STEEL AUTHORITY OF INDIA LIMITED

PRESENTATION OF VOCATIONAL TRAINING AT

DURGAPUR STEEL PLANT

DURATION : 19TH MAY 2014 - - 1ST JUNE 2014

BYSONU DAS11/MME /30

DEPARTMENT OF METALLURGICAL AND MATERIALS ENGINEERING

NATIONAL INSTITUTE OF TECHNOLOGY,DURGAPUR

Set up in late 50’s.  Initial annual capacity of 1 million tons of crude steel per year, the capacity of

Durgapur Steel plant (DSP) was later expanded to 1.6 million tons in the 70's. 

Massive modernization program was undertaken in the plant in early 90's, which, while bringing numerous technological developments in the plant.

Enhanced the capacity of the plant to 2.088 million tons of hot metal. 1.8 million tons crude steel .

1.586 million tons saleable steel. The entire plant is covered under ISO 9001: 2000 quality management system.

DSP’s Steel Making complex and the entire mills zone, comprising its Blooming & Billet Mill, Merchant Mill, Skelp Mill, Section Mill and Wheel & Axle Plant, are covered under ISO: 9002 quality assurance certification.

Plant covering an area 6.4 km.

It is situated at a distance of 158 km from Calcutta, It is situated on the banks of the Damodar river. The Grand Trunk Road NH-2 and the main Calcutta-Delhi railway line pass through Durgapur.

About Durgapur steel plant

Products :

PRODUCT-MIX TONNES/ANNUMMerchant Products 2,80,000Structural 2,07,000Skelp 1,80,000Wheels & Axles 58000Semis 8,61,000Total Saleable steel 15,86,000

Flow chart of Durgapur Steel Plant

Operational Departments 1.Raw material handling plant 2.Coke ovens 3.Sinter plant 4.Lime calcination plant 5.Oxygen plant 6.Blast furnace (4 nos. out of which 3 is in working condition) (Gross capacity of 2.088million tonne/annum). 7.Steel melting shop 7.1 )BOF shop with 3 converter capacity 110 tonne each

ladle. 7.2)Continuous casting plant(capacity .773 million

tonne/annum). 8.Blooming mill (capacity .950 million tonne/annum). 9.Billet mill(capacity .957 million tonne/annum , continuous Morgan

design). 10.Section mill(capacity .212 million tonne/annum). 11.Skelp mill(capacity .25 million tonne/annum). 12.Merchant mill (capacity .28 million tonne/annum , continuous

Morgan design with 4 Repeaters ). 13.Wheel and axle plant(capacity 58000 tonne/annum).

MERCHANT MILL

Capacity - 0.28 million tonnes / yearType of mill - continuous Morgan designHorizontal stands - 13, Repeaters - 4

Plain rounds - 12 - 32 mm diaTMT bars - 12 - 25 mm dia

The Merchant Mill produces plain round and Thermo-Mechanically Treated (TMT) bars in the range of 16mm - 28mm. The entire product range of TMT bars and rods

at DSP is branded .

Product range :

TMT : TMT means Thermo mechanically treated steel its a new-generation-high-strength steel having superior properties such as weld-ability, strength, ductility and bend-ability meeting highest quality standards.

 Steel bars get intensive cooling immediately after rolling to make the surface layer hard.

The internal core is hot at the same time.  Due to further cooling in atmosphere and heat

from the core, the tempering takes place.Improved properties such as yield strength,

ductility and toughness and corrosion resistance with above properties, TMT steel is highly economical and safe for use.

To produce the rods having size (15-28)mm Dia .

Input material (100*100)mm and 9 meter long slab usually come from Bloom and Billet mills & from CCP.

By pusher

slab

Reheating

chamberCoke

oven gas +Bf gas mixture

Series of 14 roller

Thermax furnace +

water quenchin

g

TMT Bar

InspectionInspection of mechanical properties

Zone 1Side charging

Zone 2Reheated slab discharging

Capacity 70 tons,Temp. ~1100-1200 c

Stand no 3,4,5 drive 400HP DC motor.Stand 1,2,6,9 drive 500HP DC motor.

Stand 10 & 11 600 HP DC motor.Stand 12 & 14 800 HP DC motor

Discharge

Schematic illustration merchant mill

CONCLUSION

 Familiarized with the environment of a steel plant. Studied and observed the manufacturing process of steel –

from raw material handling process (by reclamation and tapping processes) to finishing.

Observed the functioning of Gas Cleaning plant, Dwight-Lloyd Sinter Machines and manufacturing of Thermo Mechanically Treated (TMT) bars.

Performed Magnetic particle inspection and Ultrasonic testing for detection of surface and bulk discontinuity respectively .