Sharan JSW

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RAMAIAH INSTITUTE OF TECHNOLOGY

DEPARTMENT OF INDUSTRIAL ENGINEERING AND


MANAGEMENT

FOR THE ACADEMIC YEAR 2020-2021

INTERSHIP REPORT ON
“JSW STEEL LIMITED”

UNDER THE GUIDANCE OF


SDFGJHSDF

SUBMITTED BY
K.SHARAN GANAPATHY
USN- 1MS17IM019

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ABSTRACT
I carried out my internship at JSW STEEL LTD
Vijayanagar for a duration of one 4 weeks. JSW Steel is
one of India's leading integrated steel manufacturers with a
capacity of 16 MTPA(million metric tons per year). It is one
of the fastest growing companies in India with a footprint in
over 140 countries. The JSW Steel Vijayanagar plant is the
first integrated steel plant to reach 12 MTPA capacity in a
single location. It is the first in India to use the Corex
technology for hot metal production.
Limestone is one of the most basic raw materials employed
in the steel industry and is used both in iron making and
steel making processes. Lime (CaO) is one of the oldest
chemicals known to man and the process of lime production
is one of the oldest chemical industries. In this period of 1
month detailed study of Lime calcination plant is carried out

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CONTENTS

1. INTRODUCTION 05-06

2. JSW STEEL PROCESS FLOW CHART 07

3. PLANT VISIT 08

4. PRODUCTION PROCESS BY JSW 09-17

5. LIME CALCINATION PLANT 18-28

6. CONCLUSION 29

7. REFERENCE 30

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1. INTRODUCTION
JSW is part of $10 billion OP Jindal Group. It has grown to
$5 billion in little over a decade and has presence across
various sectors – Steel, Energy, Minerals, Port &
Infrastructure, Cement, Aluminium and IT.
JSW Steel, the flagship company of the JSW Group, is
today an integrated steel manufacturer. JSW Steel is the
largest private sector steel manufacturer in terms of
installed capacity.

The Group set up its first steel plant in 1982 at Vasind near
Mumbai. Soon after, it acquired Piramal Steel Ltd., which
operated a mini steel mill at Tarapur in Maharashtra.
The Jindal’s, who had wide experience in the steel industry,
renamed it as Jindal Iron and Steel Co. (JISCO). In 1994, in
order to achieve the vision of moving up the value chain
and building a strong, resilient company, Jindal Vijayanagar
Steel (JVSL) was setup, with its plant located at
Toranagallu.
JSW Steel is one of the lowest cost steel producers in the
world. It has established a strong presence in the global
value–added steel segment with the acquisition of steel mill
in US and a service centre in UK. The Company has also
acquired mining assets in Chile, USA and Mozambique.
Today JSW Steel has plants in six locations in India –
Vijayanagar in Karnataka, Salem in Tamil Nadu, and
Tarapur, Vasind, Kalmeshwar and Dolvi in Maharashtra.

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KEY MANUFACTURING FACILITIES
LOCATIONS PRODUCTS
JSW steels Karnataka • Slabs, billets blooms,
HR coils and sheets,
cold rolled close
annealed coils and
sheets, galvanized
products, wire rods bar
rods and angles

Dolvi Maharashtra • Hot rolled coils

Salem Tamil Nadu • Special steel long


products
Tarpur Maharashtra • Galvanized, Galvalume
and colour coated
products
Vasind Maharashtra • Galvanized and colour
coated products
Kalameshwar Maharashtra • Galvanized, Galvalume
and colour coated
products

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2. JSW STEEL PROCESS FLOWCHART

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3. PLANTS VISITED
• Raw Material Handling System (RMHS)
• Benefaction Plant II
• Pellet Plant II
• Sinter Plant I
• Corex I& II
• Blast Furnace III & IV
• Coke Ovens III,IV & CDQ
• Refractories
• LCP
• SMSII
• HSM II
• LP Mills & BRM II
• CRM II
• Central Maintenance Dept.
• i shop & Central Repair Shop

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4 PRODUCTION PROCESS OF STEEL BY
JSW
Agglomeration
1. Beneficiation: In the mining industry beneficiation
or beneficiation in extractive metallurgy, is any process
that improves (benefits) the economic value of the ore
by removing the gangue minerals, which results in a
higher- grade product (concentrate) and a waste
stream (tailings).

2.Pelletizing:Pelletizingistheprocessofcompressingor
moldingamaterial into the shape of a pellet. A wide
range of different materials are pelletized including
chemicals, iron ore.

3. Sintering: Sintering is the process of compacting and


forming a solid mass of material by heat or pressure without
melting it to the point of liquefaction. Sintering happens
naturally in mineral deposits or as a manufacturing process
used with metals, ceramics, plastics, and other materials.

Iron Making
1. Blast furnace: The blast furnace is a huge, steel stack
lined with refractory brick, where iron ore, coke and
limestone are dumped into the top, and preheated air is
blown into the bottom. The raw materials require 6 to 8
hours to descend to the bottom of the furnace where they
become the final product of liquid slag and liquid iron. The
hot blast temperature can be from 900 °C to 1300 °C (1600
°F to 2300 °F) depending on the stove design and
condition.

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2. Corex: JSW Steel is the first Indian Company to use the
Corex technology to produce hot metal. Corex is a smelting-
reduction process developed by VAI, for cost- efficient and
environmentally friendly production of hot metal from iron ore
and low grade coal. The process differs from the conventional
blast furnace route in that low grade coal can be directly used for
ore reduction and melting work, eliminating the need for coke
making units. The use of lump ore or pellets also dispenses with
the need for sinter plants.

Steel Making
1. Steel Making Shop (SMS): There are 3 SMS‟s in
JSW rated capacity SMS1 4MPTA, SMS2 7MTPA and
SMS3 10MTPA. The functions of SMS is the hot metal is
received from the BF and corex and it is charged in
converter with 20% of scrap and 80% of hot metal and
some fluxes, different grades of steel are produced based
on the customer’s requirements in the form of slabs billet
and blooms.

2. Direct-Reduced Iron (DRI): All metallurgical work is


carried out in two separate process reactors - the reduction
shaft and the melter gasifier. Lump ore, sinter, pellets or a
mixture are charged into a reduction shaft where they are
reduced to direct-reduced iron (DRI) by a reduction gas.
Discharge screws convey the DRI from the reduction shaft
into the melter gasifier where final reduction and melting

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takes place in addition to all other metallurgical and slag
reactions.

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Mills
1. Hot Strip Mill (HSM): There are two HSM in JSW
having capacity of 3.2MTPA
and 5.72 MTPA respectively. The functions of the HSM are
it provides coils with the help of slabs. Vijayanagar HSM-I
and HSM-2 with commissioned capacities of 3.2 MTPA and
5 MPTA respectively are equipped with sizing presses and
an automatic line inspection facility which makes this facility
the widest Hot Strip Mill in India. Due to their thinner
gauges and finer surface quality, these are often superior to
commercial grade cold rolled (CR) coils and may substitute
for CR products in certain applications. The convenient
coastal location of JSW unit facilitates easy access to plant
and makes the import and export of raw materials and finished
good extremely.

2. Cold Rolling Mill (CRM): II India’s largest Auto


grade steel plant at Vijayanagar Works was commissioned
on October 19, 2013 with a capacity of 2.3 MTPA. The
project will cater the Auto industry in India and some of the
best global car makers will use the CRM II products. JSW
houses India’s fastest and widest hot strip mill, which can
roll products up to 2,100mm width and a speed 1250mpm.
It is the first steel plant to install Continuous
pickling/annealing line in India. The total capacity after
expansion in 5 MTPA. The mill was commissioned along
with electrical erection and automation in the shortest span
and integrated with the mill.

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RMHS PLANT BENIFITIAL PLANT

SINTER PLANT

PILLET PLANT

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Raw Material Handling Section
It is backbone of industry which supply raw material of
requisite quality in adequate quantity to respective
department.

Functions of RMHS
• Receives raw materials in adequate quantity.
• Allocate space for raw material stacking.
• Effective bedding and blending of incoming raw
materials from different mines to get homogeneous
mixture.
• Timely supply raw material to respective department

8. Research and Development


Research and development (R&D) activities at JSW
Steel is focused towards Plant Performance
Improvement (PPI), development of new processes
and products, energy conservation and waste
utilization. Some of the newer areas of work are
recycling of wastes, such as coal fines, mill scale and
other iron bearing wastes by agglomerating these
materials into briquettes, beneficiation of BHQ, which
would revolutionize hot metal making in future amongst
others.

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9. Vision, Mission & Values
At JSW Steel Ltd, the vision has been developed through
the belief of the patriarch chairman Late Shri O. P. Jindal,
who said “Where others see walls, I see doors”. The vision
of JSWSCPL is derived from the vision of its parent
company JSW Steel Ltd.
Vision: Nurture Leadership in Coated Products by Creating
Value for Stakeholders in an Environmentally Sustainable
way.
Mission: Supporting India's Growth in Core Economic
Sectors with Speed & Innovation
Values: Transparency, Strive for Excellence, Dynamism,
Passion for Learning.

10. Expansion Plan


Over the next two years, JSW Steel plans to roll out
additional 200 JSW Shoppes. The Company also plans to
open Shoppes in the SAARC region, starting with Nepal
and Sri Lanka
The unique concept and its smooth implementation have
grabbed attention across the globe. Harvard Business
School has made this initiative, a case study that can help
their students understand the intricacies of the distribution,
sales and marketing process in India.

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11. Products manufactured by JSW
1. Hot rolled coils (HR-coils)
2. Cold rolled coils (CR-coils)
3. TMT Bars
4. Wire rods
5. Galvanized
6. Galvalume
7. Colour coated products
8. Neo-steel TMT Bars

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BLAST FURNACE

SMS PLANT

BAR ROD MILL

HSM PLANT

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4. LIME CALCINATION PLANT
4.1 INTRODUCTION
Calcination or calcining is a thermal treatment process to
bring about a thermal decomposition. The process takes
place below the melting point of the product. The name
calcination is derived from the Latin word ‘Calcinare’ which
mean to burn lime. Limestone is a naturally occurring
mineral. It exists nearly all over the world. The chemical
composition of this mineral varies greatly from region to
region as well as between different deposits in the same
region. Therefore, the end product from each natural
deposit is different.

LIMESTONE COMPOSITION
Typically limestone is composed of calcium carbonate
(CaCO3), magnesium carbonate (dolomite) (MgCO3), silica
(SiO2), alumina (Al2O3), iron (Fe), sulphur (S) and other
trace elements.

4.2 SOURCE OF LIMESTONE


Limestone is one of the most basic raw materials employed
in the steel industry and is used both in iron making and
steel making processes. Lime (CaO) is one of the oldest
chemicals known to man and the process of lime production
is one of the oldest chemical industries. Quicklime was
produced in US as early as 1635 in Rhode Island.
Technical progress which was non existing in centuries
past, has rapidly advanced the lime industry during the last
fifty years in the area of process methods and design.
Limestone is generally classified into the following types:

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• High calcium – The carbonate content is composed
mainly of calcium carbonate with a magnesium carbonate
content not more than 5 % (usually less).
• Magnesium – This contains magnesium carbonate to
about 5 – 20%.

• Dolomitic -This is also known as dolomite and contains


over 20 % of MgCO3. However the maximum MgCO3
content does not exceed 45.6%. The balance amount is
calcium carbonate.
Limestones from different sources differ considerably in
chemical compositions and physical structures. The
chemical reactivity of various limestones also shows a large
variation due to the difference in crystalline structure and
the nature of impurities such as silica, alumina and iron etc.
The varying properties of the limestone have a big influence
on the processing method. Hence it is necessary to know
comprehensive information of the limestone such as
physical and chemical properties, the burning
characteristics and kinetic parameters for the calcination of
the limestone. This aids optimal design and operation at
lime kilns.

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5. PRODUCTION OF LIME
The production of good quality lime depends upon the type
of kiln, conditions of calcination and the nature of the raw
material i.e. limestone. At relatively low calcination
temperatures, products formed in the kiln contain both
unburnt carbonate and lime and is called ‘underburnt’ lime.
As the temperature increases, ‘soft burnt’ or ‘high reactive
lime’ is produced. At still higher temperatures, ‘dead burnt’
or ‘low reactive lime’ is produced. Soft burnt lime is
produced when the reaction front reaches the core of the
charged limestone and converts all carbonate present to
lime. A high productive product is relatively soft, contains
small lime crystallites and has open porous structure with
an easily assessable interior. Such lime has the optimum
properties of high reactivity, high surface area and low bulk
density. Increasing the degree of calcination beyond this
stage makes formed lime crystallites to grow larger,
agglomerate and sinter. This results in a decrease in
surface area, porosity and reactivity and an increase in bulk
density. This product is known as dead burnt or low reactive
lime.

5.1 Calcination process


Calcination reactions usually take place at or above the
thermal decomposition temperature. This temperature is
usually defined as the temperature at which the standard
Gibbs free energy is equal to zero. In case of limestone
calcination, a decomposition process, the chemical reaction
for decomposition of the limestone is
CaCO3= CaO + CO2 (g)
The standard Gibbs free energy of reaction is approximated
as ?G°r = 177,100 ? 158 T (J/mol). The standard free

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energy of reaction is zero in this case when the temperature
T is equal to 1121 K or 848 deg C. Hence the chemical
decomposition reaction for pure CaCO3 will start at 850 deg
C.
Calcination of calcium carbonate is a highly endothermic
reaction, requiring 755 M Cal of heat input to produce a ton
of lime. The reaction begins when the temperature is above
the dissociation temperature of the carbonates in the
limestone. This typically is between 850 deg C and 1340
deg C. Once the reaction starts the temperature must be
maintained above the dissociation temperature, and carbon
dioxide evolved in the reaction must be removed.
Dissociation of the calcium carbonate proceeds gradually
from the outer surface of the particle inward, and a porous
layer of calcium oxide, the desired product, remains.

The factors affecting Calcination


Crystalline structure affects the rate of calcination, internal
strength of limestone and resultant crystal size of lime after
calcination. The smaller crystals agglomerate during
calcination and forms larger crystals which in turn cause
shrinkage and volume reduction.Calcination at higher
temperature means higher agglomeration and more
shrinkage. Also the density of limestone is related to the
crystal structure. The shape of crystals determines the void
space between crystals, and hence the density of the
limestone. Larger voids allow easy passage for CO2 gases
during calcination and it results in a reduction of volume
during calcination. Some limestone, due to its crystalline
structure, disintegrates during the calcination process. This

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type of limestone is not useful for calcining. This type of
limestone become so dense during calcination that it
prevents the escape of CO2 and become non porous. This
type of limestone is also not suitable for calcination.

SIZE
The smaller size limestone is more suitable for calcination
in rotary kilns and it allows optimum residence time. The
lower calcining temperature also allows less fuel
consumption. In contrast, larger size limestone and low
calcining temperature is needed for vertical kilns. If the
temperature rise is too rapid, the outer layer of the
limestone pieces is calcined very fast. As the temperature
rises, the surface of the limestone shrinks and closes the
pores created by the escape of CO2. This causes
increased internal pressure within the limestone. Since the
CO2 gas cannot escape, the limestone explodes and
disintegrates producing unwanted “fines” thus reduces the
quality of the lime.

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LIME CALCINATION PLANT PROCESS FLOWCHART

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5.2 KILN
A kiln is a thermally insulated chamber, a type of oven, that
produces temperatures sufficient to complete some
process, such as hardening, drying, or chemical changes.
Kilns have been used for millennia to turn objects made
from clay into pottery, tiles and bricks. Various industries
use rotary kilns for pyroprocessing—to calcinate ores, to
calcinate limestone to lime for cement, and to transform
many other materials.
Calcining kilns are basically comes in two categories. They
are i) rotary kilns and ii) vertical
kilns.

ROTARY KILN
Rotary kilns can be long kilns with straight rotary coolers
while verticals kilns can be several types. Calcining kilns
need lime stone with decrepitation index. Decrepitation
index of limestone is a measure of its susceptibility to
disintegration during calcination. Low value of decrepitation
decreases the porosity of the bed thus impeding the flow of
the gases and reducing the kiln efficiency. Rotary kilns also
need limestone with good tumbling index

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VERTICAL KILN
The Vertical Shaft Kiln or VSK is probably the first type of
kiln that was used and it can be traced back to the 5th
century A.C. in Greece, when they were used for limestone
calcining (Reiter, AC, 11/1997, p. 23). In the 20th century,
they have been largely replaced by rotary kilns, which were
implemented for the first time in 1880. However, in several
countries such as China and India, many of these kilns are
still operating (4000 units in China in 2005) and even, some
companies still offer this technology for sale.

Different types of kilns for calcination limestone

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LIMESTONE SUPPLIERS
Limestone and Dolomite are imported from UAE and
Bagalakot

6. APPLICATIONS OF LIMESTONE
Limestone is very common in architecture, especially in
Europe and North America. Many landmarks across the
world, including the Great Pyramid and its associated
complex in Giza, Egypt, were made of limestone.
• It is the raw material for the manufacture of quicklime
(calcium oxide), slaked lime (calcium hydroxide),
cement and mortar.
• Pulverized limestone is used as a soil conditioner to
neutralize acidic soils (agricultural lime).
• Is crushed for use as aggregate—the solid base for
many roads as well as in asphalt concrete.
• Geological formations of limestone are among the best
petroleum reservoirs;
• As a reagent in flue-gas desulfurization, it reacts with
sulfur dioxide for air pollution
control.
• Glass making, in some circumstances, uses limestone.
• It is added to toothpaste, paper, plastics, paint, tiles,
and other materials as both white
pigment and a cheap filler.

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• It can suppress methane explosions in underground
coal mines.
• Purified, it is added to bread and cereals as a source
of calcium.
• Calcium levels in livestock feed are supplemented with
it, such as for poultry (when
ground up).
• It can be used for remineralizing and increasing the
alkalinity of purified water to prevent
[17]
from the iron.
• It is used in sculptures because of its suitability for
carving.

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7. CONCLUSION
The purpose of this Internship is to make the engineering
students acquire the knowledge about industries and to
have hands on experience on the various machines. So
that, they can be made us ready for the industry according
to the company standards and their requirements. This
internship helped us to attain new skills and abilities to
handle the situation inside a company. By working in the
industry we are able to gain lots of knowledge which will be
helpful for us in the way of life.

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REFERENCE
12. internship
13. www.jswsteels.com
14. www.wikipidia.com

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