A.

Company Profile
Name of the company
: Jaypee Rewa Plant (JRP) Jaiprakash Associates Limited Cement Division.

Establishment Year Chairman No of Employees Products

: : :

1986 Mr. Manoj Gaur 3330 Product Range (Cement)

Type - Grade OPC-53 OPC-43 OPC-33 OPC - IRS T40/53S PPC BUNIYAD PPC BULAND PPC

Brand Name SUPER PLUS TIGER BUNIYAD BULAND

Production Capacity Motto

Health

: :

3.3 MTPA Work for Quality, Safety, & Environment

B. Brief History
Year 1979:
Jaiprakash Associates Private Ltd. (JAPL) formed. Ultra Rasayan Udyog Ltd. was formed for setting up Malathion Technical plant in Sikandrabad (U.P.), which was changed to Jaiprakash Enterprises Ltd.

Year1980:
Hotel Siddharth was set up.

Year1982:
Hotel Vasant Continental was set up.

Year1986:
Commissioning of 1st unit of 1 MTPA Jaypee Rewa Plant. Formation of Jaiprakash Industries Ltd. (JIL) by amalgamating JAPL into Jaypee Rewa Cement Plant.

Year1991:
Commissioning of 2nd unit of 1.5 MTPA Jaypee Rewa Plant (JRP) in District Rewa (M.P).

Year1992:
Formation of Jaiprakash Hydro Power Ltd (JHPL).

Year1995:
Formation Jaiprakash Power Ventures Ltd (JPVL). Hotel Jaypee Residency Manor set up.

Year1996:
Commissioning of 1.7 MTPA Jaypee Bela Plant (JBP) in District Rewa, M.P.

Year1999:
Jaypee Palace Hotel, Agra set up.

Year2000:
Acquisition of land for Jaypee Greens Ltd.

Year 2001:
Commissioning of .6 MTPA Jaypee Blending Units at Allahabad district in U.P. The first of its kind in the country. Jaypee Institute of Information Technology (Deemed University Since November 1, 2004) at Noida, U.P.

Year2002:
Commissioning of 1.0 MTPA grinding unit in district Ambedkar Nagar in U.P. Jaypee University of Information Technology (State University), Waknaghat was set up.

Year2003:
Commissioning of 25 MW captive Thermal Power Plant-1 at JRP. Formation of Jaiprakash Associates Ltd (JAL) formed by merging JIL with Jaypee cement Ltd.

Year2004:
Commissioning of 25MW captive Thermal Power Plant-2 at JRP. Commencement of Work for setting up 3MnTPA Cement Plant at Baga & Baghri at District Solan in H.P. and 1.5 MTPA.

Year2005:
Successful completion of up-gradation scheme, enhancing the total capacity of Rewa Operation to 7.0 MTPA. Shares of JHPL Listed on BSE/NSE. First hydro power company to be listed in the country.

Year2006:
Setting up of Madhya Pradesh Jaypee Minerals Corporation Ltd. (MPJMCL). Commissioning of 38.5MW captive Thermal Power Plant-3 at Jaypee Rewa plant. Railway siding operational at Jaypee Bela plant. Commencement of work for setting up a new green field 1.5 MTPA cement plant in district Sidhi, M.P. Acquisition of cement plants & assets of U.P. State Cement Corporation Limited (in Liquidation) of 2.5 MTPA capacity.

 Acquisition of Gujarat Anjana Cement Limited for setting up a Green field cement plant of 1.2 MTPA capacities Bhuj district in Kutch, Gujarat.

Year2007:
Signing of MOU with Gujarat Mineral Development Corporation (GMDC) for setting up a new Green Field Cement Plant of 1.2 MTPA capacity, in JV in Kutch district, Gujarat. Signing of MOU with Government of H.P, or setting up a new Green Field Cement Plant of 2.0 MTPA capacity at Chamba district in H.P.

C. Introduction
Jaypee Rewa cement is sub division of Jaiprakash Associates Ltd. Jaiprakash Associates is one of the biggest construction companies in India. Mr. Manoj Gaur is the Executive chairman of this company with its head office is in New Delhi.

Jaypee Rewa cement is single largest production unit. Its annual production is about 3.3 Million Tons. There are two units installed for the production of clinker namely Unit-1 &Unit-2.

Unit-1: Supplied by Krupp. Plysious (Germany). 1.5 million ton capacity was commission in December 1986.

Unit-2: Supplied by F. L. Smidth (Denmark) 1.8 million ton capacity was commission in April 1991.

D. Cement Manufacturing Process

I. Mining
The cement manufacturing process starts from the mining of limestone, which is the main raw material for making cement. Limestone is excavated from the quarries at about 6 m from ground level after drilling and blasting and than loaded on to the dumpers which transport the material and unload it into the hoppers of limestone crusher.

II. Crushing Stacking & Reclaiming of Limestone:

The limestone crusher crushes the limestone to approximately 70 to 80mm size and discharge the material onto a Belt Conveyer which takes it to the Stacker via the Bulk Material Analyzer. The material is stacked in longitudinal stockpiles and than Limestone is extracted transversely from the stockpiles by the Reclaimers and conveyed to the Raw Mill

hoppers for grinding of raw meal.

III. Crushing Stacking & Reclaiming of Coal:

The process of making cement clinker requires heat. Coal is used as the fuel for providing heat. Raw coal is stored in the coal yard. Raw coal is dropped on a belt conveyer from a hopper and is taken to a crusher for being crushed. Crushed coal discharged is stored in the longitudinal stockpiles from where it is reclaimed by the Reclaimer and taken to the coal mill hopper for grinding it to fine coal.

IV. Raw Meal Drying/Grinding Homogenization:

&

Reclaimed limestone along with some laterite stored in their respective hoppers is fed to the Raw Mill for fine grinding. The hot gases coming from the Cooler House are used in Raw Mill for drying. Grounded Raw Meal is than transported to the Electrostatic Precipitator (ESP) /Bag house, where it is collected and then stored and homogenized in the concrete SILO. Raw meal extracted from the SILO is than fed to the top of the pre-heater for pyro-processing.

V. Clinkerization
Cement clinker is made by pyro-processing of Kiln feed in the pre-heater and the rotary Kiln. Fine coal and air is used as fuel to heat the Kiln and the pre-calciner located at the bottom of the 5/6 stage pre-heater. Hot clinker discharged from the Kiln drops on the gate cooler and gets cooled. The clinker discharged by the Cooler House falls onto the pan conveyor and it is than transported to the clinker stockpiles/SILO. The clinker is than taken from the stockpiles/SILO to the Ball Mill Hoppers for cement grinding.

VI. Cement Grinding & Storage

Clinker and Gypsum (for OPC) and also Pozzolana (for PPC) are extracted from their respected hoppers and fed to the cement mill. These ball mills ground the fed materials to a fine powder. The mill discharge is than fed to the elevator, which takes the material to the separator, which separates fine product and the coarse material. The latter is sent to the mill inlet again for regrinding and the fine product is stored in concrete SILO.

VII. Packing
Cement extracted from SILO is than conveyed to the automatic electronic packers where it is packed in 50 Kg polythene bags and dispatched in trucks.

SHUTDOWN OPERATIONS IN KILN AND COOLER HOUSE (UNIT-2)

I. Detailed Description
a.

Rotary Kiln
Kiln is cylindrical rotary equipment rotating on supporting rollers at about 3.5 RPM and discharges on the completion of calcinations reactions. Firing is done from Kiln outlet with the help of burner pipe.

i.

Technical specification of Rotary Kiln:

Unit-2 Maker Pre-calciner Diameter Length Capacity Rpm Burner pipe Slope Fuel Used Thrust roller FLS SLC 4.75 M 75 M 5500 TPH 3.8 Duoflex 8 Coal Hydraulic

Thermal Load Supporting Roller

14.44 6nos

ii.
a. b. c. d. e. f.

Construction:
Kiln inlet (consist seal, grease pump, lines, cylinders etc) Girth gear (Gear, pinion, spray system) Thrust roller (Hydraulic cylinder, oil line) Supporting roller & tyre (Consist of bearing, chair plate, bolts etc) Kiln outlet seal (S.S shims, crown shell, seal) Burner pipe(consist of air pipe, coal pipe, diesel pipe etc)

Kiln inlet Kiln inlet is sealed by sealing arrangement. Greasing is done by pneumatic pump seal. It consists of 10 to 14 segments so that it can be mounted and disassembled from Kiln inside. A conical section forms an extension of the inlet ring. A brick retaining ring has been mounted at the end of conical section.

Girth Gear Kiln is rotating by Gear pinion arrangement. Girth gear is mounted on Kiln with the help of spring plates.

Specifications of Girth Gear are as follows: KILN GIRTH GEAR P.C.D. 7149 mm No. of Teeth 220 Width of Teeth 640 mm Thrust Roller The function of thrust roller is to control axial moment of Kiln in both upward & downward directions.

Supporting Rollers & Tyre Supporting rollers are for support of Kiln. They are in contact with tyre which is fitted in Kiln shell.

Kiln Outlet There is a sealing arrangement at Kiln outlet.

Burner Pipe It is for firing of fine coal into the Kiln. Air is controlled by damper and fine coal by solid flow meter. Duoflex type of burner is used in Kiln Unit-2

iii.

Maintenance
Refractory Lining The high temperature inside the Kiln leads to severe thermal shocks which cause cracks in the brick lining as well as Castable. Also, during the half yearly maintenance as the Kiln is stopped, leads to high temperature changes which causes cracks in the brick lining. This may cause the molten liquid to reach the Kiln shell causing damage to it. Hence the Kiln stoppages are usually averted as much as possible. It may be noted that temperature of shell does not rise beyond 300 C The Castable is used wherever brick lining cannot be used in Kiln generally in sections which are not straight.

Process of Replacing Brick Lining Check the refractory brick lining during the maintenance time. If the brick lining is cracked than we replace the lining. The cost of brick lining is quite high so we use bricks according to the temperature they are supposed to sustain. Usually high alumina percentage bricks are placed near the Kiln Inlet where the temperature is highest and material flows in molten form.

 During lining of bricks a ceramic plate is placed in between the two refractory bricks using adhesive. This is provided to avoid stresses in the brick during thermal expansion. A Ram is placed inside the Kiln which presses and supports the brick lining. The last brick to be placed is known as Key Brick which is placed with 2 shims maximum in order to tighten the whole ring. When the entire lining is completed, the pneumatically driven brick lining machine is used in order to press the lining for final fit. The bricks which were used were DALMIA 625 and 425 where first letter denotes the diameter and last two the thickness of insulation. For e.g.: 625 means the brick is for lining 6 m diameter Kiln and insulation thickness is 250 mm. Since the diameter of the Kiln is 4.75 m so these bricks are placed in the ratio of 1:1. Castable is placed over the tip casting plate by welding small sections over the tip casting plates and than filling Castable in it. After the Castable has solidified we cut the extruding parts. And remove the support plates.

Tip Casting Plate The Tip Casting plate is placed at the tip of the Kiln outlet. These plates are those over which a ring of Castable lining is made. These plates protect the Kiln shell from the hot molten material when the Castable lining has worn off due to the continuous abrasive action of between molten material and tip. Process Tip Casting Plate is imported from outside and is placed just on the tip of the Kiln and screwed to the tip. Later this forms a base for the Castable.

Chair Plate, Shims and Guide Blocks The live ring migration is equal to the relative motion between Kiln Shell and Tyre during a single revolution. It is an indicator of ovality of Kiln Shell. Chair plates are inserted between the Kiln Shell and Tyre and Shims are inserted in between to reduce the clearance. This stops the mitigation. It should be seen that mitigation of Tyre does not exceed beyond 20 mm as it would reduce Kiln lining life.

Guide blocks are also provided to keep the live ring in its axial position on the Kiln shell. This implies the transfer of axial thrust on the Kiln shell between live ring and side guides. The relative moment of the face depends upon the ovality of Kiln shell. Therefore, there is a chance of high wear. The maximum clearance between the guide blocks and the tyre should not exceed 4 mm. At the time I was at the Plant a design change of guide block was taking place. Previously adjustable guide blocks used to be bolted over the Chair Plates. But over a period of time the nuts used to get jammed and were no longer adjustable hence the newer version of guide blocks were directly bolted over the Chair Plates.

Crown Shell and Sealing Plate Due to high temperature and oxidation due to atmosphere surrounding it the crown shell and sealing plate may wear off and get damaged. So during shut down these damaged plates need to be checked and should be replaced if damage to them is more than a limit. The function of Crown shell is that it acts a nozzle for the air blowing from side cooling the lip of the Kiln.

Also Sealing plate does not allow the hot gases from the Kiln to escape thus trapping energy. Rollers Rollers are also checked because they sustain heavy loads hence even a small particle will lead to great loss and wear the surface. These rollers are not replaced rather grinded so as to make them polished and workable.

b. Cooler House
It is a vital part of Kiln System and a decisive influence on plant performance. It is for the cooling of clinker (less than 100 degree), as produced in Kiln.

i. Technical Specification of Grate cooler

Type Make Capacity Size No. of gates No. of cooling Air fan Folax FLS(Germany) 5500 TPD 37.8m length*5.1m width 4 11

ii.

Main Functions of Cooler House

Clinker cooler has two main functions to perform. These are as follows: 1. To cool the hot clinker quickly (from 1400 to normally 100-200 degrees). 2. To provide necessary hot air by recuperating as much heat as possible from hot clinker by heating up air use for combustion of coal in pre-calciner and Kiln.

After introduction of red hot clinker into the cooler, it falls over IKN plates. These are fixed grate plates and hence to move the clinker an air blaster is placed at the start of the Cooler House. After this the clinker moves to mechanically driven gates. These grates are such that one row of grates is fixed and one row of

grates is reciprocating with the help of motor. These reciprocating grates ate installed over a beam which moves over the rollers. The grates are having holes from which pressurized air flows and cools the clinker quickly. Clinker cools down gradually as it moves, due to the air blown by the centrifugal air pumps which is taken from the atmosphere. Air flowing from below through the cooling grate plates helps in cooling the clinker quickly Clinker escaping out of the cooler is fed to a hammer crusher, since lumpy material requires crushing. Crushed material is transported to clinker silo through deep bucket conveyor. Temperature of clinker escaping out of cooler is about 208oC.

iii.

Grate Cooler operation

The grate cooler operates with a cross current principle in which the

clinker moves horizontally while cooling air blow in from below through the grate and clinker layer.

As the hot clinker falls from Kiln, it forms clinker bed on the grate plates and is than transported through the cooler over alternatively fixed and reciprocating grates. At the inlet of Cooler House, clinker is quenched and spread evenly across the cooler width by the cooling air. The grate is fabricated in order to obtain a thick clinker layer and a uniform distribution of air through the clinker bed in the interest of heat recovery. During the clinker transportation from the cooler, a part of dust and small size clinkers fall off from the grates and get collected into hoppers under the grates. These hoppers have dust bin valves at their bottom which opens only when a certain weight has been reached. The dust is released in the same DBN conveyors which carry the clinkers. The drag chain and rotary air lock system feed these clinkers and dust to clinker transport system. A dust collecting ESP is also installed known as cooler ESP. Exhaust gases from collection is fed to the ESP for dust collection.

iv.

Construction

Cooler parts are as follows: IKN Grate (fixed) Cooler I-IV Grate Cooler Fans Hammer Crusher: IKN kids, Fans S.S Grate plates, S.S Bolts Fan, Belts, Pulley, Motors Hammers, Pans, Rollers

IKN Grate It is a stationary grate plate. Previously, there used to be similar S. S Plates in place of IKN plate but a change was made by the production department. They are not only having a guaranteed 1 year life but also have increased the production of Unit-2.

IKN-KIDS There are 6 to 8 stationary and stepped enclosed air beams. These air beams are aerated by individual ducts. Refractory side dams are used to collect and aerate segregated clinker from discharge. Air blasters are used to avoid snowman formation.

S.S Grate Plates These plates are of old design. It has holes over it with air blowing from below. Due to air blowing with heavily from below causes widening of air holes which causes clinker to pass from it to lower chamber where rollers reciprocating the plates are placed.

Fans For Cooling purposes high efficiency fans are placed below over the ground which suck air and send it for cooling

Cooler Fan Maker Fan Capacity- In/Out Pressure RPM Hammer

REITZ 46190m3/hr, 45360 m3/hr 4.7 KPa 1480

At discharge end of cooler hammer crusher is provided consisting of a rotor with shaft. Hammers are mounted on each row. Hammers are casted out of high chrome or manganese steel. Clinker is crushed to a size of 15-25mm by Hammer Crusher.

v.

Maintenance

Shutdown Activities
All Cooler Grate Plates, Side Blocks should be checked If we find that the Grate Plates have worn off too much by abrasion action of clinker or high velocity air gushing from below than it is replaced. During my visit this operation was going in the Cooler House. The old Grate Plates had their holes widened due the high velocity air and also the thickness of those plates was reduced due to the Clinker abrasive action. The replaceable lip is also checked. A lip is provided in order to hold the side grate

plates. These plates in a row are welded to each other and any gap bigger than 3 to 5 mm is filled between the Grate Plates. All compartment internals as pull rod, single and twin supporting rollers and grease lines should be checked. All Grate connecting rod and non-drives must be checked Dust valve hopper leakage should be checked for holes etc which needs to be patched and under Grate compartment jail needs to repaired/replaced Just below the Grate plates there is a net type arrangement which is used to allow the dust to fall into hopper connected to dust valves. This net sometimes gets clogged by large clinkers which need to be removed. Also sometimes they may create a hole in the hopper causing leakage. The net over the leaking hopper is cut in this and the hopper is thoroughly checked for holes and repaired. Hammer crusher hammers, impact plates, lining needs to be repaired/ replaced Hammers get worn off due to continuously striking the clinker and breaking it to smaller pieces. The hammer are either replaced or used again by reversing them. The impact plate just below the crusher also gets worn off by continuously striking clinker over it. There might be holes created in them. The size of the crushed piece can also be set by a screw provided for changing inclination of

impact plate. Also hard basing is done at the end of the Cooler House so as to protect it from continuous abrasion taking from the moving clinker. The welding alloy LH 745S is used for this purpose it provides hard surface at high temperature. Pan conveyor or damaged track wheels should be checked and changed. Under Grate beams etc. should be checked All Cooler Fan Belts, bearing, Impellers should be checked.

A. Company Profile
Name of the company Establishment Year Chairman No of Employees Products
Products Coke Ammonium Sulphate Naphthalene Crude Anthracene Road Tar Crude Benzol Nitration Grade Benzene Toluene Solvent Naphtha Light Pyridine Ferrous Sulphate Pig Iron Steel : : : : Bokaro Steel Plant (SAIL) 1972 Mr. S.P Verma 25000

and

Production Capacity

4.3 MTPA Steel

B. Introduction
Bokaro Steel Plant, the biggest steel complex in India, was designed with the collaboration of former USSR. It is one of the main units of Public Sector Organization, Steel Authority of India (SAIL). Bokaro Steel City is situated on the bank of river Damodar in the North, river Garga in the East, Chas-Ramgarh road in the south and Muri -Chandrapura line in the west. It is about 50 kms from Dhanbad, which is on the main DelhiHowrah Railway line. It has been long acknowledged that Bokaro would be one of the best possible locations for a large sized Iron & Steel Plant. Its present capacity is 4.3 MT and is rapidly modernizing itself to double its production. At present it is working with 5 Blast Furnaces and 8 Coke Oven batteries.

Units of Bokaro Steel Plant

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Raw Material & Handling Plant (RMHP) Coke Ovens By Product Plant Sintering Plant Blast Furnace Steel Melting Shop Slabbing Mill Hot Strip Mill Hot Rolled Coil Finishing Cold Rolling Mill Roll Grinding and Bearing Shop Slag Granulation Plant Scrap & Salvage Department Refractory Research & Control Lab Inspection & Quality Control Industrial Engineering Department Water Supply Oxygen Plant Acetylene Plant

21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

Protective Gas Plant Machine Shop Forge Shop Structural Shop Steel Foundry Pattern Shop Ingot Mould Foundry Iron & Copper Foundry Thermal Power Plant Production Planning & Control

C. Brief Description of Units Visited

I. Raw Material & Handling Plant
Purpose:
1. To obtain homogeneity of chemical and physical composition of different raw materials received from different sources by method of blending. To keep an optimum stock of materials in order to take care of irregularities of supply arising due to strike in railways, mines etc. To release the wagons irrespective of consumption of material by customers. Thus, it avoids the demurrage charges.

2.

3.

II. Coke Ovens

Metallurgical and Engineering Industries generally require coke as fuel. For the production of solid, porous, coke ovens of certain characteristic properties needed.

In Bokaro Steel Plant, coke is chiefly used as fuel and for reduction of iron ore. The Coke Oven here is largest in India. It has got 8 batteries at present. Each battery contains 69 ovens. The process of making coke consists of the destructive distillation of coal in the absence of air. The coal is heated in closed chamber thereby driving out the volatile components present in the coal and leave behind the residue called coke. This phenomenon is called as the carbonization of coal. The carbonization of coal can be carried out at different temperature depending upon the type of coke we need. Different sections of Coke Oven plant are: 1. 2. 3. 4. Coal Tower Coal Handling Plant Coke Oven Battery Coke Sorting Plant

III. By Product Plant

The high temperature carbonization of coal is basically adopted for production of metallurgical coke for use in Blast Furnace. The gas so produced is also used as fuel for making, shaping and treatment of steel after detailed process of cleaning to make it suitable for plant uses. In the process of cleaning some primary by-products, namely crude tar, benzol, ammonium sulphate etc are obtained. The primary and secondary chemicals that can be produced from these are of great importance for the growth of chemical industry.

IV. Sintering Plant

It has been found that the production rate can be increased if the raw material is sent into the Blast Furnace in sintered form. Keeping this in view, BSL has the largest plant in India. There is provision for partially

cooling the sinter on the machine itself. The ignition furnace is of double hearth and provision is there for adding extra amount of coke on the topmost layer of the charge. This plant not only helps in supplying a suitable charge for the Blast Furnace, but also eliminates other intricate problem.

V. Blast Furnace
It is the root plant of any steel producing complex. It is the unit where reduction of Iron Ore takes place. Hot metal is the final product from the Blast Furnace. There are five furnaces, each of capacity 2640 Tons/ Day with a useful volume of 2000 cubic meter. The annual capacity of Blast Furnace is 4.82 MT.

VI. Steel Melting Shop

The raw material for the Steel Melting Shop is Hot Metal coming from Blast Furnace. Here pure oxygen is blown into the hot metal. Impurities are oxidized and metal is transformed into steel. The Steel Melting Shop at Bokaro is largest in India with an annual production of almost 4.3 MT. There are 5 LD Converters in SMS 1 of 100 T each where as in SMS 2 these LD converters are of annual capacity of 300 T each. The steel produced is meant for plates and sheets.

VII. Auxiliary Shops

The main function of Auxiliary Shops of Bokaro Steel Plant is to extend help in a specified manner to the principal production line by producing spare parts to exact specifications. The objective of the set up of various Auxiliary Shops is the economization of the production complex and/or easy running of the production process. Some of these Shops are as follows: 1. 2. 3. 4. 5. 6. Ingot Mould Foundry Steel Foundry Forge Shop Machine Shop Structural Shop Pattern Shop

D. Detailed Description
I. Raw material and handling plant
This plant deals with the raw materials which are coming from various sources. It deals with around 10 MT of raw material per annum that amounts to about 400 to 500 wagons which has to be unloaded per day with each wagon carrying 60-70 tons per wagon. Mr. R.R. Kumar (AGM RMHP) described about the plant and gave an introduction about its operations and functions.

a. Functions of RMHP
1. Unloading of Raw Materials within a given time The material which comes within the plant by the well spread railway routes within the plant has to be unloaded as quickly as possible. For this purpose Tipplers are provided in the yard where each wagon is uncoupled and placed inside the Tippler and tilted to be emptied. The amount of wagons which have to be emptied is so much sometimes that they have to remain docked in the yard for days and because of this reason the company has to pay a heavy leverage of 10 15 Crores each year. 2. Storage with proper blending This function is achieved by two types of machines Stacker and Reclaimer. To keep the plant running we need continuous supply of raw materials which is achieved by stacking them in 18 different beds. Since the quality of material may differ hence blending is needed. Stacker distributes the material in piles horizontally using boom conveyors. so when Reclaimer reclaims the material, it takes

the entire pile at a time hence blending the different composition or material together. 3. Supply to Internal Customers These are the following Internal Customers of RMHP 1. Refractory Material Plant (RMP) 2. Blast Furnace 3. Sintering Plant

b. Types of raw material

RAW MATERIAL Iron Ore Lump (Hematite) Iron Ore Fines (Hematite) Limestone for Sinter Plant Dolomite for Sinter Plant Limestone for RMP Dolomite for RMP SIZE 10-40 mm <10mm SOURCE Kiriburu, Meghanathburu Kiriburu, Meghanathburu Bhawnathpur, Kuteshwar Bhawnathpur, Birmitrapur, Sonakhan, Rajanpur Jaselmer, Dubai Baradwar

<25

75-25mm

c. Process
The Raw Material coming from different parts of the world reaches RMHP via rail routes to the captive yard inside RMHP. At this yard there are 4 Tipplers located whose function is to unload the raw materials. There are 3 cradle tipplers and 1 hydraulic tippler. The cradle type tippler has a cradle located at top and on 1 side on which the BOX wagon rests while it is being toppled by an angle of 170 where as the hydraulic tippler holds the wagon by hydraulic arms and topples it. The cradle type unloads a wagon at the rate of 20 wagons/hr where as the hydraulic type unloads it at the rate of 12

wagons /hr. But the cradle type Tippler may cause damage to the wagons which may increase railways cost of material handling and is quite noisy. There is a R & C sampling lab also known as Yard Lab nearby consisting of equipments such as jaw crusher, evaporator etc. This lab takes sample from each rake (59 wagons) of material arriving at the yard. They do the physical size test and classify the material as fines and lump. For chemical test the material is converted to a fine powder and sent to the R & C Lab where a spectrometer test is done in order to determine the composition of the raw material. This is done so as to maintain the quality of the raw material. Below each Tippler there are two hoppers located which empty the raw material over to oppositely moving conveyor belts which empty it in a chute moving over a conveyor which carries it to the junction house. The junction house than decides where the raw material has to be sent. There are numerous junction houses within the plant which keeps the track of material movement. Each junction house has 3 conveyors moving in each direction in which 2 are used and 1 is kept in case of breakdown of one of them. The junction house sends the material for stacking in 18 beds (280m*27.5m*9m) with the help of double boom stackers. The raw material in beds is as follows: Bed 1 Sinter (It could be either purchased sinter in case of shortage or it could be for storage during breakdown) Iron Ore Fines Iron Ore Lump Flux for Sintering Plant

Bed 2 to 6 Bed 7 to 10 Bed 11 to 14

Bed 15 to 17 Bed18

Materials for RMP Sinter, L.D, Slag, Corzite

There are 2 stackers for Bed 15 to 18 and rest 4 stackers for Bed 1 to 14. These stackers moves between the bed and could be moved from one position to other by placing it on a platform. These stackers could stack at the rate of 1200 Tons/Hr. Similarly there are 6 barrel type Reclaimers, 1 Bucket Wheel Reclaimer and 1 Shovel and Travelling Reclaimer which are used for reclaiming the raw material and sending it to the customers. The Barrel Type Reclaimer reclaims the material at the rate of 1000 Tons/ hr and Bucket Wheel Reclaimer reclaims at the rate of 500 Tons/ Hr. There are screening units for limestone and lump ore within the RMHP. The raw materials have to travel miles within the plant so there is possible breakage of materials hence they have to be screened before sending it to the internal customers since the size of material is very important during charging. The capacity of both screens is 500 Tons/Hr.

II. Blast Furnace and Pig Casting Machine

a. Raw material
MATERIAL Iron Ore Coke Sinter Limestone SOURCE RMHP Coke Oven Sintering Plant RMHP

b. Process
The raw materials (Iron Ore, Coke, Sinter, Limestone etc.) are carried to the blast furnace by conveyor belts from their respective sources (RMHP, Coke Oven, Sintering Plant). The notable part during charging is the size of the charge. Hence the fines and the lumps of ores are separated in the RMHP itself. Further during material handling of raw materials there is fine generated at different levels so there are Vibrating Dust Separators at the start of the Blast Furnace from where fines are separated and sent to the sinter plant to be converted into Crude or Spongy Iron. The raw material is emptied into their respective hoppers until they reach Skip Pit where the raw material is weighed by weighbridge and is loaded in the Skip (13.5-14.5 m3). In a Shift maximum 45 charges are done with each charge having 20 skips. A same schedule is followed for each charge. There could be a positive or negative difference of 500 Kg but the total raw material in each charge remains the same. The Skip moves over the rail in the skip bridge and empties the contents at the top of the Blast Furnace. The skip is operated by means of the skip wrench located in the wrench house.

The hot blast is supplied from the stoves to the bustle pipe and is blown through the tuyers at the bottom of the Blast Furnace respectively located in the Cast House. The molten Iron and Slag flow through the iron runner and the Slag runner. These runners are made up of refractory powder (CaCO3, Al2O3, and SiO3) which needs to be rebuilt after every 2 months. A new L&T furnace has a Siphon Hall which sucks and separates Slag from the Iron thus there is no need of two different tap holes. Just beneath the Cast house, at the end of the runner there is a ladle wagon run by a locomotive which carries the molten Slag to a Slag yard where it is stored in pits and molten Iron to SMS. About 5% of this Pig Iron is sent to the Pig Casting Machine (PCM). At the end of each runner there is manually controlled swivel and rocker type runner which helps in pouring the molten material in ladles. The waste gases from the blast furnace are taken through uptakes and gas outlets to the dust catcher and further to the Gas Cleaning Plant (GCP). This cleaned gas is taken through gas pipes to the stoves for heating the blast pipes. There are checker plates in it which can me made of refractory material or graphite which gets heated up and the heats the cold blast sent by turbo-blasters which is sent to Bustle pipe. The gaseous products of combustion evolved in the hot blast stoves are exhausted through the chimney.

c. Blast Furnace
The foundation has to carry a very heavy load. It constitutes piles driven to the bed rock over which a huge reinforced concrete structure is constructed. The steel columns mounted on the concrete ring support the mantle ring. The Blast Furnace shell and the inside brickwork is supported by mantle ring. The hearth bottom consisting of fireclay bricks and carbon blocks is laid out within concrete ring. The hearth is a cylindrical portion where the iron slag notch and tuyers are located. The bosh is the section which slopes outwards just above the hearth. The body is again a cylindrical portion above

the bosh. The shaft which is in the form of a cone comprises the portion above the body. The throat cylindrical in form is at the top of the shaft. There are box type coolers within the refractory lining of the throat and shaft through which water circulates. The coolers are mounted to the shell of the Blast Furnace. The bottoms of the hearth and side walls are having plate type coolers. In 2000 m3 Blast Furnace, the Iron notch is situated at the height of 1.1 m above hearth bottom. The slag notch is located at a height of 1.8 m above iron notch. The tuyers through which the blast is blown are located at a height of 3.4m above the iron notch. Hot blast from the stoves passes through the Bustle pipe and tuyers (28 no.) into Blast Furnace. The Bustle pipe is located at a height of 5.5m above the iron notch. Another important feature of the recently modernized Blast Furnaces is Coal Dust Injection System (CDI). Previously the company was planning to replace the old coke based furnaces by gas based furnace due to poor availability of metallurgical coke and high cost of import of metallurgical coke from Australia and New-Zealand. But CDI reduced the present consumption of coke by 50%. The charging mechanism is Bell Less Type. These systems use multiple hoppers to contain each raw material, which is then discharged into the blast furnace through valves. These valves are more accurate at controlling how much of each constituent is added, as compared to the skip or conveyor system, thereby increasing the efficiency of the furnace. Some of these bell-less systems also implement a chute/bin in order to precisely control where the charge is placed. This valve system is easy to control and have replaced the old Bell Systems. In the Furnace, a stirrer is placed for equally distributing the raw material inside. A Bleeder Valve is placed at the top of the Blast Furnace to release pressure if it exceeds 10000kg also a wench is provided to open it as and when required.

In the cast house, the electric mud gun, tap drilling machine and the slag notch stopper is located. Tap Hole drilling machine is used for drilling out and opening the Hole (iron notch) for tapping the hot metal. The closing of the hole at the end of tapping is accomplished by means of clay gun. The opening and closing of slag notch is carried out by the slag notch stopper. Reduction by means of CO begins in the shaft and proceeds in steps from the highest Iron Oxide (Fe2O3) to the intermediate oxide (Fe3O4) and further down to the lowest oxide (FeO).The reaction between FeO and CO is FeO + CO = Fe + CO2 This is called indirect reduction of the iron and takes place around 600-1000 C. The chemical reaction between FeO and solid C is: FeO + C =Fe + CO This is called as the direct reduction of Iron and takes place around 1100 C. Usually 50-60% of iron is reduced in the blast furnace by indirect reduction and 40-50% by direct reduction. This metallic iron formed initially is in the solid state since the melting point of pure iron is 1540 C The carburization of the spongy metallic iron takes place in the presence of CO and its melting point is lowered to around 1200 C. This carburized iron with about 2 % C melts and drops through the incandescent coke on the wall of the wall of the furnace hearth. At this time the iron absorbs more carbon up to 4% and settles at the hearth bottom as liquid pig iron. The reduction of Manganese, Silicon and Phosphorous from the charge takes place in the furnace simultaneously with the reduction and carburization of Iron. These elements also go over into the pig iron.

The slag forms at the lower part of the shaft due to the oxides of Iron, Lime, Silica and Alumina. Liquid ferrous slag is formed at 1200 C and at a certain proportion of the above oxides. As it moves down into the hearth, it is heated and dissolves coke ash, fluxes and the remainder of ore gangue The production of each Blast Furnace is about 2600-3000Tons/Day.

d. Pig Casting Machine

About 5% of the production of Blast Furnace is sent to PCM because: 1. Poor quality of Hot Metal 2. SMS Breakdown 3. Excess production by Blast Furnace & SMS not able to process the entire lot. Vital Equipments are: 1. 2. 3. 4. 5. 6. Wagon Shunting Wrench Ladle Shunting Wrench Ladle Tilting Wrench Belt 4 PCM 2 Lime Preparation Plant (LPP)

The molten material comes to the PCM via Locomotive and than a ladle shunting wrench is used to pick the ladle and place the ladle for pouring where another wrench tilts the ladle over a conveyor belt with pig cast coated with lime. The lime sprayed over the Pig Cast does not allow the Pig Iron to stick to the cast. Water is sprayed over the Pig Cast to cool it as the conveyor is moving. Just beneath, where poring takes place over the Pig Cast, there are plates below which dont allow the splashing to damage the machine elements below. The splashed metal is again taken for pouring by a skip. This prevents the loss of material.

Limestone is used to prepare the Lime by mixing it with water. A large amount of heat is evolved during this process. This is pumped to the Lime sprayer which sprays it over the Pig Cast from below. This process is continuous with the conveying action. The Pig Cast is kept in the Cold Pig Yard and can be transported using Locomotives. There are 4 electromagnetic cranes having 10 Ton capacity each which are used for transferring Pig Iron to the Wagon. At the time of my visit the PCM was closed for maintenance.

III. Machine Shop

In order to keep the plants continuously in working condition each plants have their own Area Repair Workshop which deals with the specific maintenance problem of that Plant. The Machine Shop is the Centre Repair Workshop where parts are given final touches. It has got 4 Bays, LE (Light Engineering), ME (Medium Engineering), HE (Heavy Engineering) and Assembly Bay. Each Bay has got an overhead Crane with a capacity varying from 5 tons to 30 tons. LE Bay houses simple lathes and turret lathes with bed length varying from about 1m to 3.5m. It also has small size gear hobbing machine and milling machines. ME Bay houses medium size gear hobbing machine, Gear shaping machine etc. HE Bay houses Asias largest vertical boring machine with stroke length of 4m. It also houses other large size vertical and horizontal boring machines. The Assembly Bay is the place where the parts are assembled and final product is ready for dispatch. Near the Machine there is another shop Structural Shop which houses an Annealing Furnace which is used for annealing large size ladles etc.

IV. Forge Shop

The Forge Shop is a part of auxiliary shops of Bokaro Plant. It takes its raw material from Steel Foundry and from outside as per specification and supplies it to the internal customer Production Planning Shop (PPS) which gets the further work done by Machine Shop

a. Machines
Steam & Air Forging Hammer 5T 3T 2T Pneumatic Forging Hammers 1T 4T 25T 2 Ton Forging Manipulator 1 Ton Forging Manipulator Band Saw Bogie Hearth Furnace Box Type Furnace NO 1 1 1 2 2 2 2 2 1 3 2

b. Process The job is first heated in the furnace at about 1200-1250C just below the melting point of iron. Then it is picked up by crane incase the job exceeds human holding capacity and the pneumatic ally driven jaws of manipulator holds it. The manipulator jaws are pneumatically driven and not hydraulically because we require impulse action in the jaw arms of manipulator. When the hammer strikes the job, the job applies impulse force over the jaws which if hydraulically driven remain rigid hence the job breaks where as the pneumatically driven hammers are flexible to impulse force and leaves and holds the job immediately as

hammer strikes. The manipulator moves over the railroad by a mechanical drive and because we require accurate movements of arms of jaws we use hydraulically driven mechanism. During forging due to heavy forces over the job its crystal structure distorts which is improved by heat treatment. Sometimes a job becomes soft on cooling in case of copper where as sometimes the job becomes hard in case of iron. Hence annealing and seasoning is done later for proper hardness of the job. The hardness is checked by the Inspector who pierces the job and checks the depth and measures it with the standard. Sometimes rough sizing of job is also required in that case the Forge Shop has a band saw which cuts the job in blanks. Sometimes the job is not required immediately but after a period of time. In that case the job is sent to open entry where they are seasoned in open to improve the crystal structure of the part. There are two types of furnaces present in the shop 1. Bogey Type This type of furnace is used for heating the job entirely at a single time. There is a bogey in which the job is placed and it goes inside the furnace. 2. Box Type This type of furnace is used if the job is not to be heated entirely i.e. a part of it is kept outside and part of it is heated in the furnace. The fuel which is used in the furnace is Coke Oven Gas and Oxygen in the ratio of 1:4 and small amount of Hydrogen.

V. Foundry
a. Ingot mould foundry
This foundry specializes in making Ingot Moulds and Slag Pots from the hot metal supplied by the Blast Furnace. The materials which are required for preparing the mould are: 1. 2. 3. 4. 5. Bentonite High Silica Sand (Corzite) Return Sand Regenerate Sand Water RMHP Allahabad (M.P- 1700 C)

Process First Step in the process of molding is preparation of sand. The constituents of sand are as follows: 1. 2. 3. 4. 5. Bentonite (Binder) High Silica Sand Return Sand Regenerate Sand Water : : : : : 10-12 40 40 5 5 % % % % %

These constituents are mixed together in this proportion with some additives such as molasses and placed in two sand mullers or commonly known as sand mixer. The difference between Bentonite, Return Sand and the Regenerate Sand is that the Bentonite Sand is the fresh sand coming from RMHP where as the Return Sand is the sand which is prepared by destroying defected mould and the Regenerated is the sand which is retrieved from the sand and water mixture after hydro-blasting at about 150kg/cm2.

A centre core is also prepared from High Silica Sand and additives. The mixture is prepared as follows: 1. 2. 3. 4. High Silica Sand Part A (Binder) Part B (Hardener) Part C (Accelerator) : : : : 100 20 1 4 Kg Kg Kg Kg

The mixture is thoroughly mixed and it is placed inside the Core Box but it is not rammed. It sets itself to the size of the pattern and thats why it is known as self setting sand. It is than sent to 3 ovens where it is heated with CO gas for 10 hours and than it is cooled for 1 hour inside the oven and 1 hr outside the oven. The stopper dryer is than used for drying the core by keeping it at 100-120 C for about 48 hours. The mold is prepared from the two parts the drake and the copes After these two things are prepared than the mold is prepared by placing the prepared core over the drake and keeping the cope over it. A sheet pattern is placed in between the core and case of cope. The molding sand is sand now filled in between the core and the case and rammed by sand slinger. Now as the mold is prepared, hot metal coming from the Blast Furnace is poured in the mould through the runner and the gate present in the mould and it is kept for solidification for about 72 hours. Later the cope and drake is lifted using a cope lifting machine. A 5 % coal powder is added in the additives in molding sand which when comes in contact with the hot metal causes a gaseous layer to be formed between the casting and the sand. The graphite paint is also applied over the molding sand which prevents the sand fusion. To collapse the core, we strike the casting over iron pillars and thus the core collapses and breaks away. It must be noted that Silica Sand cannot be used for molding basic materials (Magnesium etc.) since Silica Sand is slightly acidic. For this purpose Olivine Sand is used which is generally found in Europe.

After the Ingot Mould is prepared the milling operation is performed over the ends of the molds to remove the bulges or extra material attached. Finally, the Ingot Mold is placed over bottom plate. This bottom plate acts like a reinforced plate for holding the Ingot Mould and sent to Steel Melting Shop (SMS). The Ingot Moulds have a life of about average 25 castings. The Ingot Molds are of following specification: 1. 2. 3. 4. 17 Ton 20 Ton 25 Ton 28 Ton

The first two are having ribs so that the Ingot formed gets ribs for holding it in Slabbing Mill. There are two other foundries namely:

b. Iron and Copper Foundry

It is where non-ferrous alloys such as copper, brass, zinc and aluminum as well as Cast Iron casting are done.

c. Steel Foundry :
The foundry takes scrap steel from the SMS and use it for its casting purposes.

VI. Steel Melting Shops

a. Steel Melting Shop (SMS)-1
The Steel Melting Shop-1 consists of 4 L-D Convertors which is used for converting the Hot Metal from the Blast Furnace into Ingots. Process The process of converting hot metal into is a 5 step process. It is as follows: 1. Hot Metal from the furnace is supplied by rail routes to SMS-1 through ladles to Mixer Bay Mixer which use CO gas as fuel. The furnaces are preheated to about 1300 C to prevent metal sticking to the furnaces. This heating is done in order to prevent the hot metal sticking to the ladle. This is done in order to homogenize the old hot metal and the new feed. 2. The Hot Metal is sent to the LD Convertor via ladles (5 No each of 130 Ton) which reduces the C % to .10 to .15 %. In this Limestone and Dolomite is added to remove the impurities in the form of slag. Oxygen blasting is done in order which causes the impurities to burn away by forming oxides and the proceeding chemical reaction causes the temperature rise. 3. After conversion is completed, tapping is done. During tapping, FerroMg and Silicon-Mg is added to remove oxygen which can cause blister to be formed in casting. If the carbon percentage has decreased too much than re-carburization is done using coke bags which is purged through Argon Gas. 4. After tapping is done in the ladle, the ladle is lifted using cranes and tapping is done using sliding gate mechanism. The gate is opened which is fitted below the ladle and the mould is filled. Aluminum shots added

to the casting if oxygen content is found to be high since it forms Al 2O3 which is lighter and floats over the surface.

b. Steel Melting Shop (SMS)-2 & CCS

This is a new shop which is set up in conjunction with continuous casting shop. The process of conversion from hot metal to steel is same as in the case of SMS-1. The only difference is that here we have only 2 converters instead of 5 in SMS-1 but of higher capacity of 300 Tons. In continuous casting shop we have a Steel Refining Unit in which the refining of steel is done. It is used for heating a ladle of 300 Tons at a time using an electric arc. The Aluminum bricks are added which are used for removing oxidized material from the crude steel also the refining of other elements such as Cr, Mn etc is done. The ladle is than kept over a car and sent to the continuous casting machine over which it lifted by crane and kept over high Cr manganese pipe which could sustain higher temperature. This fluid as flows starts solidifying and passes through the mold thereby taking the shape of slab. Now it is cut to the actual size by means of acetylene gas. The Slab is than send to Hot Strip Mill to produce steel rolls upto thickness of 2 mm which is later sent to the Cold Roll Mill for reducing its thickness to .15 mm.

VII. Coke Oven and BPP

The main purpose of the coke oven is to provide blast furnace quality coke to the blast furnace. During the process of coke preparation a large amount of volatile material and dust escapes which is processed in the By-Product Plant which to give a range of products which are used in various fields like pharmacy, roads, railways etc. The coke arrives via rail routes to the tippler (2 No which unloads in the similar fashion as in the case of RMHP and send via 2 conveyor belts to the Silo. There are 81 Silo. These Silo's are numbered from 1 to 53 odd numbers, 2 to 54 even numbers and 1A to 53A odd numbers. Capacity of each Silo is 2500 Tons. Each Silo consists of coal coming from a different source namely Australia, New-Zealand, Karghali, Kathara, Moonidi, and Jharia etc. These coals have different ash percentage and different volatile material. The captive coal mines of the SAIL produces coal of various qualities having ash percentage between 15-25% where as the imported coal have ash percentage between 78%. So accordingly these need to mix in order to obtain coke. The Indian Coal and imported coal are mixed in the ratio of 1:4 almost. From the Silo the coal is sent to Hammer Crusher which has a capacity of crushing 350Tons/Hr. which crushes the coal to about -3.2 mm size. The homogenization and mixing of coal used to occur via mixture but now it is not anymore used. The mixing occurs automatically when the coal is transferred through several conveyor belts. From t The crushed coke is transferred to Coal Tower (4 no's) with each having a capacity of 3200 Tons. From there the coal i supplied to the 8 Coke Oven Batteries. Coke Oven Battery consists of 69 coke ovens and 70 heating walls. In each Coke Oven there are 3 charging holes on the top and is charged by the charging car. On the side of the Coke Oven one would see a huge Push car which is used to ram out the coke prepared in the oven. The leveling ram levels the top of the coal. On the other Side one would see the Guide car which supports the rammed column of coke and guides it to the quenching car.

The Coke Oven walls are made up of refractory material having hole in between through which the Coke Oven Gas and Blast Furnace Gas as a fuel are burnt which causes the bricks to become red hot. There is no air inside the oven so the coal burns without air at about 1200 C. The flue pipes of the refractory tunnel s connected by the flue tunnel with Twin reverse valve by help of which flow reverses after some time. The two heating walls are connected over the top by means of pipes. It carries the burnt gas out through the chimney. The top of the coke oven is connected by pipes coming out which is connected to the pipe which carries the burnt particles and volatile particles to the By Product Plant. From the coke oven it is sent for quenching in Quenching Tower where water is dropped from the overhead pipe. The Quenched coke is sent for Coke Crushing Station and than to Coke Screening Station from where the coke of 25 mm size is sent to Blast Furnace and coke of size between 25-80 mm is sent to crushing station again.