A REPORT

on
NMDC IRON STEELPLANT, NMDC Ltd.
NAGARNAR, JAGDALPUR (CHHATTISGARH)
From

MAHAKAL INSTITUTE OF TECHNOLOGY,

UJJAIN
UNDER THE ESTEEMED GUIADNCE OF
Shri Sanjay Panjiyar GM (P&M)
Shri Pravin B. Agarkar DGM (Utility & Services)
INTERNSHIP PERIOD: 18TH JUNE 2019 TO 04TH JULY 2019

SUBMITTED BY:- K. PAWAN RAO

 NMDC IRON & STEEL PLANT
Department Of Mechanical Engineering

CERTIFICATE

This is to certify that the project report entitled “NMDC Iron and Steel Plant” is
being submitted by K PAWAN RAO (ROLL NO: 0704ME161022) in partial
fulfilment for the award of the degree of Bachelor of Engineering (Mechanical
Department). It is a bonafide work carried by him in proper guidance and
supervision.

Shri Pravin B. Agarkar

Utility & Services
NMDC IRON & STEEL PLANT
DGM (Mech.)
PLANT
 ACKNOWLEDGEMENT

I take this opportunity to extend my gratitude to NATIONAL MINERAL

DEVELOPMENT CORPRATION for providing me with an unbelievable
practical learning experience during summer training. It was indeed a pleasure
to be a part of such organization. The completion of this project would not be
possible without the participation of so many people whose names may not all
be enumerated. I sincerely appreciate and gratefully acknowledge their
contributions. However, I would like to express my deep apparition and
indebtedness to the following:
Shri Sanjay Panjiyar, GM (P&M) who showed keen interest and considered
patience for coordinating all the project activities that helped the project work to
get successfully completed.
Shri Pravin B. Agarkar, DGM (Utility & Services), Engineer-In-Charge for
his endless support understanding spirit throughout the project period.
Shri Munde Nayan Sir and Ravi Shankar Sir for their endless support,
kind and knowledge that benefitted me a lot.
My parents, relatives, friends who one way or the other shared their support,
morally, financially and physically, thank you!
Above all, to the Great Almighty, the author of all knowledge and wisdom, for
his countless love.
 CONTENT

o INTRODUCTION TO NMDC.

o NATIONAL MINERAL DEVELOPMENT COOPERATION.

o SALIENT FEATURES OF NISP NMDC.

o PLANT LAYOUT.

o INTRODUCTION TO COMPRESSED AIR STATION.

o SYSTEM IN COMPRESSED AIR STATION.

o IMAGES OF PLANT.

o CONCLUSION.
 INTRODUCTION
The NMDC (National Mineral Development Corporation) Ltd. is a mineral
producer of the central government of India (PSU). It is owned by the
government of India and is under administrative control of the Ministry Of
Steel. Iron-ore, copper, rock phosphate, limestone, dolomite, gypsum, bentonite,
mange site, diamond, tin, tungsten, graphite, etc. exploration is involved.
NMDC Ltd is a ‘Navaratna’ Public Sector Undertaking under the Mineral of
Steel, Government of India, formed in the year 1958, primarily engaged in the
business of exploring minerals and developing mines to produce raw materials
for the industries. NMDC boasts of being the largest in the country and eight
largest in the world in iron ore production and provides ore to its clients at one
of the cheapest rates in the world. NMDC also owns only mechanized diamond
mine of Asia.
NMDC has marked its footprints in sponge iron, wind energy and exploration of
wide range of minerals including iron ore, copper, rock phosphate, limestone,
dolomite, gypsum, bentonite, magnesite, diamond, tin, tungsten, graphite, beach
sand, etc. To secure future supplies of raw material for the country’s steel
production, fertilizer production and energy security through acquisition of
overseas mineral assets of iron ore, cooking coal, manganese ore, rock
phosphate and potash. NMDC has meanwhile achieved success in acquiring
mines in Australia while acquisition of iron ore mines in Brazil and rock
phosphate assets in Australia are in advanced stages. It has also got mining lease
for gold mining in Tanzania.
NMDC believes in horizontal integration as well as in vertical integration and
diversification. It has invested in steel sector and formed NMDC steel Ltd. as
first giant step to meet nation’s requirement and fulfil its ambition.
 NATIONAL MINERAL DEVELOPMENT CORPORATION

The NMDC (National Mineral Development Corporation) Limited is a central-

controlled mineral producer of the Government of India. It is owned by the
Government of India and is under administrative control of the Ministry of
Steel.
It is involved in exploration of iron ore, copper, rock phosphate, limestone,
dolomite, gypsum, bentonite, magnesite, diamond, tin, tungsten, graphite etc.
It is India’s largest iron ore producer and exporter producing about 30 million
tons of iron ore from 3 fully mechanized mines Chhattisgarh and Karnataka. It
also operates the only mechanized diamond mine in the country at Panna in
Madhya Pradesh.
OPERATING MINES:
 Bailadila Iron Ore Mine, Kirandul Complex, District South Bastar,
Dantewada (C.G)
 Bailadila Iron Ore Mine, Bacheli Complex, District South Bastar,
Dantewada (C.G)
 Donimalai Iron Ore Mine, Donimalai, District Bellary (Karnataka)
 Diamond Mining Project, Majhgawan, Panna (Madhya Pradesh)

NISP as part of its expansion, value addition and forward integration program is
setting up a the 3 MTPA capacity greenfield Integrated Steel Plant in Nagarnar,
located 16 kilometer from Jagdalpur in Chhattisgarh state.
The foundation stone for that project was laid on 3rd September 2008.
 SALIENT FEATURE OF NISP

Capacity 3 MTPA
Capacity (HR 2.89 MT/YR.
Coils/Sheets/Plates)
Coke Oven & CDCP 2*67 ovens,7mtr tall batteries,
Sinter Plant 460 sq mm,1 No.
Blast Furnace 4500 Cu.m
Pig Casting Machine 3*1700 Tons per day, 3 Machines
Steel Melting Shop 2*175 BOF Converters
This Slab Caster + Hot Strip Mill 2 Strand Continuous Casting and HSM 2
(HSM) 2RM + 4FM = 2 Down Coilers
Other Units By Product Plant, RHMS,LDCP,Oxygen
Plant
PLANT LAYOUT
 NISP INFRASTRUCTURE

COKE OVENS & BY PRODUCT PLANT

Coal is converted into coke by heating the prepared coal blend charge in the
coke ovens in the absence of air at a temperature of 1000 C – 1050 C for a
period of 16 to 19 hours. The volatile matter of coal liberated during
carbonization is collected in gas collecting mains in the form of raw coke oven
gas passing through stand pipes and direct contact cooling with ammonia liquor
spray.
SALIENT FEATURES
No of Ovens 2
No of Batteries in Each 67
Oven
Coal Tower Capacity 4000T
Gross Coke Output 1762800 T/Year
BF Coke Output 1480000/Year
Useful Volume of Oven 41.6 Cu. M
Cooking Hours 16 Hours
CDCP Capacity 52-56 T/Hour
SINTER PLANT
Sintering is agglomeration of fine mineral particles into a porous mass by
incipient fusion caused by heat produced by combustion within the mass itself.
Iron ore fines, coke breeze, limestone and dolomite along recycled metallurgical
wastes are converted into agglomerated mass at the Sinter Plant, which forms
70-80% of iron bearing charge in Blast Furnace. The vertical speed of sintering
depends on the suction that is created under the grate. At NISP, two exhausters
are provided for each machine to create a suction of 1500 mm water column
under the grate. Each exhauster is driven by a 5.6 MW motor capable of rotation
of the fan at 1000 rpm.
SALIENT FEATRUES

Size of Sintering Machine 460 sq mm

Dimension of Machine 103 x 4.5 x 0.7 m
Production 4736160 T/Year
Size of the Material 5-40 mm
Raw Material Ore fine, Limestone, Dolomite, Mill Scale,
Flue Dust, Coke Breeze
Chemical Composition Fe, Si02, Al2O3, CaO, MgO, S, P and LOI
Oven Dimension 16000 x 410 x 7000 mm

BLAST FURNACE

Iron is made in the blast furnace by melting iron bearing material with the help
of coke and air. The solid charges material like sinter, sized iron ore, coke etc.
are charged in the vertical shaft of the Blast Furnace at top and hot air blast is
blown through the tuyers located at the bottom. The oxygen from the hot air
combines with the carbon of the coke and generates heat and carbon monoxide.
The gases, while ascending upwards react with descending charge materials.
Eventually the charge melts and hot metal and slag are produced and tapped out.
The cooled gas is also used as fuel in the plant. The Paul-Wurth, bell less top
system is installed for furnace charging.
SALIENT FEATURE

Useful Volume of the Furnace 4506 cubic meter

Working Volume of the Furnace 3815 cubic meter
Production 9489 T/Day
No. of Tuyeres 38
No. of cast House 2
Torpedo Ladle Capacity 350 T
BF Gas 367500 Nm3/h used as fuel for boiler
No. of Tap Holes 4
Hot Blast Temperature 1200 Degree Celsius
STEEL MELTING SHOP
Steel is made in steel melting shop in the refractory called LD converters by
blowing oxygen through the hot metal bath. While iron making is s reduction
process, steel making is an oxidation process. The oxygen reacts with the
carbon in hot metal and release large quantities of gas rich of carbon monoxide
along with a large amount of dust. The gases released from the convertor are
collected, cooled, cleaned and recovered for use of fuel in steel plant.
SALIENT FEATURES
Hot Metal Desulphurization 2 x 175T
Basic Oxygen Furnace at a time 2 x 175T
Ladle Furnace 2 x 175T
RH-OB Degasser Unit 1 x 175T
Processing of Hot Metal 3000000T/Year
Tap to Tap Time Minimum=30 min
Average=50 min
Oxygen Consumption for Blowing 55Nm3/T
No. of Heats/Day in BOF Process Average = 54, Maximum = 58

THIN SLAB CASTER & HOT STRIP MILL (HSM)

The steel-casting ladle containing the liquid steel will be transported from the
BOF shop to the ladle handling bay of the continuous casting shop by means of
a self-propelled ladle transfer car. After treatment in the one line ladle furnace/
RH-OB (off-line), the liquid steel ladle will be lifted by the ladle handling EOT
crane and placed on the ladle turret of continuous casting machine.
The cast strand will be cut into desired length in pendulum type shear and fed to
the respective tunnel furnace. The tunnel furnace will be of recuperative type
furnace which serve both to heat up the thin slabs to the uniform rolling
temperature and also convey the hot slabs to the hot strip mill.
The hot thin slabs entering the hot strip mill through tunnel furnaces will be
rolled to strips. The run out roller table will convey the hot strips from the exit
of the last mill stand to the down coiler for cooling. The strip will be cooled
while passing over the run out table by a laminar cooling system.
SALIENT FEATURES

No. Of Single Strand Thin Slab Caster 2

No. of tunnel Furnace 2
Capacity 2896000 T/Year
Thickness of the Slab 55mm to 1650mm
Length of Strand A Line 240m
Length of Strand B Line 193.8m
No. of Roughing Strands 2
No. of Finishing Strands 4
Buffer Capacity Max. 15 minutes

RAW MATERIAL HANDLING SYSTEM

RMHS plant receives and stacks the material like iron ore (fines and lumps),
limestone, dolomite, quartzite, coking coal, non- coking coal from various
modes of transportation and supplies to packages like Sinter plant, Blast
Furnace, Coke oven, Steel Melting Shop, Lime & Dolo Plant.
SALIENT FEATURES

Stacker Reclaim for Coal Handling 3 No.

Stacking Reclaim for Ore/Flux Handling 4 No.
Wagon Tippler 4 No.
Slew Stacker 1 No.
Barrel Reclaim 1 No.
Crusher 4 No.
Smooth Double Roll Crusher 2 No.
Rod Mill 3 No.
Reversible Hammer Mill 9 No.
Total Length of Conveyor 37km
Junction Tower 83 No.
Conveyor 108 No.
 POWER AND BLOWING STATION
To cater the needs of steam for Turbo Blowers & Turbo Generators, a Power
and Blowing Station have been envisaged. The Power & Blowing station
comprising of three nos. of multi fuel gas fired boilers with auxiliaries, two no.
Steam Turbo-Generator with auxiliaries and space for three nos. of Steam
turbine driven Turbo-blowers with all auxiliaries.

Major equipment shall be as follows:

1. 3 x 160 t/h multi fuel Gas Fired Boilers
2. 2 x 40 MW Steam Turbo Generators
3. DM Water Plant
4. Cooling Water System including pump house, cooling towers etc.
5. AC & Ventilation System
6. Compressed air system
7. Firefighting facilities
8. Electrics
9. Instrumentation & control
10. Telecommunication facilities
11. Civil & structural works
12. Emergency DG set (tentative capacity: 750 kVA)
13. Handling & hoisting
14. LDO day storage tank
 INTRODUCTION TO COMPRESSED AIR STATION

Main function of Compressed air Station is to Supply service and

Instrument air to various units of plant like RMHS, Coke Oven , Sinter
Plant for Maintenance and operational purposes.
Compressed air Station shall supply service and Instrument air at 9
kg/cm^2 , flow rate of each 160Nm^3/Min and temperature at discharge
outlet will be 39oc.
In NISP Two Compressed Air Stations are Installed, Namely Compressed
Air Station-1 & Compressed Air Station-2.

Compressed Air Station-1 :-

3, 3-stage Centrifugal Compressors are Installed in CAS-1, 2 are in

working and 1 is Stand By.
CAS-1 will supply Compressed Air to (RMHS),Coke oven, By products,
Sinter plants, Blast furnace, lime &Dolo Facilities.

LAYOUT OF CAS -1

TRANS

e
T

il

t
F-1 Control Store
Electrical Room
Room Room

Plan

Dosi

Syst
Che
t&
RO

m.

ng
TRANS
F-2
MAINTENA
NCE BAY

COOLING
DRIER- DRIER- TOWER
C- 1 C- 2 C- 3
1 2
3 2 1
CAR PARKING
 Compressed Air Station-2 :-

7, 3- Compressors are Installed in CAS-2, 6 are working and 1 Stand By,

CAS-2 will Supply Compressed Air to Melting shop(SMS),Thin slab
caster (TSC),Hot strip mill(HSM), Oxygen plant and other Auxiliary
facilities of the steel plant.

Lay out of CAS-2

Control Room
Ventilation
TRANS

Room
F-1
Electrical Room

TRANS
F-2
MAINTENANCE BAY

COOLING
TOWER
C- C- C- C- C- C- C-
DRIE DRIE 7 6 5 4 3 2 1
R-1 R-2

CAR
PARKING
 Important System\Equipment in compressed air station.

1. Starting Air Compressor & Dryer

2. Compressor
3. Water System
3.1. Cooling Tower
3.2. Cooling Water Recirculation pump
3.3. Flow Control valves.

1. Starting Air Compressor

Starting Air Compressor is a reciprocating compressor which supply

compressed air to pneumatic actuators installed in compressor like inlet guide
vane, Blow off valve, and supply seal air to compressor impeller.

FIGURE-1
Starting Air Compressor
 2.Compressor

Compressors installed at compressed air stations are 3 stage Centrifugal

compressors of FS ELLIOT Make rated flow rate of this compressor is 160
Nm^3/min.

Important parts of compressor:

i. Suction Filter
ii. Inlet Guide Vane
iii. Impeller
iv. Gear Box
v. Inter Cooler
vi. After cooler
vii. Moisture Separator
viii. Blow off Valve
ix. Lubrication System
a. Auxiliary oil pump
b. Main oil pump
c. Oil cooler
d. Filter
e. Oil mist Eliminator

I. Suction Filter:
Suction Filter consist of Primary and Secondary filter, and Each
compressor is provided with one suction filter, which filters inlet air
which will enter impeller
Suction filter provided with a differential manometer, if differential
pressure is more than set point it indicates filter is chocked and it has to
be changed.

FIGURE-2 : Primary and Secondary fil

 II. Inlet Guide Vane:
Inlet Guide vane is an assembly in suction line of first stage impeller
which guides inlet air into first stage impeller. It is pneumatically
actuated and air for actuation is supplied by starting air compressor.

III. Impeller:
Impeller is component of compressor with rotating vanes, with its
rotation it increases energy of gas hence pressure of air will increase

IV. GEAR BOX:

Compressor is driven by 6.6KV, 1400KW, 30000 RPM HT MOTOR.
Gear Box reduces the speed to required level.
First stage impeller mounted on low speed pinion and second and third
stage impellers are mounted on high speed pinion all the pinions are
driven by the bull gear which rotates at speed of the motor.

V. Intercooler & After Cooler:

When Air Pressure is increased its temperature and volume will increase,
to reduce the temperature and volume of compressed air shell and tube
type heat exchangers are installed in compressor, these will reduce the
temperature and volume of air and pressure will retained.

VI. Lubrication system:

The lubrication system consists of a main oil pump, auxiliary oil pump , oil
filter, oil cooler, oil pressure control valve, pressure and temperature
indicating devices, a reservoir, thermostatic mixing valve, oil reservoir
heater and necessary piping, fittings and valves.

Its main function is reduce temperature at gear mating point and provide
lubrication at those points.

Auxiliary oil pump will start before starting of compressor and it will
pump oil to be lubricating points before initial start-up of compressor.
Main oil pump is shaft driven once compressor is started, main oil pump
generates required oil pressure auxiliary oil pump will automatically
stops.
 Operation philosophy of Compressor:

1. Atmospheric Air Filter at Suction filter enters the compressors First stage
impeller and compressed, Supply of inlet air to First stage impeller is
controlled by Inlet Guide vane which is pneumatically operated.
2. After inlet compression compressed air enters intercooler where heat and
moisture of is removed from compressed air.
3. After air cooled and dried it enters compressors second stage and it
further compressed.
4. The air then Directed through a second intercooler to once again remove
heat and moisture.
5. Finally air enters the compressors final stage impeller and compress the
air to the design pressure i.e 9 kg/cm^2
6. This compressed air through discharge header reaches after cooler and its
temperature is reduced to 39oc.
7. Condensate drain valves are provided at intercooler and aftercooler to
drain out condensate.
8. After, After cooler Air goes to moisture separator and moisture is
removed from air it is supplied supply header.

FIGURE-3 , COMPRESSOR
1.Water System:
Water is required in the operation of compressor, starting air compressor
and in Air conditioning and ventilation System.
Water system include
3.1. Cooling Tower
3.2.Cooling Water Recirculation pump
3.3. Flow Control valves

Cooling Tower:

FIGURE-4: COOLING TOWER

Cooling towers are one of the most important industrial utilities used to
dissipate the unwanted process heat to the atmosphere through the cooling water
in the heat exchangers across the plant site. Cooling tower is one of the most
expensive utility in terms of power consumption and water circulation.
Maintaining water quality in the circulation loops is one of the major challenges
in process optimization for most efficient performance.
Latest technological developments have made the water conservation more
efficient and use of chemicals more limited by introducing “Recycling / reusing
water practices” and.

The primary task of a cooling tower is to reject heat into the atmosphere. They
represent a relatively inexpensive and dependable means of removing low-grade
heat from cooling water. The make-up water source is used to replenish water
lost to evaporation. Hot water from heat exchangers is sent to the cooling tower.
The water exits the cooling tower and is sent back to the exchangers or to other
units for further cooling. Cooling towers are able to lower the water
temperatures more than devices that use only air to reject heat, like the radiator
in a car, and are therefore more cost effective and energy efficient.

Cooling tower at compressed air station -1 has 2 cells capacity of 588 m3/hr and
it is counter flow cooling tower.
Cooling tower at compressed air station-2 has 3 cells and capacity is of 677
m3/hr and it is counter flow cooling tower.

Water flowing in tubes in the of intercooler and after cooler absorb heat and
temperature of water will increase.
This water will go to return header and reach cooling tower from top.
Fans installed in Cooling tower cell will suck air and cool water in Counter flow
Direction.
IMAGES OF PLANT

Blast Furnace Overview

Power & Blowing Station

Steel Melt Shop

Raw Material Handling System

Coke Oven Battery

Conveyor Gallery for Coal Supply

Sinter Plant Top View

 Sinter Plant Conveyor

SMS Gas Cleaning Plant

 Oxygen Unit

Raw Water Reservoir

 Overhead Tank

Conclusions:
 Compressed Air is important utility in operation and maintenance of
various units
 To run compressor efficiently Maintaining temperature of oil and water at
required level is important, in this regarding cooling tower and flow
control valves play important role.
 Chocking of Suction Filter decrease the flow rate of air to the impeller
hence it should change when pressure drop is high across filter.
 Any kind Contamination in Lubrication oil should be avoided.