INDUSTRIAL INTERNSHIP

Observational Training at Bokaro Steel

Plant,Jharkhand

Made By:
Ritwik Tiwari
16BEE1101
Company Profile
 Bokaro Steel Plant is the fourth integrated steel plant of SAIL. Established in
the year 1964 with Soviet collaboration, it is the first Swadeshi Steel Plant of
India with maximum indigenous components and equipment. It was lately
merged with SAIL first as a subsidiary and then as a unit under Public Sector
Iron & Steel Companies (Restructuring & Miscellaneous Provisions) Act 1978.

 Its 1st blast furnace was started in 2nd October 1972 and on 26th February
1978 it completed the 1st phase of 1.7 MT of ingot steel production. Presently
it has five blast furnace and a total capacity to produce 4.5 MT of liquid steel.
With the continuous up gradation in technology incorporated, it is expected
to cross 15MT target by 2020. The first shop of Bokaro Steel plant got the ISO
9001 certificate in 1994 and its SAIL JYOTI products enjoys a loyal market.
Major Landmarks in history of B.S.P.
 1966, Jan- Construction work started
 1972, Sept- First coke oven and sinter band commissioned
 1972, Oct- First Blast Furnace commissioned
 1973, Dec- Steel Melting Shop-1 started production
 1977, June- Cold Rolling Mill Complex-1 commissioned
 1983, June- Steel Melting Shop-2 started production
 1991, Sept- Cold Rolling Mill Complex-2 commissioned
 1997, Sept- Continuous Casting Shop started production
Various shops visited during the
internship
Raw Material Handling Plant(RMHP)
 One of the most important units of an integral steel plant. The major input
for steel making comes from mines to this section.
 Different raw materials handling by this department are as follows:
a. Iron-Ore of different grades
b. Limestone of different grades
c. Dolomite of different grades
d. Manganese
e. Coals of different grades
 FUNCTIONS:
1. Release of different raw materials wagons from different mines by wagon tipplers
2. Supply of raw materials to different customer departments as per their requirement .
Instrumentation and Automation(I&A)
 Instrumentation: The art and science of measurement and control of the
process variables within a production or manufacturing area.
 Automation: is the creation of technology and its application to control and
monitor the production and delivery of various goods and services.

 APPLICATIONS:
1. Mechanical Thermostat
2. PI,PID,P controllers
3. Calibration
Cold Rolling Mill(CRM)
 Cold rolling can be defined as a compressive deformation process in which
there is either a continuous or a stepwise deformation with more than one
rolls. Hot rolled steel is generally cold rolled at ambient temperature to
produce material of following characteristics:
 Thinner gauge material
Material with improved strength
Bright, Smooth & Dense surface finish
Galvanization
Distribution Network(DNW)
 Damodar Valley Corporation- 200kW power supply
 Bokaro Power Supply Company Limited- 132kW power supply
 Power distributed is by transmission lines or overhead lines.
 Types of breakers used:
 A. MCB – Miniature Circuit Breaker
 B. OCB- Oil Circuit Breaker
 C. VCB- Vacuum Circuit Breaker
 D. MOCB- Minimum Oil Circuit Breaker
 E. ACB- Air Circuit Breaker
 F. ABCB- Air Blast Circuit Breaker
 G. SF6 breaker (latest)
DNW continued
 Types of cable used:
 A. OFC- Optical Fibre Cable
 B. EPR- Ethelene Propylene Rubber (Used in stacker)
 C. FRLS- Fire Retired Loss Sheet
 D. PVC- Poly Vinyl Chloride
 E. PILC- Paper Insulated Lead Cover
 F. XLPF- Cross Link Poly Ethelene
 Types of transformer used:
 Current Transformer
 Potential Transformer
Coke Oven and By-Product Plants
 Coking Coal & Non Coking Coal
 Main Purpose is to produce quality coal in large amount.
 12 coke oven present at Bokaro Steel Plant.
 The composition achieved after carbonization is:
 Fixed carbon: 77%
 Ash content: 22%
 Volatile matter: 1%
 A typical composition of coke-oven gas is:
 Methane: 22-25%
 Hydrogen: 55-60%
 Nitrogen: 2-3%
 Carbon-monoxide: 8-10%
 Carbon dioxide: 4-6%
 Calorific value: 4200-4400Kcal/cubic meter
By Products Produced:-
 Crude tar
 Naphthalene
 Naphthalene oil
 Wash oil
 Press oil
 Pitch
 Ammonia
 Benzene
 Toluene
 Xylene
 Naphtha
 Benzol
Sinter Plant(SP)
 Sinter is porous agglomerate of mineral fines formed after incept fusion.
 Sintering is a process of preparing sinter in which a high temperature is
maintained for two basic purposes:
 1. Waste management
 2. Advantageous properties of sinter
 Sintering as a process uses all wastes generated in the mines site, handling
and the mill zone, so it is a good source of waste management. Apart from
this, sinter has lots of advantages than lumps to use as a burden material in
Blast Furnace. Now days, 70% of Blast Furnace burden is sinter.
 Ore Fines
 Flux (limestone Dolomite)
 Coke
SP continued
 Advantages of Sinter:
 1. Self fluxed
 2. may charged up to 80% safely
 3. improves the productivity of Blast Furnace
 4. process fine grained raw materials into a coarse grained iron ore
Blast Furnace(BF)
 Core metallurgical reactor to produce hot metal.
 The inputs required for the Blast Furnace are:
 Iron-Ore Lamp
 Sinter
 Metallurgical Coke (25mm to 80mm)
 Lime-Stone
 Manganese
 Nut Coke
 The outputs from the Blast Furnace are:
 Hot Metal
 Blast Furnace (BF) gas
 Gangue Material in the form of slag
Inside a Blast Furnace
Steel Melting Shop(SMS)
 Continuous Caster- Heart of Steel Melting Shop

 Raw Material used:

 Limestone
 Dolomite
 Aluminium
 Ferro-Alloys
 3 types of product produced from this shop:
 1. Killed Steel- completely deoxidized
 2. Semi-Killed Steel- partially oxidized
 3. Reamed Steel- process of enlarging the whole
Products and Market
 SAILCOR
 SAILPROP
 SAILMEDSI
 SAILRIM
 HRNO
 SAILMA
 WTCR

 All the products of BSL are marketed in India through SAIL’s Central Marketing
Organization(CMO).
 SAIL’s International Trade division looks for export of steel in foreign
countries.
CONCLUSION
 The training at BOKARO STEEL PLANT was very helpful.
 Engineering students gain theoretical knowledge through books. It is volatile
and not much of use without knowing its practical implementation.
 Training is one of the important aspects for an engineering student’s career to
strengthen the practical concepts. It was an awesome experience in training
as the things we all learnt in our previous years was seen implemented
practically.
 I had a chance to see the blast furnace and steel melting shop where the
main working of the steel plant is being done and I also saw the working of
various shops like coke oven, DNW, I&A which were very interesting. So the
training was very helpful to me to understand power system more.
THANK YOU