Ppt on bokaro steel plant

This ppt is define a general overview of Bokaro Steel Plant, how to make a steel in the industry & all procedure is given in the ppt and also CBRS department is include where the automobile parts of machine is overhauling.

1. RAJASTHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY JAIPUR DEPARTMENT OF MECHANICAL ENGINEERING A PRACTICAL TRAINING SEMINAR ON “BOKARO STEEL PLANT(sail)” DELIVERED TO: DELIVERED BY : DIPESH PATIDAR PRASHANT KUMAR (ASTT. PROFESSOR,ME) BRANCH:-ME Roll No :-

2. CONTENT INTORDUCTION History COMPANY profile Process flow Facilities RMHP COCK OVENS & BY-PRODUCT PLANT SINTER PLANT Blast furnace SMS SLABBING MILL

3. Hot STRIP mill (HSM) Cold rolling mill (CRM) CBRS ENGINE OVERHAULING REFRENCES Conclusion

4. introduction Steel Authority of India Limited (SAIL) is the leading steel-making company in India . SAIL is India's largest steel producing company with a turnover of Rs. 47,042 crore . SAIL is among the five Maharatnas of the country's Central Public Sector Enterprises. It is a fully integrated iron and steel maker . applications of steel products: domestic construction engineering Power railway Automotive defence industries

5. history After independence, for rapid industrialization of the country, Hindustan Steel Private Limited was set up on January 19, 1954 at Rourkela( Odisha ). The President of India held the shares of the company on behalf of the people of India . Sail today: It is one of the largest industrial entities in India. It has five integrated plants , three special steel plants and one subsidiary plants. These are principally located in the eastern and central regions of India.

6. Integrated Steel Plants

7. special steel plants Visvesvaraya Iron and Steel Plant ( VISL) in Karnataka Salem Steel Plant (SSP) in Tamil Nadu Alloy Steels Plants (ASP) in West Bengal

8. Company profile

9. BOKARO STEEL PLANT Fourth Integrated Steel Plant in Public Sector , well known as Swadeshi Plant Collaboration agreement with Soviet Union (USSR) on 25 th Jan, 1965 ( SAIL Foundation Day) Total area 33,045.35 acres Capacity First Phase : 1.7 MT of ingot steel Second Phase : 4.0 MT of ingot steel After modernization : 4.5 MT of liquid steel Enough scope for further expansion ( Plan for 7 MT ) types of products Flat product Rolled product

10. products Hot rolled sheets(HRS) Hot rolled coils(HRC) Galvanised plain and corrugated (GP/GC) sheets Cold rolled sheets (CRS) Cold rolled sheets(CRS) Tin mill black plates (TMBP)

11. GROSS TURN OVER

12. Sintering Plant BF1 BF2 BF3 BF4 BF5 Blast Furnace 300 T Con-1 300 T Con-2 Steel Melting Shop - 2 Steel Melting Shop - 1 130T Con-1 130 T Con-2 130 T Con-3 130 T Con-4 130 T Con-5 Tandem Mill-1 Tandem Mill-2 Soaking Pit ll SPM 1 & 2 Hot Dip Galvanizing Line Galvanized Sheet Shearing Line Galvanized Sheet Corrugation Line HR Coil HR PLATE / SHEET CR Coil CR Sheet GP Coil Galvanized Corrugated & Plain Sheet Iron Ore Fluxes O H P Continuous Casting Department Reheating Furnace SAIL Bokaro Pig Casting Machine H R C F PROCESS FLOW BF Coke Coking Coal Coke Breeze PL-II PL-I ANNEALING CRCF COKE OVEN BATTERIES DCR Mill Slabbing Mill Hot Strip Mill Iron Ore, Lime Stone & Dolomite Fines

13. FACILITIES Raw Materials & Material Handling Plant Coke Ovens & By-product Plant Blast Furnaces Continuous Casting Shop Slabbing Mill Hot strip mill(hsm) Cold Rolling Mill(crm) Auxiliary Shops

14. RAW MATERIAL & MATERIAL HANDLING PLANT The main objective of raw material handling plant/ore handling plant/ore bedding and blending plant is to :- raw material preparation (like crushing , screening etc.). unloading of wagons/rakes within specified time norm. maintain buffer stock. supply consistent quality raw materials un-interruptedly to different customers. homogenize materials from different sources by means of blending.

15. Process Flow Diagram of RMHP/OHP/OBBP Despatch to Customer Bedding & Blending Screening Unit Designated Beds Auto Sampler/ Sampling Unit Wagon Tippler/ Track Hopper Iron Ore (Lump +Fines), Lime Stone, Dolomite (Lump + Fines), Mn Ore From Mines Base Mix Preparation Unit

16. Coke ovens & By products Products produced from by product plant . N G Benzol N G Toluene Xylene L S Naptha S B Oil PCM Road Tar Coal tar wash oil Extra hard pitch Hard medium pitch Hot Pressed naphthalene All by products of By Product Plant are sold through e- auction.

17. Coke making is the process to convert coking coal, through a series of operations, into metallurgical coke. The Coke Oven Complex at Bokaro converts prime coking coal from Jharia , Dugda and Moonidih and medium coking coal form Kargali , Kathara and Mahuda , blended with imported coal, into high quality coke for the Blast Furnaces.

18. PROCESS FLOW DIAGRAM OF COKE OVEN & CCD

19. Sinter plant Sintering plant is the process for agglomeration of fines mineral particles into a compact porous and lumpy mass by incipience fusion caused by heat produced by combustion of solid fuel within the mass itself. Three Sections Are Raw material section. Stock bin and proportioning section. Sinter machine section

20. Blast furnace A Closer view of Blast Furnace

21. Blast furnace 5 blast Furnaces in bsl each of 2000 cubic meter useful volume and 2640 T/day HM capacity Hot Metal Temperature 1460-1480 C BF Productivity: 1.4 T/m 3 /Day Capacity of B F 4.585 MT of Hot Metal per annum

22. MATERIAL FLOW DIAGRAM FOR BLAST FURNACE Sintering Plant Dust catcher In BF Gas Cleaning Plant RM & MHP SP Process Steam Net work Stove of BF Charging Section of Blast Furnace Coke Ovens For Sale Pig Casting M/C For Distribution Mixer of SMS IMF Slag Dump Yard TBS BFCHSG /SGP Blast Furnace Hot Metal Iron Ore Lime Stone Mn Ore Sinter Coke Slag Granules for Sale Raw BF gas Flue Dust Cleaned BF Gas Partially Cleaned BF Gas Iron Ore (Lump) Lime Stone, Mn Ore, Q u artzite Sinter Coke Cold Pig Process Steam Hot air Cold air Slag Quartzite

23. Steel melting shop Hot Metal from the Blast Furnaces is converted into steel by blowing 99.5% pure Oxygen through it in the LD converter. Suitable alloying elements are added to produce different grades of steel . Bokaro has two Steel Melting Shops - SMS-I and SMS-II. SMS-I SMS-I has 5 LD converters of 130T capacity each. It is capable of producing Rimming steel through the ingot route. SMS-II SMS-II has 2 LD converters, each of 300 T capacity, with suppressed combustion system and Continuous Casting facility. It produces various Killed and Semi-Killed steels .

24. SLABBING Mill 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 accuracy during rolling and hot and cold scarfing help produce defect-free slabs. Slab Dimensions Thickness – 170 to 230 mm. Width – 910 to 1850 mm Length – 7.7 to 10.5. Rolling temperature – 1300 degree Celsius. Soaker crane – 4 number of capacity 50/40 tones. Re-heating furnace – 5. Soaking pits – 12 groups and each group has 4pits

25. HOT STRIP MILL (HSM) Hot Rolling involves plastic deformation of a metal under squeezing force (a pair of Rolls) above its re-crystallization temperature. designed to roll thin & wide strips Capacity: 3.955 MT of HR Coils Rolling Speed : 20 m/sec Max . CONSTRUCTION 3 Walking Beam Reheating Furnaces & 1 Pusher type furnace Vertical Scale Breaker 5 Roughing Stands, 7 Finishing Stands Hydraulic AGC in last four Strands 4 Hydraulic Coilers with automatic strapping & Robot marking

26. Hot Metal being charged into the converter

27. Material Flow Diagram of HSM Slab yard Furnaces Furnaces VSB R1 R2 R3 R4 R5 F. Shear F6 F7 F8 F9 F10 F11 F12 C C C C Coilers Finishing Stands Roughing Stands

28. COIL DIMENSIONS Strip thickness 1.6 to 16.0 mm Strip Width 910 to 1,850 mm Coil inside dia 650 mm Max Coil outside dia 2,300 mm Max coil weight 32 T Application of product wagon building tube & pipe industry drum & furniture `manufacturing

29. Cold Rolling Mills Cold rolling is done to produce thinner gauge strip of smooth finish with better mechanical properties than those obtained by Hot Rolling Capacity : 1.66 MT of CR saleable It consists of two shops:- Crm I (reduces thickness 2-4.5mm thick into 0.63-2mm thick) Crm ii (reduces thickness 1.4-2mm thick into 0.63-1.6mm thick)

30. Crm It consists of :- H 2 So 4 Pickling Line 4-Stand Tandem Mill Annealing Furnaces Skin Pass Mill-I & Skin Pass Mill -II Shearing Line I & II Slitting Line and Shipping line

31. Process flow of crm H 2 So 4 Pickling Line T1 T2 T3 T4 T5 ANNEALING TANDEM MILL STANDS (THICKNESS IS REDUCED ) SPM I & II Shearing Line I & II SLITTING LINE (CUTTING THE COIL IN PROPER SIZE) SHIPPING LINE

32. Application of product from crm Automobile Bodies Drum & Barrels Bending & Shaping Applications Steel Furniture

33. Milestones Start of construction : 06 – 04 - 1968. Start of hot metal production : 02 – 10 – 1972. Completion of 1.7 MT stage : 26 – 02 – 1968. Completion of 4 MT stage in phases. Start of last modernization : 23 – 07 – 1993 (completed in 1997 ). Next modernization for 7 MT : Evaluation process started.

34. CENTRAL BASE REPAIR SHOP (CBRS) Itis comes under works division of bokaro steel plant. It is responsible for major Repair, Renovation, and Reclamation of Heavy Earth Moving Equipments like ( Haulpak -Dumpers, Dozers, Loaders, Excavators, and Cranes etc.). We have more than hundred numbers of such equipments in our fleet. These equipments are used for operation, maintenance and house-keeping jobs in different production areas like CO & BPP, RMHP, BF, SP, SMS, Mills etc.

35. SECTIONS OF CBRS Engine Shop. Fabrication Shop. Machine Shop. Crane Section. Shovel Section. Dumper Section. Auto Electrical. Electrical. Transmission. Spare Planning.

36. WORKING AREA OF CBRS As CBRS deals with mobile equipments its working area is very wide. We are the source to provide material handling, transports, cleaning, Expansion etc. To the production and non production zones like Raw Material Handling Plant, Coke Oven, Blast furnace, Steel Melting Shops, CCS, Mills Zone, Auxallary Zone and Township Areas etc. Network Of CBRS In Bokaro Steel Plant : Coke Oven. Blast Furnace. Steel Melting Shops – I. Steel Melting Shops – II.

37. Slabbing Mill. Hot Strip Mill. Foundary Shop. Colled Rolling Mills. Housing Keeping Of Works Division. Sintering Plant. Slag Pump.

38. ENGINE OVERHAULING Engine Overhauling is an adjustment, modification of the internal combustion engine or modification to its control unit, otherwise known as its ECU (Engine Control Unit). It is performed to yield optimal performance, to increase an engine's power output, economy, or durability. These goals may be mutually exclusive, and an engine may be detuned with respect to output (work) in exchange for better economy or longer engine life due to lessened stress on engine components. The engine is removed from the vehicle and totally stripped down - every nut and bolt is removed, cleaned, checked.

39. Most moving parts are replaced with brand new factory stock parts - often the only original parts of an engine that has been moved are the block casting, the head casting, the crankshaft, flywheel and camshaft. If any of those aren't in serviceable condition they get switched out too and the motor gets a fresh paint job.

40. NEED OF OVERHAULING Overhauling, a general term for major engine work that usually requires removing the engine from the vehicle, and rebuilding or replacing internal components (e.g. pistons, connecting rods, valves). To save engine parts from getting damaged, regular maintenance and repair should be done after certain period of time.

41. KT – 1150-C – ENGINE Details Of Particular Model Manufacturer – Cummins. Model Number - KT-1150-C. Usage - Automotive Purposes. Fuel - Diesel. Stroke - 4 Stroke. Cooling Method - Water Cooled. Start - Electric Start. Engine Specification K – K Series Engine T – Turbocharged 1150 – Displacement In Cubic Inches. C – Application Code Used For Construction Purposes. Number Of Cylinders – 6 L (Inline Configuration). Bore Into Stroke – 39.0625 Inches

42. Maximum Horse Power – 450. R. P. M. – 2100. Peak Torque – 1831 N-m. Peak Torque R. P. M. – 1500. Firing Order – 1-5-3-6-2-4. Intake Valve Clearance – 0.39 mm (~ .40 mm). Exhaust Valve Clearance – 0.69 (~.70 mm). KT – 1150 – ENGINE, manufactured by Cummins is applicable in dozer 155 and BE 650 shovel.

43. ASSEMBLY OF ENGINE : Dismantling of engine need not be carried out in a specific order but assembly of it requires a particular order. The assembly of engine components of a Cummins engine is done in a way prescribed in the part book of Cummins engine. The order followed is as following- Cylinder block. Crankshaft, main bearings, thrust bearing & vibration damper. Connecting rod, piston & piston rings. Camshaft. Housing, gear & cover. Cylinder head. Cam follower & push rod. Oil pan. Rocker arm housing, fuel injectors.

44. Breather. Water pump. Fuel pump, cover & governor. Fuel pump housing. Fuel filter. Fuel manifold. Lubricating oil pump. Filter bypass assembly. Lubricating oil cooler. Thermostat housing. Air intake manifold .

45. Turbocharger. Exhaust manifold. Air cleaner element. Flywheel housing. Flywheels. Self starter.

46. KT-1150-C-ENGINE

47. PARTS NAME NO. OF PARTS REQUIRED Crankshaft 1 Main bearings 14(7 sets) Thrust bearings 4(2 sets) Connecting rod 6 Big end bearing 12(6 sets) Piston 6 Piston rings 24(4 for each piston) Piston pins(gudgeon pin) 6 Cylinder liner 6 O rings(cylinder liner) 18(3 per liner, 1black flat, 1 black circular) Vibration damper 1 Camshaft 1 Bushing accessory drive(cover gear case) 1 Cylinder head 6 Fuel injectors 6 O rings(fuel injector) 18(3 per injector) Cam follower 6 Push rod 18(3 per cylinder head) Rocker arms 18(6 set) Crossheads 12(2 per cylinder head) Connector elbow(fuel filter) 2 Lube Oil cooler 2 Thermostat 2 Inlet manifold 1 Fuel supply pipe 1 Piston cooling nozzles 6 Lube oil filter 2 Exhaust manifold 1 Turbocharger 1 Air cleaning element 1 Housing(flywheel) 1 Breather 2 Shutdown solenoid 1

48. conclusions Engineering students gain theoretical knowledge through books. It is volatile and not of much use without knowing its practical implementation. Training is one of the important aspects for an engineering student's carrier to strengthen the practical concepts. It was an awesome experience in training as the things we all learnt in our previous year was seen implemented practically. We got to see the live performing equipment like Blast furnace. hOt strip mill( hrm), cold rolling mill and many more in SAIL.

49. references

50. Any queries???

51. THANK YOU