Bokaro Steel Plant an Overview

7/29/2019 Bokaro Steel Plant an Overview

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Bokaro Steel Plant: OverviewBokaro Steel Plant: Overview

By Siddhant HarkerniBy Siddhant HarkerniTrainee: BSLTrainee: BSL

From Mewar University,From Mewar University,

Chittaurgarh RajasthanChittaurgarh Rajasthan


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IntroductionIntroduction

The fourth integrated steel plant in theThe fourth integrated steel plant in thePublic Sector conceived in 1959.Public Sector conceived in 1959.

Bokaro Steel Plant actually started takingBokaro Steel Plant actually started taking

shape in 1965 in collaboration with theshape in 1965 in collaboration with theSoviet Union.Soviet Union.

Bokaro Steel Plant was originallyBokaro Steel Plant was originally

incorporated as a limited company on 29incorporated as a limited company on 29ththJanuary 1964January 1964

The construction work started on 6th AprilThe construction work started on 6th April

19681968


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BASIC INFORMATION Location : Southern bank of Damodar River; approx. 50 km from

Dhanbad and 140 km each from Ranchi and Jamshedpur Latitude : 230 39' Longitude : 860 09' Altitude : 210m (average) varying from 195 to 224m Climate : Extreme

Annual Rainfall : Average 157cm; Maximum 195cm Temperature : Max 480 Celsius

Min. 20 Celsius Wind direction : South-West to North-East Type of Soil : Loamy up to 1m to 2m, 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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Parts of Bokaro SteelPlant

1. RAW MATERIAL HANDLING PLANT

2. COKE OVENS

3. SINTER PLANT

4. BLAST FURNACE

5. STEEL MAKING6. ROLLING MILLS


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RAW MATERIAL HANDLINGPLANT

Basic functions:

Receive different raw materials andtheir handling

Blending of raw material

Keep buffer stock and supply raw

materials to different units

Basic facilities:

4 Rotary Wagon Tipplers - 20Wagons/Hr each

7 Twin boom Stackers - 1200 T/Hr each5 Barrel Type Reclaimers - 1000 T/Hr

each

1 Bucket Wheel Type Reclaimer - 500T/Hr

2 Transfer Cars, 10 ShuttleConveyors, 11 Cranes, 8 Telphers

The Raw Materials and

Material Handling Plant ofBokaro is responsible forreceipt, blending, storage,screening and supply of

raw materials to BlastFurnaces, Sinter Plant andLime Dolomite Shop as pertheir requirements. Theshop also maintains abuffer stock of rawmaterials to take care ofany interruption insupplies. Raw materials are

handled by four wagontipplers, stackers and


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COKE OVENSThe Coke Oven Complex at Bokaro

supplies high quality coke to the

Blast Furnaces. The process of cokemaking consists of the destructivedistillation of coal in the absence ofair. The coal is heated in a closedchamber there by driving out thevolatile components present in coaland leave behind the residue calledcoke. This phenomenon is called asthe carbonization of coal can becarried out at differenttemperature depending upon the

type of coke we need. Carbonizationtemperature is 1200-1300C which isthe optimum temperature to getcoke of uniform size for the givencoal inputs at BSL, there are 8Batteries of 69 Ovens each(including one standby battery) with4.7 m height and useful coke


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SINTER PLANT

Sintering is the process whereincipient fusion takes place bycombustion of Coke within movingbed of loosely packed fines of mainlyIron Ore, Coke & Flux so as toglomerate into a compact porousmass called SINTER.

Sintering plant at Bokaro is unique inmany respects. It has a very highsintering area per machine.It has 3 identical sinter machines in

the same building with 3 separateinterchangeable conveyors tracksavailable to feed them. Moreover

there is a provision of storing 5000tonnes of sinter at plant itself apartfrom storage of 5000 tonnes ofsinter in Blast Furnace Bunkers.

The set up of Sinteringplant at Bokarocomprises of threemain sections:-

a) Raw material sectionb) Stock bins &

Proportioning section

c) Sinter machinebuilding section


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BLAST FURNACE

The aim of Blast furnace is

to produce pig iron from oreand sinter, i.e. iron bearingmaterials. The products ofthe furnace are the pig iron(hot metal) slag and blastfurnace gas.

In Bokaro there are five blastfurnace of 2640T/day capacityeach having a working volume of

2000M3. 5 Furnaces of 2000 cubicmeter useful volume. All furnaceshave Bell-less Top charging

System for continuous charging &better distribution of charge.

Coal Dust Injection in FurnaceNo.4 and 5 and CHSGP in Furnace # 4 &

5. The Capacity of B F 4.585 MTof Hot Metal per annum.


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Steel Melting Shop-IIThere are two Converters in the Shop each of 300

hundred Ton Capacity. SMS II differs withSMS-I mainly because of blowing process and gasrecovery system. Unlike SMS-I, SMS-II have gotsuppressed combustion system, where

atmospheric air is not allowed to enter in the hoodarea and the combustion of converter gas issuppressed. Capacity of SMS-II is 2.25 MT ofliquid Steel. At present, mainly Killed steels are

produced in the shop.


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Continuous Casting ShopThe Continuous Casting Shop, the fastest in the country, is

equipped with advanced Level-3 automation and controlsystems. The shop has a Ladle Furnace and a Ladle RinsingStation for secondary refining of steel. The shop has twofully automated Double-strand Slab Casting Machines.These machines are equipped with Straight Moulds (uniquein India) and Continuous Straightening facilities to producehigh quality slabs also Automatic Mould Level Control(unique in India) for better surface quality.

CCS produces mild steel. It also produces low alloy steels.


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Slabbing MillSlabbing mill transforms ingots into slab by rolling. The ingots of various sizes

and weights are received from SMS I and after being rolled into slabs,

they are sent to our internal customer HSM.The capacity of the mill is 4 MT and is of universal type, capable of rolling

ingots up to 38 tons. The rolling rate varies from 600 to 800 T/Hrsdepending upon the size of the ingots and the thickness of the slab to berolled.

The mill was commissioned on 30th December 1974. We have 12 groups of

Soaking pits with each group having 4 pits : Total 48 pits wherein ingotsare heated to a temperature above 1300C.SECTIONSSlabbing mill complex has been divided into four main sections. They are :a) Ingot Storage Yardb) Soaking Pit

c) Mill Properd) Slab Storage Yard


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Hot Strip MillThe Hot Strip Mill at Bokaro Steel Plant is a continuous 2,000

mm wide strip mill. It is referred to as a 2,000 mm millbecause the barrel length of the rolls used in this mill is2,000 mm. This mill is designed to roll thin and wide stripsfor use in various industries such as wagon building, tubeand pipe industry, drum manufacturing, furnituremanufacturing and lastly, for use in the Cold Rolling Mill.

The fully automatic Hot Strip Mill of Bokaro Steel has a widerange of products. This is the only continuous Hot Strip Millin India.


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Cold Rolling MillThe Cold Rolling Mill at Bokaro produces high quality sheet

gauge material, Tin Mill Black Plate and Galvanized Products.Cold rolling gives thinner gauge strip of very smooth and densefinish with better mechanical properties that are used forvarious purposes.

The CRM complex comprises two Pickling Lines, two Tandem

Mills, an Electrolytic Cleaning Line, a Continuous Cleaningand Annealing Line, Bell Annealing Furnaces, two Skin PassMills, a Double Cold Reduction Mill (DCR), Shearing Lines,Slitting Lines and a packaging and despatch section.


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AuxiliariesThere are a no of auxiliaries department

that are an integral part of BSL thatinclude Galvanizing Shops, Repair Shops,Distribution Networks, Labs etc whichensure that apart from the departmentsfunctioning well their maintenance is alsoproper and any problem that occurs can be

handled without fault.


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Future of Bokaro SteelPlantThe future looks promising for the industry as BSL

is aiming to increase production of steel from 4.3to 7 Mt tones within a span of 2 years. With myown experiences and with all the modernizationgoing on its true that the target will be surpassed

much before that.Also the Plant is a place full of job opportunities for

us aspiring engineers to come here and leave amark here, to work hard and learn.


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THE END.

Bokaro Steel Plant an Overview

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