Bhilai Steel Plant - Internship Report

I had done my 2 weeks Vocational Training from Bhilai Steel Plant, Bhilai situated in Chhattisgarh. I am sharing my final internship report which I made for the submission in my University.

1. VOCATIONAL TRAINING AT BHILAI STEEL PLANT Under the guidance of Academic Mentor – Prof. Md. Izhar Hussain PRESENTED BY- AMUL RAJ 4 TH SEM, METALLURGICAL & MATERIALS ENGINEERING 01UG18050013 OP JINDAL UNIVERSITY, RAIGARH INTERNSHIP REPORT ON

2. Acknowledgement The internship opportunity I had with Bhilai Steel Plant, Bhilai was a great chance for learning and professional development. Therefore, I consider myself as a very lucky individual as I was provided with an opportunity to be a part of it. I am also grateful for having a chance to meet so many wonderful people and professionals who led me though this internship period. I have taken efforts in this training. Bearing in mind previous I am using this opportunity to express my deepest gratitude and special thanks to my Industry Mentor, Mr. Shobhraj Sinha who in spite of being extraordinarily busy with his duties, took time out to hear, guide and keep me on the correct path and allowing me to carry out my training at their esteemed organization and extending during the training. However, it would not have been possible without the kind support and help of my Academic Guide, Prof. MD. Izhar Hussain . He was always InTouch with me for any kind of help I needed. I would like to express my gratitude towards my parents & member of SAIL-BSP, Bhilai for their kind co-operation and encouragement which help me in completion of this training. Thank You !

3. An Overview of Bhilai Steel Plant Eleven times winner of Prime Minister's Trophy for Best Integrated Steel Plant in the country, Bhilai Steel Plant (BSP) is India's sole producer & supplier of world class rails for Indian Railways including 260 metre long rails, and a major producer of large variety of wide and heavy steel plates and structural steel. It is an organization under Steel Authority India Limited (SAIL), situated in the city of Bhilai in the state of Chhattisgarh. It was established in the year 1955 with the help of USSR. With an annual production capacity of 3.153 MT of saleable steel, the plant also specializes in other products such as wire rods and merchant products. The entire range of TMT products (Bars & Rods) produced by the Plant is of earthquake-resistant grade and superior quality. The plant also produces heavy structural including channels and beams.

4. Departments covered during the training period 15/06/2020 – 27/06/2020 Coal Chemical Department Visit to Asia’s largest Blast furnace Steel Melting Shop

5. PROCESS FLOW CHART OF BHILAI STEEL PLANT

6. 1. COKE OVEN A Battery with RAM coke pusher A coal tower providing coal to batteries Coke quenching using phenolic water No. of Coke oven batteries in Bhilai Steel Plant - 11 Height of the batteries - Varies from 4 mts to 7 mts. Input Materials – Coal Output Materials – Coke, ash, moisture, coke oven gas Process – Heating of coal at 900 degree Celsius upto 17-18 hrs. (1500-1600 degree Celsius) Capacity of Coal tower- 3000 tons Capacity of batteries – 16 tons and 32 tons Major imports of coal – US, Russia, Australia An information of capacities of each Coke Oven present in Bhilai Steel Plant

7. 2. COAL-CHEMICAL DEPARTMENT DECANTER BENZOYL RECOVERY PLANT DISTILLATION SULPHUR EXCESS AMMONIA STORAGE TANK TAR STORAGE TANK EXHAUSTER HOUSE The coke oven gas is distilled at different temperatures to obtain the various by-products. After the extraction of all the necessary by-products the final gas is then used for re-heating purposes in Blast Furnace, Coke Oven and Mills. Above images are the display of various process during the distillation of the Coke Oven Gas.

8. 3. SINTERING PLANT Sinter materials in a conveyer belt Sinter Materials being seperated There are 3 sintering plants in Bhilai Steel Plant, namely SP -1,2, and 3. Sinter plants agglomerate iron ore fines with other fine materials at high temperature, to create a product that can be used in a blast furnace. The final product, a sinter, is a small, irregular nodule of iron mixed with small amounts of other minerals. Input – Fe ore fines, flux, coke dust, mill scale, scrap fines, limestone, BOF slag, Mn ore. The encircled area shows the batch wise entry of sinter materials into the blast furnace

9. 4. BLAST FURNACE Blast Furnace-8, named ‘ Mahamaya ’ , One of Asia’s largest Blast Furnaces Series of Blast furnaces with stove and cast house in it’s opposites sides. Molten Metal coming out through channels in a cast house There are 8 blast furnaces in Bhilai Steel Plant. BF 1-3 are early established, BF 4-6 were during the mid 70s and BF 7 & 8 are recently established. The coke, iron ore, and limestone along with sinter materials are heated at 900°C - 1300°C with hot blast furnace gas being provided inside it with the help of tuyeres . The hot gas comes from a stove being heated all the time where the coke oven gas is reheated. Once the process is over the drill machine is used to open the tap hole and let the molten metal flow into the channel. The channel gets separated into two parts and slag is separated from the either side of the channel. Molten metal is then collected into a ladle/torpedo and then is ready to be taken to Steel Melting Shops.

10. 5. STEEL MELTING SHOP PRIMARY STEEL MAKING A Basic Oxygen Furnace SECONDARY STEEL MAKING Vacuum Arc Degasser Ladle Furnace R-H Degasser Continuous Casting Route There are 3 Steel Melting Shops in Bhilai Steel Plant among which SMS-3 is the latest and newest one. The molten metal is brought into the converter shop of a steel melting shop through the torpedo and here are poured into a ladle and the ladle is dumped into a BOF. Oxygen is blown through a pipe into the furnace and scraps are added to it ( mill scale/ iron scarps). The furnace is tilted to an axis of 360° and slag is removed from the top of it. Now the molten steel is poured into a ladle and is taken to further processing's such as VAD, LF, RH DEGASSER where various elements are stabilized into the steel as per the requirement of the customer. De - Sulpharization is done to reduce the sulphur content which is done in a VAD. LF is used to reheat the molten steel. RH degasser helps to reduce the dissolved hydrogen gases to maintain the quality of the steel. Finally the ladle is taken to a Continuous casting shop where the molten steel is poured into the cast and Blooms of steel are obtained as per required dimensions and are cooled down and sent to various other mills.

11. 6. MACHINE ASSEMBLY & RE-ENGINEERING SERVICES A typical machine shop representation in a steel industry Machine assembly & Re- Engineering Services is the machine shop built under 4 MT expansion of BSP to cater to the spares and assemblies requirements of Converter Shop, Continuous Casting Shop, and Plate Mill. The shop has got two machining bays (Light bays and Heavy & Medium bays 78×24 M each). And one Assembly bay (72×24 M) which forms a Tee with the machining bays. Main assemblies done are 5-roll set, 8-roll set, 10-roll set, and Pinch rolls used in Slab Caster of Continuous Casting Shop.

12. HIGHLIGHTS Bhilai Steel Plant (BSP) is eleven-time winner of the Prime Minister's Trophy for best integrated steel plant in the country. The plant is the sole supplier of the country's longest rail tracks, which measure 260 metres (850 ft). SAIL has an annual turnover of INR 66967 Crores or 8.91 Billions US Dollars in which for the FY -2019, Bhilai Steel Plant has contributed 25% of its revenue. An annual production of 4.70 MT of Hot Metal in BSP and overall a production of 16.3 million metric ton annually of SAIL has been observed. SAIL operates and owns 5 integrated steel plants at Bhilai , Rourkela, Durgapur, Bokaro and Burnpur (Asansol) and 3 special steel plants at Salem, Durgapur and Bhadravathi .

13. CONCLUSION Within these two weeks of vocational training I’ve got the basic knowledge about the whole steel making process. What I’d learnt in books were a little confusing and theory bind-up. Moreover the visit to each and every essential department brought me a clear knowledge about steel making. I came to know about the steps during the preparation of coke to reactions in a blast furnace. Steel Melting Shops are the heart of a steel industry and I’ve observed step-by-step procedures during the preparation of steel to blooms and pellets. I’ve also noted down some key points regarding the processes and reactions involved in a blast furnace as a reference. Thus, this vocational training of two weeks helped me a lot in building my blocks of steel industry strongly. I admire more trainings from different organizations in future for better learning.

14. THANK YOU !