SAIL

1
An Overview Of
STeeL AUTHOriTY Of inDiA
(BOKArO STeeL PLAnT)
THERE IS LITTLE BIT OF “SAIL” IN EVERYONES LIFE
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BOKArO STeeL PLAnT

CONTENTS
INTRODUCTION
PRIMARY AREA
 Raw Material Handling Plant

 Coke Ovens and Coal Chemicals
 Sinter Plant
 Blast Furnace
 Steel Melting Shop
 Fabrication
MILLS AREA
 Blooming & Billet Mill

 Rolling mill
 Slabbing mill
SERVICES AREA
 R & C Laboratory
 Foundry Shop
 Oxygen Plant
 Power Plant
 CEM/WRS
 Plant Civil Engineering
 Electrical Repair Shop
Introduction
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Bokaro Steel Plant - the fourth

integrated plant in the Public
Sector - started taking shape in
1965 in collaboration with the
Soviet Union. It was originally
incorporated as a limited company
on 29th January 1964, and was
later merged with SAIL, first as a
subsidiary and then as a unit,
through the Public Sector Iron &
Steel Companies (Restructuring &
Miscellaneous Provisions) Act
1978. The construction work
started on 6th April 1968.
The Plant is hailed as the country’s first Swadeshi steel plant, built with
maximum indigenous content in terms of equipment, material and know-how.
Its first Blast Furnace started on 2nd October 1972 and the first phase of 1.7
MT ingots steel was completed on 26th February 1978 with the commissioning
of the third Blast Furnace. All units of 4 MT stage have already been
commissioned and the 90s' modernization has further upgraded this to 4.5 MT
of liquid steel.
The new features added in modernization of

SMS-II include two twin-strand slab casters
along with a Steel Refining Unit. The Steel
Refining Unit was inaugurated on 19th
September, 1997 and the Continuous Casting
Machine on 25th April, 1998. The
modernization of the Hot Strip Mill saw
addition of new features like high pressure
de-scalars, work roll bending, hydraulic
automatic gauge control, quick work roll
change, laminar cooling etc. New walking
beam reheating furnaces are replacing the less efficient pusher type furnaces.
A new hydraulic coiler has been added and two of the existing ones revamped.
With the completion of Hot Strip Mill modernization, Bokaro is producing top
quality hot rolled products that are well accepted in the global market.
Bokaro is designed to produce flat products like Hot Rolled Coils, Hot Rolled
Plates, Hot Rolled Sheets, Cold Rolled Coils, Cold Rolled Sheets, Tin Mill Black
Plates (TMBP) and Galvanized Plain and Corrugated (GP/GC) Sheets. Bokaro
has provided a strong raw material base for a variety of modern engineering
industries including automobile, pipe and tube, LPG cylinder, barrel and drum
producing industries.
BASIC INFORMATION
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 Location : Southern bank of Damodar River; approx. 50 kms from

Dhanbad and 140 kms each from Ranchi and Jamshedpur.
 Latitude : 230 39'
 Longitude : 860 09'
 Altitude: 210 meters (average) varying from 195 to 224 meters.
 Climate : Extreme
 Annual Rainfall : Average 157 cms; Maximum 195 cms
 Temperature : Maximum 48½0 Celsius, Minimum 2½0 Celsius
 Wind direction : South-West to North-East
 Type of Soil : Loamy up to 1 to 2 meters, sandy soil below that
 Total land area : 33,045.35 acres(Plant, Slag-dump, Cooling, Ponds,
Ancillaries, Marshalling
 Yard: 17,208.01 acres
 Township (including Airstrip) : 10,114.53 acres
 Garga Reservoir : 3,886.87 acres
 Railways : 1,835.94 acres

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PRIMARY AREA
RMHP (RAW MATERIALS HANDLING PLANT
Raw Material Handling Plant or Ore Handling Plant or Ore Bedding and
Blending Plantplay a very important role in an Integrated Steel Plant. It is the
starting point of an integrated steel plant, where all kinds of raw materials
required for iron making/steel making are handled in a systematic manner,
e.g., unloading, stacking, screening, crushing, bedding, blending, reclamation,
etc.
Different types of major raw materials used in an integrated steel

plant are-
1. Iron Ore
2. Lime stone
3. Dolomite
4. Manganese Ore
5. Ferro and Silico manganese
6. Quartzite and Coal
For Blast Furnace route Iron making the main raw materials required
are-
1. Iron ore lump

2. Blast furnace grade lime stone
3. Blast furnace grade dolomite
4. Coke
5. Sinter
6. Scrap
7. LD Slag
8. Mn Ore
9. Quartzite
The main objective of raw material handling plant/ore handling

plant/ore bedding and blending plant is to:-
 Homogenize materials from different sources by means of blending
 Supply consistent quality raw materials un-interruptedly to different
customers
 Maintain buffer stock
 Unloading of wagons/rakes within specified time norm
 Raw material preparation (like crushing, screening etc.).

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The main functions of RMP/OHP/OB&BP are –

 Unloading& stacking of raw materials,
 Screening of iron ore lump & fluxes,
 Crushing of coke/flux and base mix preparation,
 Dispatch of processed inputs to customer units
Different types of raw materials such as iron ore lump, iron ore fines,
limestone, dolomite, manganese ore, etc,.are supplied by SAIL mines (Raw
Materials Division, SAIL) or purchased from outside parties. Right quality raw
material is basic requirement to achieve maximum output at lowest operating
cost. Quality of raw materials plays a very important and vital role in entire
steel plant operation. Quality of raw materials (incoming) and processed
material(outgoing) is monitored by checking the incremental samples collected
from the whole consignment Samples are collected at Auto Sampling Unit or
Sampling Unit. The samples prepared after quarter and coning method are
sent for further analysis.
Different Raw Materials and Their Sources
Sl. Raw Materials Sources

No.
1 Iron Ore Lumps Barsua,Kalta,Kiriburu,Meghataburu,

(IOL) Bolani,Manoharpur,Gua,Dalli,Rajhara,Rowghat
2 Iron Ore Fines Manoharpur,Gua,Dalli,Rajhara

(IOF) Barsua,Kalta,Kiriburu,Mghataburu, Bolani,
Rowghat
3 BF grade Lime Kuteshwar, Bhabanathpur,Nandini,Katani

Stone
4 BF grade Dolomite Birmitrapur, Sonakhan, Birsa Stone Lime

Company
5 SMS grade Lime Jaiselmer,Imported lime-stone from Dubai

Stone
6 SMS grade Belha, Baraduar

Dolomite
7 Manganese Ore Barjamunda, MOIL(Purchased)
8 Mixed Breeze Coke Generated inside the plant (Blast Furnace &
Coke Ovens)
9 Mill Scale Generated inside the plant

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10 Flue dust Generated inside the plant
11 LD Slag Generated inside the plant
Main functions of RMHP:-

 Tippling of wagons.
 Stacking and reclaiming of raw materials.
 Crushing of flux and coke.
 Sinter-mix preparation and supply to Sinter Plant
 Iron ore lump screening.
 Screened iron ore supply to Blast Furnace.
 High grade limestone, dolomite & iron ore lump supply to BOF.
Major equipments:-
(A) Wagon tipplers:-

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 These are 3 in number

 To unload the raw materials brought in rakes of
wagons from various mines
(B) Wing Trippers:-
 Two operated mechanically and one hydraulically
 To stack material on the beds
(C) Old Reclaimers:-

 Plough and Harrow type
 For reclaiming the materials
(D) Stacker cum Reclaimers:-
 4 in number
 For stacking on beds as well as reclaiming from
beds
 Two beds for Iron ore and two beds for flux
(E) Slewable Stacker:-
 1 in number
 For Sinter-mix preparation (i.e. stacking for
Sinter-mix)
(F) Blender Reclaimer:-
 1 in number
 To reclaim the Sinter-mix
Major sections:
(1) Sinter-mix preparation:
 Capacity of 12051 T/day
 Raw Materials stored in 18 bunkers of junction
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Main constituents of sinter mix:
Iron ore fines 0-10 mm
Limestone fines 0-3mm
Dolomite fines 0-3mm
Coke fines 0-3mm
 Also waste generated in the plant like flue dust,

mill scale, Ferro scraps are added
 Sinter mix is sent to the Sinter Plant
(2) Flux Crushing Plant:

 6 Impact hammer type crusher to crush
Limestone and Dolomite
 3 Primary Crushers of 200 TPH and 3 Secondary
Crushers of 250 TPH
 Required size of –3 mm obtained by closed loop
crushing system
 Crushed Limestone and Dolomite conveyed to
sinter-mix proportioning bunkers.
(3) Coke Crushing Plant:
 6 Smooth Roll Crushers to crush the coke
 Coke breeze offloaded at track hoppers is
reclaimed by two paddle feeders and conveyed
to storage bunkers
 Coke crushed to –3 mm and conveyed to
sinter-mix proportioning bunkers.
There are 8 dust extraction system and 8 dust suppression system for pollution control.
Sources of raw materials

Raw Material Size (in mm) Main Source
Iron ore fines 0-10 Bolani
Iron ore lump 10-50 Bolani

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BF/SP gr. L.S 5-50 Birimitrapur
BF/SP gr. dolo 5-50 Birimitrapur
BOF gr. L.S 25-55 Jaisalmer
Coke breeze 0-20 Internal
COCC (COKE OVENS & COAL CHEMICALS):-

Coke Ovens is an important department in an integrated steel plant. The
main objective of this department is to produce coke by carbonization of coal.
Coke is an essential raw material for production of Hot Metal.
During the process of carbonization of coal, a number of valuable

chemicals are obtained. This department also deals with the recovery and
processing of these chemicals.
Input – Output Model:
Washed Coal Wagon Wing Bed Reclimer

(-25 mm) Tipplers Tripper erners
THERE IS LITTLE BIT OFBlending

“SAIL” IN EVERYONES LIFE
Silos
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Primary
Crusher
Service Pneumatic
Bunkers 4 of Selective Crushing
Classifier
4000T each
Unit
Secondary
Crusher
Coal for
BF coke
making
To Battery
Major Sections:
(1) Coal Handling:
 To supply coal of required quality and quantity to

service bunkers for BF coke making
 Washed coal and imported coal received in
wagons are unloaded by means of Box Tipplers (3)
 The tippled coal is stacked in silos (14) as per
quality and grade

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 Coal of different quantity is drawn from Blending

silos and selectively crushed and blended in
Selective Crushing Unit
 Blended coal is sent to service bunkers for BF
coke making
(2) Coke Ovens Battery:
 There were 5 batteries of 78 ovens each and a
half battery of 39 ovens
 Now we have 3 batteries of 78 ovens each and a
half battery of 39 ovens
 Capacity of oven is 16.6 tonnes on dry basis
 Coking time 18 to 20 hours
 Flue temperature 1230o C
 Coke of size 20 to 80 mm is sent to BF,
undersize coke is sent to RMHP.
There are four special cars in this section:

(a) Charging Car: Takes coal from service bunkers to individual ovens
(b) Ram Car: Pushes the coke out of individual ovens
(c) Guide Car: Guides the coke during pushing operation
(d) Quenching Car: Receives the hot coke for quenching
The quality parameters of cleaned coal are:

Blend coal ash 15%
Ash in BF coke 19%
Fineness of crushing -3 mm (85%)
(3) Coal Chemicals Plant:

 By–product plant which recovers the chemicals
from the gas and allows clean gas to be used in
coke ovens and other plant as fuel
 4 gas streams with capacity of 3300 cube
meter/Hr each
This plant has four major sections:

 Benzol Plant
 Tar distillation

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 MNCP
 BOD plant
Properties / Requirement of Coke for BF use:

 As fuel
 As reducing agent
 Must have high mechanical strength
 Must be in required size range

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SINTER PLANT
A large quantity of fines is generated in the mines, which cannot be charged
directly into the Blast furnace. Moreover many metallurgical wastes are
generated in the steel industry itself, disposal of which is very difficult. In order
to consume this otherwise waste fine material they are compacted together and
made into lumps by a process known as SINTERING. Sintering is a technology
for agglomeration of fine mineral particles into useful Blast furnace burden
material. This technology was developed for the treatment of waste fines in the
early 20th century. Since then sinter has become the widely accepted &

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preferred Blast furnace burden material. At present improvement in Iron &

Steel production without sinter is unbelievable. No iron & Steel making plant
can be conceived without sintering process.
Raw materials used in Sinter Plant
1. Iron ore fines

2. Coke breeze fines
3. Millscale+fines
4. Lime stone fines
5. B.O.F.Sludge
6. B.O.F.Slag
7. Dolomitefines
8. BurntLime
9. BFReturnfines+InplantR/fine
The ore fines, lime stone fines, dolomite fines, lime dust, coke breeze & some
other metallurgical wastes are proportioned based on charge calculation. Then
these are mixed in a balling drum with the addition of water and then loaded
into grates of moving pallets. The purpose of Balling drum is to mix the raw
materials (called base mix) with water and make balls. After mixing and ball
formation this base mix is loaded on moving sinter machine pallets. HEARTH
LAYER which consists of finished sinter of size fraction 16to 25mm forms the
bottom layer. Base mix is loaded above the hearth layer. As soon as these raw
materials reach the ignition furnace, Top layer is ignited in the IGNITION
FURNACE by burning of gases. Air is drawn downwards through exhausters.
The heat from top layer is gradually transferred to subsequent bottom layers.
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Due to burning of coke particles bonding take place between the grains and a
strong & 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, screened, cooled and dispatched to Blast furnace. The
ideal size of sinter required in blast furnace is in between 5mm to 40mm. The
other sizes are screened & returned back to sinter bins.
Sinter making
Sintering of fines by the under grate suction method consists of the mixing of
fines with finely crushed coke as fuel and loading the mixture on the pallet
grates. Ignition of the fuel proceeds on the surface of charge by a special
ignition arrangement, called ignition furnace (where gaseous fuel is burnt to
produce high temperature to ignite the fuel in sinter mix) the gases used in
ignition furnace are mainly coke oven gas and mixed gas. Mixed gas is
combination of coke oven gas and blast furnace gas. Further the combustion
is continued due to suction of air through the layers of the charge by means of
Exhausters. Due to this, the process of combustion of fuel gradually moves
downwards up to the grates.
From the scheme obtained in a few minutes after ignition, it is

observed that the sintering process can be divided into six distinct
zones:
1. Zone of Cold Sinter (60 to 100 degree Celsius)
2. Zone of hot Sinter (100 to 1000 degree Celsius)
3. Zone of intensive combustion of fuel (1000 to 1350 degree Celsius)
4. Heating zone (1000 to 700 degree Celsius)
5. Zone of Pre-heating of charge (700 to 60 degree Celsius)
6. Zone of Re-condensation of moisture (60 to 30 degree Celsius)
In all the zones except the zone of combustion, the reactions taking place are
purely thermal where as in the zone of combustion reactions are thermal and
chemical. The maximum temperature attained in the zone of combustion will
be 1300-1350 degree Celsius. The vertical speed of movement of the zones
depends on the vertical speed of sintering. Heat from the zone of ready sinter is
intensively transmitted to the sucked air. In the zone of combustion of fuel hot
air and preheated charge comes into contact with each other24which with the
burning fuel will result in the formation of high temperature. Maximum
temperature will be developed in this zone and all the physical-chemical
process takes place resulting in the formation of Sinter. In the zone of pre-
heating the charge is intensively heated up due to transfer of heat from the
sucked product of combustion. In the zone of re-condensation of moisture, the
exhaust gases during cooling transfer excess moisture to the charge.
Temperature of this zone sharply decreases and will not increase till all the
moisture is driven off. As the fuel in the zone of combustion is burnt away,

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Sinter, the height of which increases towards the grates, is formed above this
zone from the red hot semi-fluid mass, forcing out subsequent zones.
Disappearance of the zone of combustion means the end of sintering process.
The sinter cake is then crushed, screened, cooled and dispatched to Blast
furnace. The ideal size of sinter required in blast furnace is in between 5mm to
40mm. The other sizes are screened & returned back to sinter bin.
Chemical reactions in sintering process:

Sinter is produced as a combined result of locally limited melting, grain
boundary diffusion and re-crystallization of iron oxide during sintering. The
basic metallurgical
Reaction takes place in sintering zone.

1. C+O2---CO2 + 4220calories
2. CO2 + C --- 2CO + 53140 calories
3. 3Fe2O3+ CO ---- 2Fe3O4 + CO2 + 8870 calories
4. Fe3O4 + CO ---- 3FeO + CO2 - 4990 calories
Factors affecting sintering process
1. Quality of Input raw materials

a. Quality of Iron ore fines: +10 mm should be nil
: -1mm should be 30% maximum
: Alumina (Al2O3) 2.5% maximum
: Silica (SiO2) 2.5% maximum
Increase in +10mm fraction will result in weak sinter & low productivity
Increase in –1mm fraction will decrease bed permeability resulting in low
productivity Increase in % of Alumina increases RDI(Reduction Degradation
Index) resulting in generation of –5mm fraction & also resulting in chute
jamming.(Due to high Alumina in B/Mix.
b. Quality of Flux: -3mm fraction should be 90% minimum (Crushing index)

: Less crushing index results in free lime, causing weak sinter 25
c. Quality of Coke: -3mm fraction should be 90% minimum (Crushing index of
coke)
: +5mm fraction should be nil
: Increase in 5mm fraction decreases the productivity
2. Moisture:
Moisture in the form of water is added in the base mix in balling/nodulising
drums. Water acts as binder of base mix. Addition of water in base mix plays
important role in sinter bed permeability. Ideally 6 to 7% of total base mix of

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water are used. Higher % of water results in low permeability & less sintering
speed. Less % of water results in less balling, hence less permeability,
resulting in low productivity.
3. Ignition furnace temperature:

Ignition of sinter mix is carried out through ignition hearth where a
temperature of 1150to 1350 degree Celsius is maintained by burning gaseous
fuel by the help optimum air/gas ratio.32.5% of co gas & 67.5% of Bf gas is
used to maintain calorific value1900kcal/m3.Higher hearth temperature
results in fusing of sinter at top layer. This reduces the bed permeability,
hence low productivity. Low heart temperature results in improper ignition.
Sintering process will not be completed, hence –5mm fraction will increase, i.e
recalculating load will increase.
Note- BF&CO gas mixing ratio and calorific value varies in different plant
under SAIL unit.
4. Coke rate:
Coke acts as a solid fuel in base mix in the sintering process. It is normally 6%
of total charge. Higher coke rate will fuse the top layer, thereby decreases the
bed permeability. Sticker formation will increase. Low coke rate will result in
incomplete sintering.
5. Machine speed:
Speed of sinter machine can be varied as per the condition of sintering
process. BTP (Burn through Point) temperature decides the completion of
sintering process. It is observed normally in second last wind box from
discharge end side of sinter machine where the temperature reaches up to 400
degree Celsius (approximately). Higher machine speed, lower BTP causes
more–5mm generation, hence lower productivity. Lower m/cspeed, higher BTP
temperature causes low productivity
Note: BTP Exhaust gas temperature which indicates the completion of
sintering processes called BTP. It is approximately around 400 degree
centigrade.
Crushing, Cooling & Screening of sinter
The finished sinter cake is then crushed to the size of 100mm by using
crushers.Normalising of finished crushed sinter is then done on coolers by
means of air blowers(induced draught fans),so that cooler discharge end
temperature is about 80 degree centigrade. For effective cooling, bigger size of
sinter should be on bottom portion &smaller size should be on top. Finally
various fractions of sinter is screened out.-5mm fraction of sinter returns back
to bunkers. 16 to 25mm fraction is also screened out to be used as hearth
layer. Rest sizes goes to blast furnace, after screening +10mm fraction should
be 65%minimum and –5mmfraction should be 8% maximum as per
requirement of blast furnace
Advantages of using Sinter

1. To utilize the ore fines generated at mines to transform to an acceptable feed
in blast furnace
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2. To utilize economically all the metallurgical wastes like Mill scale, L.D slag,
B.O.F slurry, Flue dust, Ferro scraps etc.
3. To utilize the coke breeze generated in coke screening at coke ovens as fuel,
otherwise has no metallurgical use
4. To reduce coke rate in B.F by ensuring free available lime for slag.
5. To increase productivity of B.F
BLAST FURNACE
Blast Furnace is the most important part of an integrated steel plant. It is
considered as the heart of an ISP. The objective of Blast Furnace is to take the
raw material from RMHP, coke from Coke Ovens and Sinter from Sinter Plant
and convert it into pig iron or ”Hot Metal”. Coke serves as the heat source and
reducing agent while Limestone and Dolomite are used as flux, which combines
with gangue to produce slag. A Blast Furnace is so called because it uses air
blast as oxygen source for the process.
There are four Blast Furnaces in DSP, out of which 3 are in running condition.

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Input – Output Model:
Sinter Iron ore lump
Coke
Blast
Hot Blast Hot Blas BF Gas Clean BF
Furnace GCP
Gas
Hot metal
Slag
PCM
SMS
BF is a counter current heat and mass exchanger, in which solid raw materials
are charged from the top of the furnace and hot blast, is sent through the
bottom via tuyeres.The heat and is transferred from the gas to the burden and
oxygen from the burden to the gas. Gas ascends up the furnace while burden
and coke descend down through the furnace. The counter current nature of
the reactions makes the overall process an extremely efficient one in reducing
atmosphere. The real growth of blast furnace technology came with the
production of high strength coke which enabled the construction of large size
blast furnaces.
The raw materials and their quality:
In India steel is being produced largely through the blast furnace/ B.O.F.route.
Iron ore, sinter and coke are the major raw materials for blast furnace
smelting.

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The following raw materials used for the production of pig iron: -
(i) Iron ore
(ii) Limestone
(iii) Dolomite
(iv) Quartzite
(v) Manganese ore
(vi) Sinter.
Iron ore: Iron bearing materials; provides iron to the hot metal. It is the
principal mineral in blast furnace for extraction of pig iron; generally rich in
iron content varying from 60% to 66%. The high alumina content makes the
slag highly viscous and creates problems for stable furnace operation.
Limestone: Acts as flux. Helps in reducing the melting point of gangue present
in the iron bearing material and combines effectively with acidic impurities to
form slag in iron making.
Quartzite: Acts as an additive quartzite is a mineral of sio2 (silica) and under

normal circumstances contains about 96-97% of sio2 rest being impurities.
Manganese ore: Acts as additive for the supply of Mn in the hot metal. Mn ore
is available in the form of combined oxides of Mn and Fe and content of Mn is
about 31-32% for steel plant use
Coke: Acts as a reluctant and fuel, supports the burden and helps in
maintaining permeable bed.
Sinter: It is iron bearing material. Sintering is the process of agglomeration of

fines(steel plant waste) by incipient fusion caused by heat available from the
fuel contained in the charge. The lumpy porous mass thus available / obtained
is known as “sinter”.
Coal dust: Acts as an auxiliary fuel, reduces coke consumption in the bf

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Coal tar: Acts as an auxiliary fuel, reduces coke consumption in the bf
High lines and Stock house:
High lines: The main responsibility of high lines section is to receive the raw
materials required for the production of hot metal from various sources,
storing and transporting them to the top of the furnace in time, for the smooth
running of the furnace.

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Ore yard: Raw materials arriving to the blast furnace department from various
sources are unloaded in the ore trench of ore yard. After the ore trench, ore
yard is located towards the blast furnace. The ore yard is meant for stocking
and averaging of materials. The materials from ore trench are transported to
ore yard with the help of ore bridge cranes (OBCs). Raw materials from the ore
yard are charged by means of electrically operated transfer cars (OTCs); carry
the materials into the respective bunkers. Sinter From bunker located on the
extension tracks of high line was collected in transfercars moving on rail tracks
or sinter comes by means of conveyor belt and is stored in receiving hopper.
Sinter is screened, and the fines are returned through conveyor belts Coke (25
-80mm) from coke sorting plant is supplied to the coke bunkers of the blast
furnace with the help of conveyor belts.
Stock house: Below the bunkers there is a vibro-feeder, which feeds the
material to the conveyor belt, which charges the material on screen. The bf size
material is fed to weighing hopper through ore discharge conveyor. The
weighing hopper discharges the material into the skip. There are conveyors to
remove the fines from the system.

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Raw materials including coke are transported and collected into high line
bunkers placed near the furnaces and then properly screened and weighed.
Weighing is done either by scale car or by load cell or by any suitable
arrangement. These batched proportions of the raw materials are conveyed to
the top of the blast furnace via skip car or conveyors and are charged in the
blast furnace. The distribution is maintained in such a fashion that alternate
layers of coke and iron-containing burden (sinter and iron ore) are formed
inside the bf.
Flow of material to charging skip is

 Bunkers
 vibro feeder
 conveyor belts
 weighing hopper
 Skip car.
Hoist house:
For taking charged materials to the furnace top, two-way skip hoist with 2
skips are provided. The hoist house operates the skip that is driven by two
motors. Bell hoist, equalizing valves test rods etc. are also operated from hoist
house.
Blast Furnace and Accessories

Blast furnace is basically a counter current apparatus, composed of two
truncated cones placed base to base.
 The sections from top down are

 Throat, where the burden surface is.
 The shaft or stack, where the ores are heated and reduction starts.
 The bosh parallel or belly and
 The bosh, where the reduction is completed and the ores are melted
down.
 The hearth, where the molten material is collected and is cast via the tap
hole

25

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B F Proper
The entire furnace is lined with suitable refractory and carbon blocks in the
hearth and in the periphery of the hearth bottom. In addition to refractory
lining, there are water coolers, designed to enhance the life of the furnaces.
There is a tap hole of suitable dimension and length for the purpose of tapping
the hot metal. The raw material at the top will be charged either through
'double bell system' or 'bell less system' for furnace smelting. Since blast
furnace is basically a counter current apparatus the descending stream of raw
materials extract heat from the ascending stream of gas generated from the
burning of coke at the tuber level. The ascending stream of gas contains CO
(carbon monoxide) nitrogen and hydrogen and in the events of its coming in
contact with the iron ore, reduction (this reduction is called indirect reduction)
of iron ore takes place at the upper part of the stack. Coke in the form of 'c'
also takes part in the reduction. In the hearth there are slag notches at about
1.1-1.6 meter away from the hearth bottom for flushing out slag at regular
intervals before tapping, the notches are also extensively water cooled by
'monkeys'. The number of tap hole, slag notches, their positioning and
dimension will depend upon the capacity of the furnace. Many modern
furnaces are having 2-4 tap holes without slag notches. The furnaces are
equipped with tubers (water cooled copper construction for admission of hot
blast of air) through which preheated air blast at a temperature of about 8500c
-10000c is introduced for burning of coke. Before preheating, the blast of cold
air supplied by power and blowing station is introduced into hot blast stoves at
about 3.2-353.5 kg/cm2 (gauge pressure) wherein the air is pre-heated
regenerative and sent to the furnace through hot blast main and bustle pipe.
The air blast then passes from the bustle pipe through gooseneck and tuber
stocks/blow-pipes into tubers. The pressure of the blast and its flow rate is
dependent upon the capacity of the furnaces.
As the stream of the material descends down through different temperature

zones and get two products:-
 Metal in the bottom.
 Slag, having less density floats at the top of metal, and
 BF gas from top of the furnace. It generally comprises of 21-
22% CO; 19-19.5%CO2, 54% of N2, H2 4.4%, O2 0.1%.
Temp.of top gases are in the range of 100-300oc
Liquid iron collected in the hearth is taken out by opening the tap hole with
power driven drill and oxygen lancing after regular interval into a train of
ladles kept below the runner of the cast house. Slag that comes along with the
metal is skimmed off with the help of skimmer plate towards slag runner and
collected in slag thimbles or to slag granulation plant (SGP) of cast house. Slag
thimbles are then sent to the dump yard or slag granulation plant. Metal ladles
are either sent to SMS or pig casting machine (PCM) and foundry depending
upon the composition of the metal being tapped and as per requirement.
Top charging equipment:

27
The burden material which reaches to the top of the furnace by skip car or by
conveyer is to be distributed into the furnace. For this double bell charging
system, rotating charging unit (RCU),MTA is provided or equipped with paul-
wurth bell less top (BLT) charging system, which replaces bells with charging
bins, upper material gate, upper sealing valve, lower material gate and lower
sealing valve. This system also has a gearbox to operate rotating chute. The
latter distributes the material inside the furnace peripherally indifferent rings.
This facilitates better burden distribution inside the furnace.
Double bell BLT system
STEEL MAKING

28
The Hot Metal, which is produced by Blast Furnaces, consists of various

impurities. Main impurity present is Carbon and other impurities like
phosphorus, sulphur, silicon, nonmetallic inclusions etc are also present. Steel
making is the process of purification of this Hot Metal. Steel such produced is
the pure form of metal. Hot Metal contains around 4%of Carbon, which is
reduced below 0.1% as per the requirement. Other impurities like sulphur,
phosphorus are removed and alloying elements such as manganese, nickel,
Chromium and vanadium are added to produce the exact steel required. The
schematic view and various processes involved in steel making are as follows.
HMDS—HOT METAL DESULPHURISATION

BOF—BASIC OXYGEN FURNACE
OH/TH—OPEN HEARTH/TWIN HEARTH
ARS—ARGON RINSING STATION
LF—LADLE FURNACE
RH DEGASSER—RUHR –STAHL HERAUS (Process is named on a German
town and
a German scientist)
VAD—VACCUM ARC DEGASSER
VOD—VACCUM OXYGEN DECARBURISATION
CCS/CCP—CONTINUOUS CASTING SHOP/ PLANT
The Hot Metal from Blast furnace comes in Hot metal ladles to Steel
Melting Shop by rail. It is poured into a vessel called Mixer. Mixer has a
Charging hole from where Hot metal is being charged into with the help of
heavy cranes and a sprout to take out hot metal by tilting the mixer. Main
functions of mixer are storage and homogenization. Mixed gas is supplied
through side burners in order to maintain temperature in Mixers. Once it is
taken out it can go to Hot metal desulphurization unit and then to either of the
process of steel making i.e. Open/Twin Hearth furnace or Basic Oxygen
Furnace (BOF).
SMS (STEEL MELTING SHOP)

29
SMS or Steel Melting Shop is the section where hot metal from Blast
furnace is converted into steel. The process is Basic Oxygen Furnace or LD
process. This process was first used successfully in a place called Linz in
Austria and then at Donawitz in Austria. The name LD process came from the
names of these places. Basic Oxygen Furnace was added under modernization of
DSP. It has a capacity of 1.876 MTPA.
SMS can be divided into 3 sections:

 Basic Oxygen Furnace
 Continuous Casting Plant
 New Lime Calcinations Plant
Basic Oxygen Furnace:

Hot Metal coming out of the Blast Furnace is collected in ladles and
poured into mixers. The mixers (2) serve the purpose of storing as well as
homogenization of temperature and composition. Coke oven gas is used here to
maintain the temperature at 1260o C. the quantity of raw materials for
producing one ton of steel are as follows:
Hot Metal 1073 kg
Scrap 65.9 kg
Iron Ore 15.6 kg
Briquetted lime 10.6 kg
Calcined Lime 81.3 kg
Dolomite 31.3 kg
Fe- Mn 1.11 kg
Fe- Si 1.32 kg
Al 0.15 kg
Coke Breeze 3.27 kg

30
The shop has three converters each having a capacity of 110-130T per heat. The
converters were commissioned by Mannesmann Damage of Germany. Each
converter has its own lance system 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 separation of impurities takes place very fast.
The oxygen blowing rate through the lance is 415 Nm 3/min. and the blowing
pressure is 14.2 to 14.3 bars from top. The tap to tap time of BOF is
approximately 57 minutes out of which oxygen blowing time is 18 min. the gas
obtained from BOF converter has a calorific value of 2100 Kcal/Nm 3 which acts
as a fuel.
BOF has an online process monitoring system. The system uses VAX/VMS
system which works on the principle of virtual memory. The higher level of
computerization caters to the need of quick retrieval of data about operation
parameters.
(ii) Continuous Casting Plant:
CCP, one of the critical features of DSP is the first billet caster in any ISP in
SAIL. The machines are designed and supplied by Comcast Standard AG,
Switzerland. Presently, we have two machines with six strands in each, capable
of producing billets of sizes varying from 80 mm 2 to 150 mm2.
Under traditional route, liquid steel is allowed to solidify into separate moulds
and come out as ingots, which are then rolled to get the billets. Continuous
casting route bypasses the steps of soaking and rolling in blooming and billet
mill.
Technical Features of CCP:
No. of machines 2
No. of strands/machines 6
Design Limit 80 -150 mm2
Casting Radius 6m
Heat Size 110T (normal), 130T (max)
Casting time 85 min.
Shear Up cut pendulum type

31
Molten steel is taken to ladle treatment section. The purpose of ladle treatment
is to homogenize the temperature and composition, floatation of non-metallic
inclusions and to facilitate active slag metal reactions. A dummy bar is inserted
in the mould, up to 100 mm with the help of pinch rolls. The mould is
surrounded by 4 mm water jackets through which primary water is circulated
internally. Primary cooling is thus done by dematerialized water. Other zones
are kept cool by industrial water.
The billets formed are cut to proper lengths and are allowed to cool in air
and then packed and sent to stock yard.
(iii) NLCP (New Lime Calcinations Plant):

NLCP came up during during modernization in 94-95. This plant came up
to cater to the need of BOF. The main function of this plant is to produce lime
from naturally available limestone. Lime is mainly required in steel making
process to reduce sulphur and phosphorous content of steel. Presently,
Limestone from Jaywalker is used as input material for the plant.
There are three kilns (Annular kiln shaped), of capacity 300T/day, one is
kept standby; each kiln is a vertical cylindrical structure. Limestone, which is
charged from the top, gradually descends through the kiln, where it is subjected
to control heating by two firing zones preventing the charge from direct exposure
to base flame. Coke oven gas at 5500 mm water pressure is used as fuel for
heating. Temperature range of heating is 1200 0 C - 1250o C
The calcinations process is almost complete as the charge reaches the bottom
portion of lower combustion zone and the calcite lime is discharged into a silo by
Lime Discharging device.
NLCP has got bunkers and conveyors for storage, handling and supply of fluxes
to converter shop.
ROLLING MILLS
32
The process of plastically deforming metal by passing it between rolls is known

as rolling.
TYPES OF MILLS:-
A. PRIMARY MILLS
 Blooming & Billet Mill
B. FINISHING MILLS
 Section mill
 Skelp mill
 Merchant mill
Semi Finished products of BSP
 Blooms:160 to 250x250 mm
 Billets:125x125 mm,100x100 mm
 Slabs:140 to 225x80 mm
 Ingots: fluted ingots, 8T ingot
BBM (BLOOMING & BILLET MILL)

Main objective of this mill is to produce rectangular sections called
blooms. The 8T ingots produced at the SMS are first sent to the Stripper Bay.
After this the ingots are reheated for hot rolling process to give them different
sizes. Sections above 125x125 are called blooms while sections below
125x125mm are called billets. Some blooms go to Section Mill and some to Billet
Mill. The billets go to Merchant Mill.

33
Major Equipments:
Soaking Pits:
20 n numbers and of 3 types
• Wolman type - Bottom fired with ceramic recuperations
• Ofulyns type - side fired with ceramic recuperations
• Priest type - side fired with ceramic recuperations
42” Blooming Mill

34
• 2- high reversing type with twin motor drive
• Driven by two 3000 HP DC motors
• Speeds of 0/40/60 rpm
• Side guard type manipulators to guide the ingot through

various passes
• Generally rolled in 13 passes (19 passes required for special

steel).
Primary Hot Bloom Shearing & Stocking:

• Front and back ends of blooms which develop fish tails are
sheared using1200T shear
• Shear can cut a max. cross section of 256 square inch.
32” Intermediate Mill:

 2 high reversing mill driven by one 4500 HP DC motor
 Roll diameter varies from 800 mm to 925 mm
 Springs balanced rolls
 Speed range of 0/80/120rpm
700 Shear:
• Blooms are cut to length with nominal blade load of 700 T
Important Parameters:
(a) Pit Time:
This is the amount of time the ingots have to be placed in the soaking
pits. This is equal to 1.5 times the track time, which is around 3 to
4.5 hrs for hot ingots and around 12 hrs for cold ingots.
(b) No. of passes in blooming mill:
13, in case of normal steel and 19, in case of special steel.
Billet Mill
35
Blooms produced in Blooming Mill are further rolled into billets of

various sizes. The capacity of Billet Mill is 0.957 tonne per annum. The
products of this mill are 50 mm square to 125 mm square Billets and 140 to
240 mm * 75/80 mm skelp slabs.
Major Equipments:
(a) Mill Train:
• Continuous Morgan design with 8 strands
• Vertical rolls on first and fourth strands & remaining are

horizontal, 1 to 4 are roughing stands each run by 800 HP
DC motor (1 & 2) and 1000 HP DC motor (3 &4)
• 5 to 8 (finishing stands) driven by a single 700 HP

synchronous motor
(b) Up and Down Cut Shear:

 For emergency purpose
(c) Flying Shear:

 Cuts materials in process. (maximum capacity 130
square inch)
CASTING
In modern steel plants everywhere there is a demand for more and more
quality finished products. For rolling to very thinner products, continuous
casting products are the best compared to teeming of the steel to make ingots
and then to roll the ingots to produce slabs or billets or blooms. Continuous
casting not only meets the higher production within same time frame but the
quality of such products is quite lucrative and hence demanding.
Before going into the details of CCM a brief description of the caster is given
below:
<BOF> => Raw/Crude Steel from converter => <SRU> => Refining crude steel
i.e. killing, Homogeneous Temperature and Composition => <Caster> Turret,
Ladle S/Gate, Shroud => Tundish => Mould
Liquid steel comes from the ladle into the punish. Tunis is a device
where it collects, accumulates liquid steel from the ladle and feeds to two or
more moulds through SEN depending on the m/c and process.
Casting Preparation
36
1. Steel that is to be cast is treated well at SRU for smooth casting.

2. Tundish through which casting will be done is to be prepared.
Tundish is a device through which continuity of the casting is
maintained. There are two types of casting practices are in use namely cold
tundish and hot tundish practices. Liquid steel comes from the ladle into the
tundish and in turn the tundish feeds the liquid steel into the mould through
different outlet at the bottom of the tundish. Tundish is made of steel and
inside of which is lined with refractory bricks or castable. After that tundish
boards are fixed over the refractory lined. Submerged entry nozzle (SEN) are
fixed by clamping device in each of the tundish outlet
3. Preparing of the mould:
Mould is the most important equipment in the caster m/c. primarily

mould is prepared according to the shape and size of the product. For
solidification of the initial liquid steel that enters into the mould one DUMMY
BAR head is used, which is fed into the mould with a fixed rod or flexible
chain. This DUMMY BAR head is packed. Mould is made purely of copper as
copper has the most heat discharge capacity than any other metal
economically available. All sides of this mould is made up of Cu plate and heat
from liquid steel immediately discharges trough the copper plates by mould
cooling system
Copper plates are cooled by circulating soft water through designed
tubes in the form of coils.
Here the difference of MOULD COOLING WATER Outlet Temperature &

Inlet Temperature is monitored continuously. It is very much hazardous part
in caster m/c during casting. An alarm is provided as soon as the difference of
temperature raises more. Immediate actions are to be taken and if necessary
casting should be stopped without waiting for any other decision to be asked
from anyone.
Casting Process
Liquid steel taken into ladle is refined at SRU is placed over the turret
arm and ladle SG is fixed. Then one shroud is fixed at the bottom of the ladle
collector nozzle so that no stream of liquid steel comes in contact with the
atmosphere and no spillage occurs. This liquid steel gradually fills the tundish
and from there liquid steel leaves tundish nozzle/TSG through SEN into the
mould. Initially steel rests on the DUMMY BAR head on which some chillers
are placed to get the liquid steel freeze/solidifies quickly then the m/c starts
with MOM & casting powder is to be sprayed continuously at a certain mould
level. The process continues after the DUMMY BAR head is disconnected as it
reaches at its particular position. Length of the slab/billet is maintained by
using cutting torch/ shearing blades.

37
ROLLING MILLS

38
HOT AND COLD ROLLING

39
Hot Rolling: The rolling process in which rolling is done above

recrystallisation temperature it is called hot rolling.
Cold Rolling: The rolling process in which rolling is done below
recrystallisation temperature is called cold rolling.
Recrystalisation temperature: is the temperature on rolling above which we

get strain free grains and minimum residual stresses in rolled metal. It is
normally 0.5 to 0.7 times of melting point of the metal. All SAIL integrated
plants have hot rolling mills whereas only Bokaro, Rourkela and Salem have
cold rolling mills.
LONG AND FLAT PRODUCTS

During rolling when the input is pressed from both perpendicular directions
(from top-bottom and from both sides) the volume of the metal goes into
length. This is called long product rolling. If the metal is pressed from top to
bottom and spreads on the sides it is called flat product rolling.
PRODUCTS OF ROLLING MILLS OF SAIL Bokaro Steel Plant

• HR coils, sheets, plates
• CR coils, sheets
• Galvanised plain and corrugated sheets
• Tin mill black plates
APPLICATIONS OF ROLLED PRODUCTS OF SAIL
Hot Rolled Coils, Sheets and Skelps
Used for construction of tanks, railway cars, bicycle frames, ships,

engineering, military equipment and automobile and truck wheels, frames, and
body parts. HR coils are also used as feedstock for pipe plants and cold rolling
mills where they undergo further processing.
Plates

40
Steel plates are used mainly for the manufacture of bridges, steel structures,
ships, large diameter pipes, storage tanks, boilers, railway wagons, and
reassure vessels. SAIL also produces weather-proof steel plates for the
construction of railcars. SAIL is the only producer of wide and heavy plate
products in India.
Cold Rolled Products

The products of the cold rolling mills include cold rolled sheets and coils,
which are used primarily for precision tubes, containers, bicycles, furniture
and for use by the automobile industry to produce car body panels. Cold rolled
products are also used for further processing, including for colour coating,
galvanizing and tinning. Galvanized Sheets are used in roofing, paneling,
industrial sheeting, air condition ducting and structural applications.
Electrolytic Tin Plates are used in containers for packaging of various products
including edible oils, Cola, Fruit Juices, Pickles and confectionary items.
Railway Products
Rails are the main rolled products by SAIL. It is used primarily to
upgrade and expand the existing railway network in India.
Structural’s
I-beams, channels and angle steel are used in mining, construction of
tunnels, factory structures, transmission towers, bridges, ships, railways, and
other infrastructure projects.
Bars and Rods

Reinforcement steel and wire rods are primarily used by the construction
industry.
Semi-Finished Products
Semi-finished products (blooms, billets and slabs) are converted into
finished products in SAIL’s processing plant and, to a lesser extent, sold to
rerollers for conversion to finished products
HOT ROLLING
The rolling process in which rolling is done above re crystallization
temperature is calledhot rolling. More reductions are possible in hot rolling as
compared to cold rolling.
REHEATING FURNACES
In the reheating furnaces the Input materials are heated to a specified
temperature and soaked for given time depending upon size of input and their
metallurgical requirements. Ideally, it is aimed to equalize the surface and the
core temperatures of the slab. Well soaked slabs are discharged from the
furnace at dropout temperature of 1100-1300oC.The furnace discharge
temperature also depends on the extent of heat losses downstream.

41
Types of Reheating Furnaces:

In Primary mills Soaking pits are used which are primarily batch type
furnaces. In secondary (finishing) Mills, continuous furnaces are used.
Continuous furnaces are mainly of two types pusher type and walking Beam
type. These furnaces mainly use a mixture of coke oven gas and blast furnace
gas which are readily available in integrated steel plant.
COLD ROLLING
COLD ROLLING MILL (CRM)
Purpose of cold reduction is to achieve, a reduction in the thickness, a

designed surfacefinish, desirable mechanical properties, close dimensional
tolerance and producing as per customer requirements. These thickness
reductions are achieved through multi-pass rolling in a reversing mill or
tandem mill. Apart from such mills, a cold rolling mill complex may include
other facilities for pre-and post-rolling operations. The sequence of operation
and material flow in a typical cold rolling mill complex is shown in Figure 3.1.

42
SlabbingMill
Slabbing Mill transforms ingots into slabs by rolling them in its 1250 mm
Universal Four-High Mill. The rolling capacity of the Mill is 4 MT per
annum. The shop has Hot and Cold Scarfing Machines and 2800 T
Shearing Machine. Controlled heating in Soaking Pits, close dimensional
43
accuracy during rolling and hot and cold scarfing help produce defect free
slabs.
HotStripMill
Slabs from CCS and Slabbing Mill are processed in the state-of-the-art Hot
Strip Mill. The fully automatic Hot Strip Mill with an annual capacity of 3.363
million tonnes has a wide range of products - thickness varying from 1.2 mm
to 20 mm and width from 750 mm to 1850 mm. The mill is equipped with
state-of-the-art automation and controls, using advanced systems for process
optimization with on-line real time computer control, PLCs The finishing group
consists of a Flying Shear, Finishing Scale Breaker and seven 4-high Finishing
Stands. Hydraulic Automatic Gauge Control system in the finishing stands
ensures close thickness tolerance. The Work Roll Bending System ensures
improved strip crown and flatness. The rolling speed at the last finishing stand
is between 7.5-17.5 meters per second. The Laminar Cooling System is a
unique feature to control coiling temperature over a wide range within close
tolerance. The Hydraulic Coilers maintain perfect coil shape with On-line
Strapping system. On-line Robotic Marking on the coil helps in tracking its
identity.
Hot Rolled Coil Finishing
All the Hot Rolled coils from the Hot Strip Mill are received in HRCF for further
distribution or dispatch. HR Coils rolled against direct shipment orders are
sheared and finished to customer-required sizes and dispatched to customers.
The material is supplied as per Indian specifications and many international/
foreign specifications. The shop has two shearing lines with capacities of 6,
45,000 Tonnes/ year and Rs. 4, 75,000 tones per year respectively.
Cold Rolling Mill

The Cold Rolling Mill at Bokaro uses state-of-the-art technology to produce
high quality sheet gauge material, Tin Mill Black Plate and Galvanized
Products. Cold rolling is done to produce thinner gauge strips of very smooth
and dense finish, with better mechanical properties than hot rolling strips.
Rolling is done well below re-crystallization temperature without any prior
heating of the material. The products of CRM are used for deep drawing
purposes, automobile bodies, steel furniture’s, drums and barrels, railway

44
coaches, other bending and shaping jobs and coated steels. The CRM complex
comprises of two Pickling Lines (including a high speed Hydrochloric Acid
Pickling Line with re-generation facilities), two Tandem Mills, an Electrolytic
Cleaning Line, a Continuous Annealing Line, Bell Annealing Furnaces, two
Skin-Pass Mills, a Double Cold Reduction Mill (DCR), Shearing Lines, Slitting
Lines and a packaging and dispatch section. The 5-stand Tandem Mill is
capable of rolling sheet gauges up to 0.15 mm thickness. It has sophisticated
Hydraulic Automatic Gauge Control, computerized mill regulation and
optimization control.
Hot Dip Galvanizing Complex

The Hot Dip Galvanizing Complex integrated with the CRM produces
zinc-coated Cold Rolled strips resistant to atmospheric, liquid and soil
corrosion. The Continuous Coil Corrugation Line in the HDGC produces
corrugated sheets and the Galvanized Sheet Shearing Line produces galvanized
plain sheets for a variety of applications. The first shop of Bokaro Steel to get
the ISO-9001 certification way back in 1994, this complex has maintained a
high-standard of coating quality and its SAILJYOTI branded products enjoy a
loyal market. This complex made certain innovations for higher productivity to
help re-build earthquake ravaged in Gujarat.
Services - a valuable support network
The service departments like Traffic, Oxygen Plant, Water Management

and Energy Management provide invaluable support to this gigantic plant.
Bokaro Steel has a vast networked of railway tracks and over 40 diesel locos to
smoothly run its operations. The Oxygen Plant provides Oxygen, Nitrogen and
Argon for processes like steelmaking and annealing. Water Management looks
after the huge water requirements of the plant and the township, providing
different grades of water and taking care of recycling needs. Energy
Management juggles the supply and demand of by-product gases and their
demand as process fuel.
Maintenance Departments
Bokaro has centralised maintenance departments for large-scale
electrical and mechanical maintenance, in addition to shop-based
maintenance wings for running repairs and maintenance. These facilities are
capable of executing massive capital repairs, supported by the fabrication
facilities of the auxiliary shops.
Auxiliary Shops
45
To meet its needs for maintenance and repairs, Bokaro has a cluster of
engineering shops such as Machine Shop, Forge Shop, Structural Shop, Steel
Foundry, Ingot Mould Foundry, Cast Iron and Non-Ferrous Foundry, Electrical
Repair Shop and Power Facilities Repair Shop in addition to shop-specific Area
Repair Shops. Most of the repairs and maintenance requirements of the plant
are met in-house. The auxiliary shops and maintenance wings of Bokaro Steel,
aided by in-house design teams, have executed a number of highly
sophisticated procurement-substitution, productivity enhancement and quality
improvement jobs, saving revenues and enhancing equipment availability. The
expertise and operational scale of these departments, along with the service
departments, makes Bokaro a truly integrated plant, housing many virtual
enterprises within Bokaro Steel.
The sectioning the product a value based place in customer mind. Finalize
annual sales plan and quantity, monthly, weekly, and daily rolling programme
of Rolling mills in consultation with CMO and mills. This plan is based on the
sales forecast receive from JPU SPL/ Iron and steel controller. Optimizing the
product-mix by proper utilization of available stocks. Receiving Enquiries and

46
complaints, cancellation of orders etc. Coordinating the works of mills and

traffic department so as to maximize dispatches. Co-ordinations with CMO
from stages of enquiry, for exports, development of new Profiles, sections,
modification of product scheduling till the orders are completed.
Development of new qualities of steel. Periodical market surveys of products to

analyze the market position. Implementation of suggestions received from the
customers feed bock. Ensure customer satisfaction by meeting customers
regularly, provide redressal to their problems and fulfillment of demand.
STUDY OF FABRICATION
FABRICATOR / WELDER:-
Fabrication
Metal Fabrication is the forming of metal, usually steel plate, into various
forms either by welding or other forms of metal joining processes. Metal
fabrication falls into two categories, either "light" (metals under 3mm thick) or
"heavy" fabrication.
Metal fabricate
A metal fabricator has to be able to interpret engineering drawings and

then accurately cut steel plates into the required shapes. They must then weld
them into the structure according to the drawings. Metal Fabricators must
learn to read engineering drawings, use geometric development methods and
metal forming techniques. They must also be able to use computers in making
metal products, and have a comprehensive knowledge of a range of industrial
welding and joining processes to manufacture the required items.
Fabrication has a great deal to do with manufacturing. Fabrication is an

industrial term that refers to the manipulation of raw materials (such as steel)
for the making of machines and structures. Steel and other metals are cut and
shaped during the fabrication process. Fabrication is a very hands-on part of
the manufacturing process. Although a fabrication shop and a manufacturing
plant can work independently, it is unlikely that you will find a manufacturing
establishment that does not at least have close ties to a fabrication shop. Most
manufacturers have fabricators in-house simply because of the frequency that
most manufacturing processes need the services of a fabrication shop.

47
The fabrication of a working machine or of an entire structure of a

building from nothing more than metal requires a lot of skill and planning. A
fabrication shop will begin a business transaction by proposing a plan to the
purchasing party and trying to win their bid for work. If the fabrication shop is
awarded the bid and will be responsible for a specific fabrication job, the
specific materials and sub-contractor work will need to be determined. Also,
special equipment may need to be used to complete the contracted work.
Fabrication involves the skills of engineers. In fabrication it is not

enough to just build something from raw materials; it has to be a working part
of a whole system. When fabrication is being done for a manufacturing plant,
the engineers are most likely going to be a part of that manufacturing
organization. The manufacturers are a part of the fabrication process from the
beginning because it is important for the individuals who will be responsible
for the new machine or structure to have an intimate understanding of the
fabricated project's inner workings. After all, it will be the manufacturing
employee's responsibility for the day-to-day function of that fabricated work.
Fabrication involves the use of many different materials. As most

fabricators are metal fabricators, common metals used in the fabrication
process are plate metal, formed metal, expanded metal, welding wire,
hardware, castings and fittings. The tools used to manipulate these metal
projects are also diverse but some of the more common tolls used include any
materials used in the welding process, band saws, cutting torches, etc.
Fabrication is truly a specialty where visualization is important because
fabricators must have the ability to create an end product with nothing more
than a pile of metal pieces.
Fabrication shops are generally limited in their ability to create overly

complex machining capabilities. In terms of manufacturing, the fabrication
process is essential in creating the shell of the machinery or product and it
takes the skills of other parties to complete the mechanical process. Once a
fabrication shop has finished a particular order, the product is inspected and
shipped to the client.
Fabrication is a process that many of the object, tools, and machines

that we use on a regular basis once took part in. Without fabricators we could
48
not be able to enjoy many of our buildings or anything that is built with the
help of metal. Fabricators are important to manufacturers because they have
the ability to manipulate otherwise functionless materials into something that
will help consumers.
Welding
Welding is the process of joining metals by melting the parts and then
using a filler to form a joint. Welding can be done using different energy
sources, from a gas flame or electric arc to a laser or ultrasound. Until the
beginnings of the 20th century, welding was done via a process known as forge
welding, which consists of heating up the pieces to be fixed together and then
hammering them until they amalgamate. With the advent of electricity, welding
became easier and faster, and it played an important part of the industry
scene during World War I and II. There are different welding processes in use
in modern times:
 Arc welding is done through the use of an electrical current, and can
be performed by using inexpensive equipment.
 Gas Welding is widely used for repair work, especially in anything

involving pipes and tubes. Gas welding is common in the jewelry
industry, as well as for the welding of plastics and other materials
that cannot stand higher temperatures.
 Resistance welding involves the use of additional sheets of metal to

encase the pieces to be welded together. It is the most
environmentally-friendly of all methods, but it requires costly
equipment that cannot be used in all situations.
In an industrial context, welding refers to a fabrication process that joins

materials such as metals and thermoplastics, by causing coalescence. This is
typically done by melting the work pieces and adding a filler material such as a
welding rod, to form a pool of molten material that cools to become a strong
joint. Various processes and energy sources are used for welding such as a gas
flame, electric arc, laser, electric beam, friction, and ultra sound. All these
methods involve the use of various unique equipments, specific to each
process.
 Plastic welding is the process of joining work pieces made from plastic
with the help of advanced welding techniques. Plastic welding can be
used for joining two or more work pieces made from the same type of
plastic or two or more pieces made from different types of plastic.

49
 Orbital welding is Automatic Tungsten inert gas welding. It eliminates

chances of manual errors in welding. It produces identical welds for
hundreds of times hence accuracy in welding.
Lathes and Lathe machining operations
The engine lathe, its use, and its principal parts and their uses are
knowledge and skills expected of an EN2. Although machine shop work is
generally done by personnel in the Machinery Repairman (MR) rating, there
may be times that you will find the lathe essential to complete a repair job.
This chapter will help you to identify the engine lathe’s attachments,
accessories, and their uses. Also, it will identify and explain different
machining operations and the factors related to machining operations. Of
course, you will be expected to know and to follow the safety precautions
associated with machining operations.
There are a number of different types of lathes installed in the machine

shops in various Navy ships. These include the engine lathe, the horizontal
turret lathe, and several variations of the basic engine lathe, such as bench,
tool room, and gap lathes. All lathes, except the vertical turret type, have one
thing in common. For all usual machining operations, the work piece is held
and rotated about a horizontal axis, while being formed to size and shape by a
cutting tool. In the vertical turret lathe, the work piece is rotated about a
vertical axis. Of the various types of lathes, the type you are most likely to use
is the engine lathe. Therefore, this chapter deals only with engine lathes and
the machining operations you may have to perform.
RCL (The Research & Control Laboratory)

This department is responsible for maintaining the quality of product
and develops new products to cater to the needs of customers with the ever
changing demands of the society. For this purpose periodic monitoring and
controlling of the quality of input raw material, process and final products is
required.
Major activities of this department are:
 Process control.
 Inspection.
 Analysis and testing.
 Research and development.

50
To achieve these, it has a main laboratory outside the plant and the other
laboratories are inside the plant. The laboratories inside the plant are at
RMHP, BF, BOF, Coke Ovens, Rolling Mills. The main laboratory is well
equipped with chemical, metallurgical and other test facilities.
FOUNDRY SHOP
BSP is having its own foundry, referred as captive foundry. The main products
are:
 Ingot mould (8.5T)
 Bottom Plate (3T)
 False Plate
Casting of different small structures is also done here to cater to the needs of
different shops.
Important equipments are:
 Pneumatic Rammer
 K.S. Drag barrels
 Stripping plates
 Mix-Muller’s
 Jolting Machine
 Stoves
 Guide Pit
 Cupola Furnace
OXYGEN PLANT
This is an important section since oxygen demands of various shops are
met from this department. It has five gaseous O2 storage vessels and two liquid
storage tanks. The capacity of this plant is (2X350=700TPD).
Products of this plant are:

a. Oxygen Gas - for BOF, CCP, BF, Rolling mills, ASP.
b. Liquid Oxygen - Oxygen cylinder filling
c. N2 - BOF, CCP, BF, EMD.
d. Argon - BOF, CCP, VAD
The distribution network is spread over 18 Km in the plant. The gas is also
supplied to ASP. The pressure is 350 mm of water gauge pressure.

51
POWER PLANT
Main Objectives
 To provide COLD AIR BLAST to blast furnace.
 To provide HP/LP process steam to BF, COCC, SMS, Oxygen Plant
 Power generation
HP steam at 32 Kg/cm2
LP steam at 12.5 Kg/cm2
The capacity of this plant (4x5 MW = 20 MW). It is also called as blower plant
as its main aim is to generate steam. There are seven boilers each having
capacity 60 TPH. Steam is generated at high pressure. Boiler No. 1, 2, 5, and 6
uses coal and (BF+CO) gas as fuel. Boiler no. 3, 4 and 7 are gas fired using
(BF+CO) gas.
CEM (Central Engineering Maintenance)

Its main function is to provide repair and maintenance of all important
equipment of DSP. Some of the main equipments of CEM are:
 Horizontal boring machine
 Bevel gear making machine
 Vertical boring machine
 Small pinion making machine
 Helical gear making machine
There are six sections in CEM:
1. Planning and Processing
2. Structural
3. Forging
4. Machine shop
5. Fitting shop
6. Tool room
PCE (PLANT CIVIL ENGINEERING)
PCE looks after the maintenance and repair of plant roads,
constructions etc. Design department supply all the design to the PCE
department and PCE implement all those works. All the painting, repairs etc in
the plant structures are done by this department. There is annual
maintenance contract with the outside agencies also. PCE looks after up to
flyover and RCL.

52
ERS (ELECTRICAL REPAIR SHOP)

In this department electrical motor from different units / departments
like BF, Sinter Plant, RMHP etc come for repair. In electrical repair shop
winding insulation leakages, voltage – current balancing etc is rectified. And in
mechanical repair, bearing alignment faults are rectified. A drier is used for
drying the motors during rainy seasons. Depending upon the need of motor in
various departments, priority of work is fixed. In electrical field it plays an
important role in maintenance.

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1

BOKArO STeeL PLAnT

 Raw Material Handling Plant

 Blooming & Billet Mill

 Plant Civil Engineering

 Electrical Repair Shop

Bokaro Steel Plant - the fourth

The new features added in modernization of

 Location : Southern bank of Damodar River; approx. 50 kms from

THERE IS LITTLE BIT OF “SAIL” IN EVERYONES LIFE

Different types of major raw materials used in an integrated steel

1. Iron ore lump

The main objective of raw material handling plant/ore handling

THERE IS LITTLE BIT OF “SAIL” IN EVERYONES LIFE

The main functions of RMP/OHP/OB&BP are –

Different Raw Materials and Their Sources

Sl. Raw Materials Sources

1 Iron Ore Lumps Barsua,Kalta,Kiriburu,Meghataburu,

2 Iron Ore Fines Manoharpur,Gua,Dalli,Rajhara

3 BF grade Lime Kuteshwar, Bhabanathpur,Nandini,Katani

4 BF grade Dolomite Birmitrapur, Sonakhan, Birsa Stone Lime

5 SMS grade Lime Jaiselmer,Imported lime-stone from Dubai

6 SMS grade Belha, Baraduar

7 Manganese Ore Barjamunda, MOIL(Purchased)

THERE IS LITTLE BIT OF “SAIL” IN EVERYONES LIFE

10 Flue dust Generated inside the plant

11 LD Slag Generated inside the plant

Main functions of RMHP:-

 Stacking and reclaiming of raw materials.

 Crushing of flux and coke.

 Sinter-mix preparation and supply to Sinter Plant

 Iron ore lump screening.

 Screened iron ore supply to Blast Furnace.

THERE IS LITTLE BIT OF “SAIL” IN EVERYONES LIFE

 These are 3 in number

(C) Old Reclaimers:-

 These are 4 in number

(D) Stacker cum Reclaimers:-

(E) Slewable Stacker:-

(F) Blender Reclaimer:-

THERE IS LITTLE BIT OF “SAIL” IN EVERYONES LIFE

Main constituents of sinter mix:

Iron ore fines 0-10 mm

Limestone fines 0-3mm

Dolomite fines 0-3mm

Coke fines 0-3mm

 Also waste generated in the plant like flue dust,

(2) Flux Crushing Plant:

Sources of raw materials

Iron ore fines 0-10 Bolani

Iron ore lump 10-50 Bolani

THERE IS LITTLE BIT OF “SAIL” IN EVERYONES LIFE

BF/SP gr. L.S 5-50 Birimitrapur

BF/SP gr. dolo 5-50 Birimitrapur

BOF gr. L.S 25-55 Jaisalmer

Coke breeze 0-20 Internal

COCC (COKE OVENS & COAL CHEMICALS):-

During the process of carbonization of coal, a number of valuable