Bhilai Steel Plant PPT for training purpose.pptx

a ppt on bsp by ishatwa, useful for college internship credit

1. BHILAI STEEL PLANT

2. Introduction The Bhilai Steel Plant is a large integrated steel plant located in Bhilai, Chhattisgarh, India. It is one of the flagship plants of the Steel Authority of India Limited (SAIL), a government-owned company and one of the largest steel producers in India. Bhilai Steel Plant was set up with the help of the Soviet Union and started its operations in 1959. It was inaugurated by India's first Prime Minister, Jawaharlal Nehru. Bhilai Steel Plant has diverse facilities for producing various steel products, including hot-rolled coils, cold-rolled coils, wire rods, and plates. It has the capacity to produce a significant amount of steel each year. The plant has had a significant impact on the social and economic development of the surrounding region. It has contributed to the growth of Bhilai as an industrial and urban center.

3. Table of content Steel Flow chart Coal chemical department Blast furnace Research and control lab

4. STEEL Iron with a trace amount of carbon makes up the majority of the metal alloy known as steel. To obtain certain qualities, steel frequently includes other elements in addition to iron and carbon in variable quantities. Manganese, silicon, sulfur, and phosphorus are regular alloying components. To manufacture distinct types of steel with certain properties, additional elements such as chromium, nickel, molybdenum, and vanadium may be added. Steel typically has a carbon content of 0.2% to 2.1%. The mechanical, chemical, and physical properties of steel are influenced by the amount of carbon and the presence of alloying elements. Steel is renowned for its power, toughness, and adaptability. It is extensively employed across a variety of sectors, including infrastructure, manufacturing, transportation, and construction. Steel's characteristics make it appropriate for a variety of uses, including the construction of buildings, bridges, cars, machinery, pipelines, and consumer items.

5. Manufacturing of steel From the extraction of raw materials through the completion of the production of diverse steel products, there are multiple steps involved in steel manufacturing. Input Materials: Iron ore: This is the main raw material used to manufacture steel. It comes from the earth and usually has iron oxides in it. Coking coal: Coal is used as a fuel and a reducing agent to create coke, an essential step in making steel. Limestone: During the smelting process, limestone is utilized as a flux to assist in eliminating impurities.

6. COAL CHEMICAL DEPARTMENT (CCD) The main function of Coke Ovens is to convert coal into coke which is used as a fuel and reducing agent in the Blast Furnace. Its secondary function is to recover Volatile Matter and CO gas from coal and extract chemicals known as Coal Chemicals. CO gas produced is used for heating purposes in the plant. The following by-products are produced during carbonization: 1. Tar 3. Ammonium sulphate 2. Naphthalene 4. Benzol The Coke Ovens and Coal Chemical Department has three main sections viz Coke Ovens Coal Chemical Coal Chemicals Maintenance and Repairs

7. Coke oven Various sub-sections of Coke Ovens and their functions are as follows 1. Coal Handling Plant (CHP-I) and Coal Preparation Plant (CPP-II) : To prepare a coal blend suitable for carbonization in Coke oven batteries to produce BF coke. Coals are of two types. Imported coal Indian coal Indian coal has low calorific content. So we blend the Indian coal with imported coal in the ratio of 60:40 percent. Generally, coal of better quality is imported from Australia, and New Zealand. 2. Partial Briquetting : To prepare briquettes of coal to charge along with coal into the oven.

8. RAW MATERIALS USED FOR COKE PRODUCTION PRIME COKING COAL MEDIUM COKING COAL IMPORTED COKING COAL SOFT COKING COAL

9. COKE OVEN BATTERIES The Coke Oven Department consists of 10 coke oven batteries. The first 8 batteries numbered 1-8 are 4.35 meters in height and consists of 65 coke ovens each and the 9th and 10th batteries are 7 meters in height and consist of 67 coke oven each. Each coke oven in 3 meter in width and 14 meters in length. These are twin flue regenerative, compound PVR (Pair Vertical recirculation), and side-fired type. The temperature of control vertical flues on the pusher side are 1175⁰C to 1225⁰C and 1200⁰C to 1250℃ on the coke side. These however can be increased or decreased depending upon the coking time. Coke ovens are mainly constructed of silica, fireclay, high alumina, and ordinary insulating bricks. The coke oven chimney is made of concrete lined with fireclay bricks. The normal life of a coke oven battery under Indian conditions is considered to be 25 years. The heating of ovens is done from both sides inside fired batteries with reversal of heating. The coal is taken in a charging car from the coal tower and is charged into the empty oven. Each oven has three charging holes and each charging car has three bunkers for charging coal into the ovens.

10. BLAST FURNACE CONSTRUCTIONAL FEATURE A blast furnace Throat : The blast furnace is fed alternately with charge and coke from the top by a special lock The shaft or stack : where the ores are heated and reduction starts.  This shape prevents the stack from clogging, as the downwardly increasing temperatures also cause the charging to expand. The belly :  This shape prevents the stack from clogging, as the downwardly increasing temperatures also cause the charging to expand. The bosh: where the reduction is completed and the ores are melted down. The hearth: This lowest part of the blast furnace where pig iron and slag accumulate is also called the hearth . and is cast via the taphole. Tuyeres: gas is introduced laterally at a high velocity through a port, called tuyere, into the packed bed of coke, Coke is burnt in this zone to supply heat to the process.

11. REFRACTORY IN BLAST FURNACE The selection of refractory materials in a blast furnace is crucial to ensure the proper functioning and longevity of the furnace. Refractories are materials that can withstand high temperatures, corrosive environments, and mechanical wear. In a blast furnace, they play a critical role in containing and directing the molten iron and slag at extremely high temperatures. Here are some key considerations for the selection of refractories in a blast furnace: Temperature Resistance Chemical Resistance Thermal Shock Resistance Mechanical Strength Porosity and Permeability Abrasion Resistance Alkali Resistance Refractory Lining Zones

12. Blast furnace raw material Iron ore Sinter Coke Limestone Manganese Coke dust

13. BLAST FURNACE BF is a counter-current heat and mass exchanger, in which solid raw materials are charged from the top of the furnace and a hot blast is sent through the bottom via tuyeres. The heat 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 the blast furnace process iron ore and reducing agents (coke, coal) are transformed to hot metal, and slag is formed from the gangue of the ore burden and the ash of coke and coal. Hot metal and liquid slag do not mix and remain separate from each other with the slag floating on top of the denser iron. The iron can then be separated from the slag in the cast house. The other product from the Blast Furnace is dust-laden blast furnace gas, which is further cleaned in the gas cleaning plant and is used as fuel all over the plant.

14. RESEARCH AND CONTROL LAB In this laboratory, they check the steel composition and other materials like refractories. Also, check the steel and pig iron lollypop samples to add or control the composition of that product. They also test the material’s mechanical properties like tensile strength, compressive strength, fracture defects, toughness, etc. They have a chart of steels that are used in different areas. On the basis of this composition chart, they prepare the required steel for different areas or organizations.

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