time 60 mins.
Casting temperature : 1545 – 1580°C ( depends on grade of steel casting- preferably 30 – 40 oC superheat)
Casting Radius 10 m
Cutting: Propen gas cutting torch.
Capacity : 0.75 million tonne crude steel / annum

The first machine was commissioned on 09.07.94 and the second one on 09.08.94. The mould is kept oscillating at 80 to 150 per
minute. The lubricating oil used is Rapeseed oil. The minimum temperature at LTS is 1600°C (LTS – Ladle Treatment Station).
He purpose of ladle treatment is to homogenize the temperature and composition, flotation of non-metallic inclusion, removal of
dissolved gases and to facilitate active slag-metal reactions.

The dummy bar is inserted in the mould upto 100 mm (out of 800 mm length of mould from lower to upper side) of the mould with
the help of pinch rolls. The dummy bar is packed by 6 mm asbestos rope and a chiller is placed to chill the first metal to reach mould.
The mould is surrounded by 4 mm water jackets through which primary water (40°C) is circulated internally. Primary cooli8ng of the
mould is thus done during casting by demineralised water. Besides, other zones, i.e. multistage of mould zone 1, zone 2A and zone 2B
are kept cooled by industrial water which is termed as secondary cooling.
The billets thus formed are cut to proper lengths and are allowed to cool in air, then non-destructive testing is done and then packed
and sent to stock yards according to their quality and size.

In the year 2007 – 2008 one Bloom caster and two nos. of Secondary Refining Unit ( LRF 1 & LRF 2) installed in SMS to met the
increasing demand of production with improved quality. In 2 nd phase modernization another secondary Refining Unit ( LRF 3 ) and
Bloom Cum Round caster ( BRC ) has been added in SMS / DSP . All the added units having highly online process automation system.

Some of the technical features of the CCPBLOOM CASTER

 Make: Danieli
 Machine Type: 3BLC904
 Number of strands: 4
 Machine Radius: 9m
 Unbending radius: 16 m
 Machine Productivity: 125-140T/hr
 Metallurgical Length: 25 m
 Casting Sections: 160x210, 160x230, 150x350 (mm2)
 Ladle capacity: 130 T (max) [Avg.: 120 T]
 Ladle Support: Ladle turret with lifting system
 Tundish Capacity: 24 T (overflow at 26 T)
 Tundish Level: 800 mm (overflow at 850 mm)
 Tundish Level Control: Load Cell on Tundish Car
 Tundish Support: LiftableTundish Car (cantilever type)
 Tundish stream Control: Electromechanical Stopper Rod
 Steel Stream Protection: Submerged Entry Nozzle (SEN)
 Mould Tube: Multitaper, curved 1000mm long,
 Mould Lubrication: Casting Powder
 Mould Level Control: Radioactive
 Electromagnetic Stirring: Positive for future
 Oscillating unit: Hydraulic Type
 Straightening: Modular Type (4 modules/strand)
 Withdrawal speed: 0.6 – 6 m/min
 Cutting: Oxy cutting torch with sample cutting system
 Cutting Length: 3.4 – 10 m
 Dummy Bar: Rigid
 Cooling Bed: 28m long, 12m wide
The first machine was commissioned on 09.07.94 and the second one on 09.08.94. The mould is kept oscillating at 80 to 150 per
minute. The lubricating oil used is Rapeseed oil. The minimum ladle dispatch temperature from LF is 1600-1610°C (LF – Ladle
Furnace).
The purpose of ladle treatment is to homogenize the temperature and composition, flotation of non-metallic inclusion, removal of
dissolved gases and to facilitate active slag-metal reactions and to increase temperature
The dummy bar is inserted in the mouldupto 100 mm (out of 800 mm length of mould from lower to upper side) of the mouldwith
the help of pinch rolls. The dummy bar is packed by 6 mm asbestos rope and a chiller is placed to chill the first metal to reach mould.
The mould is surrounded by 4 mm water jackets through which primary water (40°C) is circulated internally. Primary cooli8ng of the
mould is thus done during casting by demineralised water. Besides, other zones, i.e. multistage of mould zone 1, zone 2A and zone 2B
are kept cooled by industrial water which is termed as secondary cooling.
The billets thus formed are cut to proper lengths and are allowed to cool in air, then non-destructive testing is done and then lifted
and sent to stock yards according to their quality and size.
NLCP (New Lime Calcination Plant)

As the name suggest this plant came up later in 94-95 during modernization of DSP. Previously there was a Lime Plant with two Kilns.
This new plant came up to cater to the needs of BOF shop. The plant was three Annular Shaft type lime Kilns of 300 TPD capacity each
along with limestone and lime handling facilities. Annular Shaft Kilns of Warmestelle design in the first of its kind in any Indian steel
plant.
The main function of this plant is to produce lime from naturally available limestone. Lime is required in steel making process (in BOF)
mainly to reduce the Sulphur and Phosphorus content of the steel. Present calcined lime consumption rate of BOF is about 81 Kg /
TCS. Calcination is a process of controlled heating of limestone to convert it to lime. Presently lime stone from Jaisalmer in Rajastan is
being brought to use as the input material for the plant. Current yield of the plant is 60%.

Gas Fired Annular Shaft Kiln:

There are three Kilns, two are run and one is kept standby. Each Kiln is a vertical cylindrical structure of about 50 meters height.
Limestone is charged from the top with the help of charging system consisting of skip, Intermediate Chute, Rotating Hopper and
Charging Cone. The charged limestone gradually descends through the Kiln when the charge is subjected to controlled heating from
two firing zones in the kiln preventing the charge from direct exposure to bare flame. Heating is done through combustion chambers
located in each firing zone. Coke Oven gas at 5500 mm WG Pressure is used as fuel for heating.
When the charge reaches the bottom portion of the lower combustion zone of the kiln, the calcinations process is almost over and
the calcined lime is discharged from the kiln into a Silo by a hydraulically operated lime Discharging Device. From the Silo Lime is
discharged with the help of a Double Sluice lock system on to the conveyors BC 19 or BC 20.
The waste gas is passed through a bag filter from where clean gas is discharged to the atmosphere at 53.15 meter level through a
chimney.
NLCP also has got bunkers and conveyors for storage, handling and supply of F/Ore, Dolomite, Coke and other fluxes to converter
shop.
In 2nd phase modernization One dolomite plant ( NDP) has been introduced in SMS to provide calcined dolomite for BOF steel making
replacing the use of Raw dolomite.The plant is at present under commissioning stage. This burnt dolomite is used in BOF shop in steel
making process and protecting the converter refractory lining as well as ladle refractory lining . NDP having single twine Kiln with a
capacity of 300 tonne per day and projected Calcination temperature - 1000 to 1100 C .
L/S Service Bunker

Weighing Hopper

Rotating Charging
Intermediate Lime Stone
Sklp Hopper Cone
Chute

Clean Waste Gas

to Atmosphere

Coke Oven Gas as Fuel Waste Gas Bag

Upper Firing
(UCC) Zone Filter

Exhaust Gas
Coke Oven Gas as Fuel Lower Firing Blower
(LCC) Zone

Lime
Discharging
Device

SILO

Double Sluice
Lock System

To SMS Storage +10 mm Vibrating

Bunker Lime Screen

-10 mm Lime

Under Size Lime

Storage Bunker

Legend:
L/S – Lime Stone
Briquetting Machine LCC – Lower Combustion Chamber
UCC – Upper Combustion Chamber
-15 mm Briquette SMS – Steel Melting Shop

New Lime Calcination Plant Flow Chart (Schematic)

Section Mill
The installet capacity of the Section Mill in is 212,000 TPA. Blooms rolled in the Intermediate Mill and cut by a 700 Ton
Shear at Blooming Mill are fed to Section Mill for rolling into Beams, Channels, Angles etc. The blooms are stacked in the
bloom stockyard according to their grades and transferred to the charging table by means of over-head magnetic cranes.
From charging table, blooms are transferred to the roller table by means of monke skid ropes and thereafter to the
furnace charging table.

Different sections rolled in Section Mill are as follows:

1. Joists 200X100 mm
175X85 mm
150X75 mm
116X100 mm
2. Channels 200X75 mm
175X75 mm
150X75 mm
125X65 mm
3. Angles 150X150 mm
130X130 mm
110X110 mm
100X100 mm

Re-heating
The blooms are heated in two furnaces before being rolled. The two continuous reheating furnace are of the end-charge
end discharge type, divided into zones. There are in all eleven burners in each furnace; four in the end wall at discharge
end to from the soaking zone, four in the roof and three below the hearth level to from the heating zone. Coke oven gas
mixed with Blast Furnace gas is used to heat the blooms is about 1250°C. To improve the efficiency of the furnace,
incoming cold combustion air is preheated by hot flue gases in metallic recuperator. Blooms are discharge from each
furnace on to the delivery table.

Roughing Mill Stand

The roughing mill rolls are of 26” nominal diameter and 72” barrel length. This is two-high reversing closed top type ,
Driven by a 2500 HP DC motor at 90/120 rpm. The top roll has a lift of 12” and the screwing speed of 50” per minute. The
top roll is spring balanced. Universal Manipulators of electrically operated Side Guard type are provided on each side of
the mill on the main tables. Bobbin type tilting gear is provided on the heads of the ingoing side. The tilting gear is
mounted on the heads.

Intermediate Mill Stands

After initial reduction in the cross section in the previous mill the stocks being rolled are conveyed by line shaft driven
roller tables to the first stand of the intermediate mill located 209’ away. There are two stands in this mill which are
24”X68” Three-high, Non-reversing Open Top Housing type driven through a pinion housing by a single 3000 HP DC motor
at 0/90/120 rpm. The main drive will be transmitted to the middle pinion through two flexible couplings, the top and the
bottom spindles are weight balanced while the middle spindle is spring balanced.

Finishing Mill Stand

Bars leaving the intermediate mill travel along the roller tables to the finishing stand which is 24”X48” Two High Non-
reversing mill of Open Top Housing type, driven by a 1000 HP DC motor at 0/300/600 rpm. This is in line with the second
intermediate mill
Finishing End
Three hot saws are located at approximately 271’, 422’ and 642’ from the finishing stand (presently, however, only Two
Hot Saws are in operation). The bars are cooled on one of the three Transfer Banks. The products are handled by one of
the over head cranes and deposited into stacking area prior to being straightened.

Straightening Machine
The structural’s need straightening before dispatch since the bar get bent and camber during cooling. Three cold
straightening machines are installed for this purpose. Each piece is passed through the machines. In the first two
machines there are 3 rolls on the top and 4 rolls in the bottom; the bottom rolls are driven by a motor of 165 HP while
the top rolls are friction driven. The third machine is driven by two KW Slip Ring Induction motors; it has four top rolls and
three bottom rolls.
The products before dispatch are inspected and tested for chemical analysis as well as physical strength such as Tensile
strength etc.

Despatch
After straightening the bars are stacked by overhead cranes. From there they are loaded in wagons carefully by over head
cranes for despatching to stock yards to outside parties.
 Finishing Mill Main Motor Room Pusher 2 Pusher 2
Motor Room
1000 HP DC
Motor 3000HP 2500HP

Furnace 2 Furnace 1
40 TPH 40 TPH Bloom
Pinion Housing Pinion Housing
Stock Bay

24” 3 High
Roller Table
Intermediate
Mill Stand # 1
Pinion Housing 26” 2 High
Roughing Mill
Hot Saws Stand

3 2 1

Roller Table

24” 2 High 24” 3 High

Finishing Mill Intermediate Mill
3 2 1
Stand # 2

HB3 HB2 Hot Bank (HB) 1

Section Mill – Schematic Layout

 MEDIUM STRUCTURAL MILL

Overview

The Medium Structural Mill (1 MTPA) is one of the main production units of the Phase-I
expansion program of Durgapur Steel Plant (DSP), SAIL set up in their existing plant at Durgapur,
West Bengal, India.

The layout of the rolling mill is based on providing an efficient operating facility with particular
attention given to the flow of material commencing at bloom arrival through to the final delivery
of finished product bundles area.

The mill design makes the maximum use of automation and the progress of each bar is
monitored throughout the heating, rolling, cooling and handling processes providing production
data to the operators and management in a timely and precise manner so that the complete
facility can function smoothly.

Main Features of the Mill:

• MSM with universal rolling facility can produce universal beams (100mm-300 mm) and also
conventional structural like channels (100mm-300 mm), equal angles (90mm to 200mm),
rounded corner square (RCS) (60mm – 120 mm) and rounds (60mm – 120 mm) in the
desired length.

• MSM is a continuous tandem mill comprising of 16 stands (6 roughing and 10 Finishing), with
maximum mill speed of 6-7 m/sec. The stand configuration comprises of vertical rolls,
horizontal rolls and universal rolls.

• Optimum setting of roll gap upon changing rolling programme.Ability to easily compensate
the varying lateral spread and shrinkage behavior of different steel grades is unique feature
of MSM.

• Universal rolls usage gives better dimensional control and surface finish.

• Pre-setting system of the mill.The basic principal of the Pre-Setting system is to maximize
the profitability of a rolling mill by reducing the idle time due to stand and pass changing and
by achieving quickly a good quality saleable production. This is achieved by Pre-Setting both
rolls and guide equipment "Off-Line" prior to the "change" stand being placed in the mill
ready for rolling. Parallel flange beams can be rolled.

• Beams of wider flange and thinner webs can be rolled.

• Wide range of product mix- possible (131 profiles).

• The mail mill is at +5m level. This ensures better utilization of basement area at 0m level and
ease of material handling in case of input blooms and finished products.

• Input Bloom sizes of 350x240 and 300x150 with length varying from 6m to 12m
Reheating Furnace of MSM

• The reheating furnace of MSM is of 220 TPH, walking beam type furnace, with fuel type
MIXED GAS (BF + CBM) OR (BF + LPG).

• The furnace is an eight (8) zone walking beam furnace. It is fired with six (6) burners in the
top preheat zone; six (6) burners in the bottom preheat zone; six (6) burners in the top heat
zone; six (6) burners in the bottom heat zone; four (4) burners in the south bottom soak
zone; five (5) burners in the north bottom soak zone; twelve (12) roof burners in the south
top soak zone; and twelve (12) roof burners in the north top soak zone. There are a total of
57 burners.

• Design gas calorific value is 2200-2600 kcal/Nm3 (NET).

• The furnace is designed for end charging and discharging by machine and is capable of
handling full length product up to 12m long.

• The furnace is capable of discharging material within temperature range of 1150 oC to

1200oC.

Other Auxiliary Areas and Equipment

 The mill has 5 ECRs (electrical control rooms).

 11 nos. of EOT cranes for catering need of material handling, maintenance activities,
charging and offloading of feed material, loading of finished product bundles etc.
 2 nos. of dedicated Water Treatment Plants for Main Mill and Reheating furnace cooling
system.
  A Chiller Plant for air-conditioning and cooling system.
 A separate roll shop for machining of rolls and stand building activities.
 5 nos. of Transfer Cars for inter bay transfer of materials.
 An extensive hydraulic system comprising of 54 valve stands, with total capacity of
32,400 litres and monthly consumption of 6500 litres of oil, divided in to 7 areas.
 State of art laboratory for sample checking and ensuring quality as per International
standards.
 The mill also consists of a greasing and lubrication system.
 Level II automation system with ERP connectivity to Plant.

Merchant Mill

Merchant Mill was commissioned in the year 1961 with an installed capacity of 240,000 TPA (Tonnes
per Annum). It was modernized in 1992 to have a capacity of 280,000 TPA of plain rounds and
Thermo Mechanically Treated (TMT) ribbed bars. The products of Merchant Mill are plain rounds
and TMT ribbed bars of size 16, 20 & 25 mm. Now, however, Merchant Mill is rolling only TMT bars
of section 16 , 20 , 25 mm.
Billets of 100 mm2 and 9 mtr. long from CCP are stacked quality wise in the billets stock yard. They
are then transferred by cranes to a Charging bed & & then by separating skid mechanism consists of
stationary and power operated carry-over skids arranged to produce a cascade effect which
separates and depiles the billets and places them on the furnace charging roller table. A hydraulically
operated billet turnover and discard device is provide to enable defective billets to be rejected into
adjacent bins and turning the billet faces as per requirement. A Ram charger pushes the billets from
Roller table into the furnace. Billets placed in the furnace are pushed across the hearth by means of
an electrically driven Cross Pusher mounted independently outside the furnace.

The reheating furnace is a two-zone type arranged for side charging and discharging. It is designed
for an output of 70 TPH. The fuel is mixed gas of CV 3000 Kcal./m3. The air for combustion is
preheated in metallic recuperator.
Billets discharged from the furnace are delivered to the first mill stand by push-out bar. A pair of
pinch rolls is located adjacent to the furnace discharge side to pull out and feed the billets into the
first mill stand. Between the pinch roll and first mill stand, a pendulum shear is located as to cut the
front ends of the billets if required.

The mill consists of 13 horizontal stands (Roughing, Intermediate and Finishing). Roughing mill
consists of first seven stands, while the intermediate and finishing mill consists of next four and last
two stands respectively.
In between 7th and 8th stand, a Crop-cum-cobble shear is provided to cut front ends of all the rolled
stocks passing out of the 7th stand. This Crop-cum-cobble shear is also used for cutting the rolled
stock into pieces in case cobble is formed in the intermediate and finishing mill.
Four nos. of 180 Repeaters are provided between stands 9 to 14 (there is no 13th stand in the mill).
These repeaters are provided to reduce the overall length of the mill also for control the loop of the
rolled bars.

Stand No. Drive

3, 4 & 5 400 HP DC motor
1 & 2, 6 to 9 500 HP DC motor
10 & 11 600 HP DC motor
12 & 14 800 HP DC motor

After the finishing mill three Thermax Carriage are situated. These Tharmax carriage (2nd and 3rd ) are
meant for water cooling at high pressure on the rolled hot bars as they pass through them. This way
the finished bars receives a short but intense cooling, resulting in the formation of a tempered
martensite structure surrounding the ferrite-pearlite core. The resulting material acquires high
strength combined with toughness and ductility. The technology utilizes the benefit of self
tempering of the bars by the heat of the core.
After Thermax Carriage a rotary shear is provided which cuts the bars into the predetermined
lengths which are then accommodated in the cooling beds(two nos.). From the cooling beds, the
bars go on to Bar Shears (two nos.) where each bar is cut into specified lengths as desired by the
customer. On-line Auto strapping unit (two nos.) is the last section in the mill having state of the art
Automatic strapping & bundling machines. In this section the bars are packed and bound into neat
bundles that are stacked section and quality wise in the despatch bays.
Apart from conventional rolling, Slit Rolling is also done in the Merchant Mill. In slit rolling, the billets
are slit longitudinally into two parts at 11th stand. In conventional rolling, only one bar is obtained
from a billet while in slit rolling, two bars are obtained from a single billet. Slit rolling is practiced for
sections for 16mm and conventional rolling for 20mm & 25 mm.
Wheel & Axle Plant
Wheel & Axle Plant is a special feature of Durgapur Steel Plant. It is the only plant in Public Sector which produces
forged Wheels . The main customer of wheels & axles is Indian Railways, although the wheels are supplied to
some non- railways customers also.
Wheel & Axle Plant was commissioned in 1962 with a capacity to produce 45,000 sets per year. Subsequently, its
capacity was raised further to 75,000 sets/year. The Wheel Plant has undergone a massive modernization in 1992-
93. The present capacity of the plant is as follows:
Capacity (Wheel) : 28,000 Tonnes / annum
Capacity (Axles) : 4,500 Tonnes / annum
Total Plant Capacity : 32,500 Tonnes / annum

In Wheel & Axle Plant of Durgapur Steel Plant, Wheels are produced by forging ,rolling and dishing while axles are
produced by drop forging with the help of a pneumatic hammer. Subsequently both are heat treated, machined
and tested before dispatch to different railways destinations. For the ease of production, wheel manufacturing
sections and axle manufacturing sections are located in two different bays of the plant.
Raw Materials for Wheel Plant
The raw materials for wheel are bottom poured round steel ingots & continuous cast round blooms. The chemical
composition of a typical wheel ingot is given below:

Loco Wheels (IRS R-34-15)

Elements % Permissible Variation
Carbon 0.57 – 0.67 +0.03 / -0.02
Manganese 0.60 – 0.85 ±0.03
Silicon (min) 0.15 -0.03
P & S (max) 0.03 +0.005
Cr (max) 0.25 +0.05 / -0.00
Combined
Ni (max) 0.25 0.5 max
+0.05 / -0.00
Mo (max) 0.06
Al (max) 0.3
V (max) 0.1 +0.02 / -0.00
Rough Shaping of Wheel
The round ingots & continuous cast blooms are sliced into a number of pieces known as cheeses/blocks. The
weight and length of each block depends upon the type of wheel produced.
Blocks free from circular cracks, Vertical cracks, cold shuts / interrupted pouring, off center setting etc. are
reheated in a rotary hearth furnace for 5½ to 6½ hours up to a temperature of ≤1260C.
The heated cheeses after descaling are upset, forged & punched in the 63/12 MN Forging & Punching Combination
Press. The Wheel blank thus obtained is then reheated in a batch type holding furnace maintained at 1200±20C
before the wheel is rolled in the computerized Wheel Mill. In the Wheel Mill, the rolling of wheel is accomplished
with the help of one tread roll, which shapes the tread profile of the wheel, two web rolls, which shape the web
portion and two edge rolls, which control the rim thickness of the wheel.
After rolling, the wheels are sent to 20 MN Dishing Press. In the Dishing Press, the form of the web is changed from
flat ring to different profiles as per the design requirements. This prevents development of high internal stresses
while cooling and increases resilience besides preventing warping of wheels. Then serial no., year of manufacturing
and batch number are stamped on the front rim face of wheel in the 3MN Marking Press. Then wheels are supplied
to heat treatment section for heat treatment to get desired physical properties.
Heat Treatment of Wheels :
The Wheel Heat treatment process is divided in two operations like;- Hardening by rim quenching and
Tempering.

a) Hardening by Rim Quenching : - The above machine is used to spray water on the rim area of the wheel to
quench it. The quenching operation increases the hardness, wear resistance and fracture toughness of the rim
of the wheel and change in microstructure also takes place. After quenching the heat, which remained in the
hub (normalized area) area of the wheel, is transferred partially to the rim area, thus increasing its temperature,
which helps in reducing the brittleness and increasing the ductility of the material besides relieving some
amount of internal stresses developed during rim quenching. After air-cooling the wheels are charged into the
tempering furnace for tempering.

b) Tempering: - The process is designed to modify the properties of steel hardened by quenching at sub-critical
temperature. The wheels after quenching and air-cooling are charged into the tempering furnace where they
are kept as per schedule. The purposes of the tempering process is to:

- Relief some amount of stresses that is induced by quenching.

- To increase toughness/machinability.

The final crystal structure of the heat-treated steel is ‘fine pearlite’ with ASTM grain size 6 – 9. After heat
treatment the wheels are tested for various physical & chemical properties as per specific requirements of the
Indian Railways. These tests are destructive in nature and thus are conducted on a specific sample drawn from
every batch of wheels.

Present hardness stipulation is 241 to

320 BHN with a Band width of 30 BHN in
a cast/batch for BG Coach wheels. For
Loco wheels the range is 300-341BHN
with a Band width of 30 BHN in a
cast/batch for LOCO wheels..
Testing
One wheel is selected at random from one batch in case of all type of wheels & the samples are made out of that wheel
for doing various destructive tests like tensile, yield strengths,% elongation,hardness etc at Physical testing laboratory
.Once the wheel samples passes all the desired tests then rest of the wheels of the batch are declared as tested OK.

Machining
All the tested Ok wheels are subjected to machining operation.
Wheels are subjected to 3 or 4 specified operations depending on the type/specifications.

Operation 1
In this, the front rim face, front boss face, front boss and rim blending, condemning groove, cracking groove and rough
boring for the next operation is performed.

Operation 2
Beside rough boring, finished machining of rim width, web thickness, boss length and profile of gage and tread of the
wheel is performed. CNC vertical machines are used for Operations 1 and 2.

Operation 3
This is applicable where chucking groove is not a part of specification/drawining.BG coach Alt12,EMU etc. are subjected
to this operation where the chucking groove which is deliberatively made clamping of wheel during second operation is
again machined out by a first operation machine before finishing.

Operation 4
Sprag holes are drilled on wheels as per specification.
Cold stamping
The Machined wheels are stamped by a pin stamping machine on front side of the rim face in which following data are
mentioned.
 Drawing No
 Manufactures identity(DP)
 Year of manufacture
 Cast No.
 Serial No. of wheel
Online testing
The machined wheels are first subjected to magnetic particle testing. In this test a low speed water jet
containing magnetic particles is impinged on the surface of the wheel in the presence of a magnetic field. Due
to presence of the magnetic field the magnetic particles align themselves along the cracks present on the
surface of the wheel. These magnetic particles are not visible with the naked eye. They are viewed with the
help of UV lamps and the presence of any sort of crack is detected.
The ultrasonic test involves passing ultrasonic waves through the rim, web and hub of the wheel. As
per the specifications, the number of Probes vary for a particular type of wheel. The probes for the rim are
kept submerged in water. The rim part of the wheel while testing is also kept under water and the wheel is
rotated at a particular rate (to test the entire rim). These probes measure the soundness and detect internal
defects present in the wheel. The entire facility is computerized. The computer screen displays the magnitude
of defect present in the wheel. When the magnitude crosses a certain critical limit the computer gives a
message to the operator that the particular wheel is unsatisfactory. The unsatisfactory wheels are either
discarded.
 After ultrasonic testing the wheels are tested for their hardness in terms of BHN (Brinell Hardness
Number) value. The wheel is slowly clamped by means of a hydraulic cylinder and an indentor impacts the
surface of the wheel thus determining its BHN value. The BHN value is determined and displayed on the
computer screen . If the value is within limits, then the wheel is passed or else it is reworked.

Dimensional Inspection
After the wheels have passed all the previous tests, visual inspection and dimensional checking of all the
wheels are carried out. All visually detectable defects on the surfaces of the wheels are detected in addition to
checking of their metallurgical and ultrasonic test status. If some minute surface defect is detected it is
corrected by a hand grinding machine. Else if a major fault is detected, if possible, it is reworked, otherwise it
is rejected.

RITES inspection & Dispatch

Final inspection is done by Rail India Technical & Economic Services (RITES). The records of all the tests done on the
wheels are checked and they do a visual inspection for the presence of any surface defects. After their acceptance, the
wheels are stamped as rites OK and are sent for protective painting (Red Oxide) and are further sent to dispatch section
for loading to different Railways destinations.

Axle Plant
The raw materials is the Round corner surface square(RCS) bloom rolled in ASP. Typical composition of Axle steel (Killed
Steel) is:
Axle steels (IRS R-16/95)
Elements % Permissible Variation
Carbon 0.37 (max) +0.03 / -0.00
Manganese 1.12 (max) +0.06 / -0.00
Silicon (min) 0.15 to 0.46 +0.04 / -0.00
P & S (max) 0.04 (max) +0.005 / -0.000
Cr & Ni (max) 0.30 (max) each +0.05 / -0.00
Mo (max) 0.05 (max)
Cu (max) 0.30 (max) +0.02 / -0.00
V (max) 0.05 (max) +0.02 / -0.00
P+S 0.07 (max)
Blooms are subjected to rigid Ultrasonic Test. Those showing signs of piping ,inclusion etc. are rejected.
Shaping of Axle
Blooms are heated in a continuous pusher type furnace. Cold bloom takes 6 to 8 hours to be ready for forging at 1220C.
Blooms are forged in axle forging hammer. This compressed air hammer has a falling weight of 7 tons. The hammer is
hand operated. It is fitted with a pair of twin swag dies which give the required shape of axle. Manipulators work in
conjunction with the hammer for hoisting, leveling titling and turning of the axle. It takes about 12 to 15 minutes to
forge an axle, the finished temperature being about 850C.

Heat Treatment
Axles are heat treated in a walking beam type furnace. The process that is followed is Normalizing where the
temperature of the furnace is maintained at 860±10C at both the zones . Through discharging door axles are taken out
after heat treatment and are placed for cooling on cooling beds. One foot gap between two axles is maintained for
achieving the required cooling rate.
Testing
After completion of heat treatment of the batch one axle is selected as a sample .A piece is taken out from the wheel
seat portion of the axle and tested for tensile strength. It is also checked for microstructure and grain size.

End cutting of axles

Ultrasonic Test is performed for checking the physical soundness of every axle after both the end cuttings. This
Ultrasonic Test is done from end to end to detect longitudinal defect if any.

Machining
Axle is sawed for the required length after which the axle is centered and countersunk at 90 and recessed for ease of
the succeeding operation. Axle is then rough for the journal, dust collar and the wheel seat diameter. Is copying lathes,
the waist is next turned. The axle is then sent to finishing lathes for finished turning of journal, dust collar and wheel
seat diameter.
After finishing operation, the roller bearing axles go for drilling and tapping of 3 holes of 7/8 inch diameter BSW at the
ends of 16.25 ton axles. After this, in center less grinding machine, profile grinding of journal, dust collar and wheel seat
is done to an accuracy of 0.025 mm. for the wheel sets of plain bearing, axles are ground on cylindrical grinding machine.
The journal and dust ring are burnished to obtain polished surface on burnishing machine.
The axles are inspected for dimensional accuracy in each stage of making as well as after completion of all making jobs
for visible surface / diameter defects.
Non destructive testing & Dispatch
After machining of axles, dimensional inspections are carried out by RITES personnel. All dimensionally OK axles are
subjected to MPI to detect any surface defects and then are subjected to Diametrical UT tests all along the axles to
detect any defect at depth. Only rites OK ( Set finished(SF) and Set order(SO) axles are dispatched(SO axles are packed
only) to different destinations specified by Railways.