Documentos de Académico
Documentos de Profesional
Documentos de Cultura
AN INDUSTRIAL REPORT ON
DURGAPUR STEEL PLANT
Acknowledgement
INDEX
S.No
CONTENTS
Page No.
Introduction
04
06
07
10
Sinter Plant
14
Blast Furnace
16
19
22
Skelp Mill
25
10
Merchant Mill
26
11
Section Mill
29
12.
32
INTRODUCTION
Durgapur Steel Plant, SAIL, was set up with the British collaboration in the
late fifties with an initial capacity of one million tonnes of crude steel per annum. The
capacity was subsequently enhanced to 1.6 million tonnes in the late sixties. The plant
undertook a large-scale modernisation programme in the early nineties. The
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technological upgradation of the plant was matched with a massive training
programmes of its human resources. Since then DSP has acquired the ISO 9000:2001
Quality Assurance Systems and has emerged as one of the most modern plants in the
country. Encouraged with a participative style of management, the Durgapur steel
collective has amply demonstrated its determination to forge ahead in the highly
competitive market scenario that has emerged over the years.
Initiated during the 1950s, Durgapur Steel Plant changed the face of India,
bringing with it a lot of technical and industrial growth for the country as a whole. The
plant was set up with an initial annual capacity of one million tonnes of crude steel per
year. However, as time progressed, the capacity of Durgapur Steel Plant (DSP) was later
expanded to 1.6 million tonnes in the 1970s. Three decades after its commencement, a
massive modernization program was undertaken, which brought a number of
technological developments in the plant. The yearly capacity of the plant was also
increased to 2.088 million tonnes of hot metal, 1.8 million tonnes crude steel and 1.586
million tonnes saleable steel.
The modernized DSP now has state-of the-art technology for quality steel making.
The modernized units have brought about improved productivity, substantial
improvement in energy conservation and better quality products. DSPs 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.
Durgapur Steel Plant is the third integrated steel plant of the then Hindustan
Steels Limited to come up under Public Sector in India. Durgapur was selected as
location of the plant, for its proximity to coal-fields, the Grand Trunk Road (NH-2),
Kolkata - Delhi main railway track, Kolkata port, power from Damodar Valley
Corporation and water from Durgapur Barrage on river Damodar.
Finished products of Durgapur Steel Plant are used in various sectors which are
mentioned in the table below:
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Raw Material Handling Plant is the starting point of steel making process. The
objective of RMHP is to receive, unload, stack and supply all the raw materials required
for steel making i.e. Iron ore, Limestone, and Dolomite. Apart from this, RMHP also
deals with Sinter mix preparation using state of the art automation system.
Iron ore, coal and limestone are the three most basic raw materials of Durgapur
Steel Plant. The plant draws its coal from the Jharia-Raniganj coal belt, while some
amount of prime coking coal, with fairly low ash content, is imported as well. The iron
ore, on the other hand, is derived from the mines at Bolani, in Orissa. Lime stone comes
from the Birmitrapur (Orissa), Jaisalmer (Rajasthan), and Jukehi and Nandwara (Madhya
Pradesh). Durgapur Steel Plant consumes a total of about 7.4 million tonnes of different
raw materials annually
8
7. High grade limestone, dolomite & iron ore lump supply to BOF.
Major Equipments:
(A) Wagon tipplers:
These are 3 in number
To unload the raw materials brought in rakes of wagons
from various mines
(B) Wing Trippers:
These are 3 in number
Two operated mechanically and one hydraulically
To stack material on the beds
(C) Old Reclaimers:
These are 4 in number
Plough and Harrow type
For reclaiming the materials
(D) Stacker cum Reclaimers:
4 in number
For stacking on beds as well as reclaiming from beds
Two beds for Iron ore and two beds for flux
(E) Slewable Stacker:
1 in number
For Sinter-mix preparation (i.e. stacking for Sinter-mix)
(F) Blender Reclaimer:
1 in number
To reclaim the Sinter-mix
Major sections:
(1) Sinter-mix preparation:
Capacity of 12051 T/day
Raw Materials stored in 18 bunkers of junction 25
Also waste generated in the plant like flue dust, mill
scale, Ferro scraps are added
Sinter mix is sent to the Sinter Plant
Main constituents of sinter mix:
Iron ore fines
Limestone fines
Dolomite fines
Coke fines
0-10 mm
0-3mm
0-3mm
0-3mm
9
6 Impact hammer type crusher to crush Limestone and
Dolomite
3 Primary Crushers of 200 TPH and 3 Secondary
Crushers of 250 TPH
Required size of 3 mm obtained by closed loop crushing
system
Crushed Limestone and Dolomite conveyed to sinter-mix
proportioning bunkers.
Main
0-10
Bolani
10-50
Bolani
5-50
Birimitrapur
5-50
25-55
Jaisalmer
Coke breeze
0-20
Internal
10
Wagon
Tipplers
Wing
Tripper
Blending
Silos
10
Bed
Reclimer
erners
11
Primary
Crusher
Service
Pneumatic
Bunkers 4 of
Classifier
4000T each
Selective Crushing
Unit
Secondary
Crusher
Coal for
BF coke
making
To Battery
Major Sections:
(1) Coal Handling:
To supply coal of required quality and quantity to service
bunkers for BF coke making
Washed coal and imported coal received in wagons are
unloaded by means of Box Tipplers (3)
The tippled coal is stacked in silos (14) as per quality
and grade
Coal of different quantity is drawn from Blending silos
and selectively crushed and blended in Selective
Crushing Unit.
Blended coal is sent to service bunkers for BF coke
making.
(2) Coke Ovens Battery:
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12
There are four special cars in this section:
(a) Charging Car:
15%
Ash in BF coke
19%
Fineness of crushing
-3 mm (85%)
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13
As fuel
As reducing agent
SINTER PLANT
Sintering is the process of agglomeration of fines by incipient fusion caused by
heat available from the fuel contained in the charge. The objective of sinter plant is to
provide good quality sinter, an efficient feed to Blast Furnace.
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14
The process of sintering started in 1940 and flourished in countries where there
was coke shortage. Advantages of using sinter are:
(a) To utilize all waste of fines nature like Mill scale, Ferro Scrap, LD slag etc.
(b) Reduction in coke rate in Blast Furnace
(c) Increase productivity of blast furnace
(d) Smooth Gas Dynamics inside BF stack.
(e) To utilize Iron Ore fines and Coke breeze.
(f) Better Operation of Blast Furnaces as Sinter is engineered product
Major equipments:
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15
(a) Primary Mixing Drum:
Materials are mixed in required proportions
calculated amount of moisture added
Drum fitted with paddles
and
Blast furnace
+16 to -16mm
Hearth layer
-6mm
-5mm
Sinter plant is a Heavy Power consuming plant and it consumes about 1/4 th of the
total power.
There are 4 ESPs (Electrostatic Precipitators) provided for each machine which
perform the process of cleaning the gases obtained during suction. These are vital
as the gases have lot of dust particles.
BLAST FURNACE
Blast Furnace is the most important part of an integrated steel plant. It is
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considered as the heart of an ISP. The objective of Blast Furnace is to take the raw
material from RMHP, coke from Coke Ovens and Sinter from Sinter Plant and convert it
into pig iron or Hot Metal. Coke serves as the heat source and reducing agent while
Limestone and Dolomite are used as flux, which combines with gangue to produce slag.
A Blast Furnace is so called because it uses air blast as oxygen source for the process.
The solid charging materials like sinter,sized iron ore,coke etc. are charged form the top
of the furnace.The hot air blast at 11000c-13000c and 5.75 kg/cm 2 is blown from the
tuyeres located at the bottom of the furnace.The oxygen from the air blast reacts with
the coke and generates heat and carbin monoxide.These gases while ascending
upwards reacts with the coke and generates heat and carbon monoxide.These gases
while ascending upwards reacts with the descending charge materials.Eventually the
charge melts and hot metal and slag are produced and tapped out.The top gases are
collected and refined and used for preheating the blast.
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17
Blast
Hot Blas
Hot Blast
BF Gas
Furnace
GCP
Clean BF
Gas
Hot metal
Slag
PCM
SMS
Process:
Raw materials i.e. iron ore, Sinter and coke are charged into the furnace from top
in required proportions. Air enriched with oxygen is preheated in stoves. Preheated air is
blown through Tuyeres in the bosh region. These are symmetrically located openings. The
raw material descending through various temperature zones are heated up and get
smelted. The reducing gases rise up and go out through ascension pipes. The hot metal
and slag obtained through smelting of raw materials trickle down and accumulate in the
hearth, which is the bottom part of the furnace. The slag, being lighter than Hot Metal,
floats on it.
The hot metal and slag are tapped through Tap Holes, drilled using drilling machines. The
hot metal thus obtained is sent to SMS to make steel or to PCM to make pigs. The slag is
either dumped in the slag yard or granulated in slag granulation plant (SGP).
Blast Furnace 3 and 4 have SGP and hence the slag coming out of these Furnaces is
granulated.
The gas ascending through the descending column is called BF gas and has high calorific
value of 850 Kcal/Nm3. It is used as fuel at many departments in the plant. This gas has
to be cleaned before being used as fuel. For this purpose, a gas cleaning plant is located
in the Blast Furnace area.
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18
In the third stage, the gas is counter currently washed with water in gas washer. The gas
coming out is then sent into a set of electrostatic precipitators, where it is cleaned to the
maximum extent. The gas leaving ESPs has a dust content of 9-11 mg/Nm 3
Details of Furnaces:
Capacity (TPD)
#1*
#2
#3
#4
1250
1820
1820
2340
1323
1400
1400
3
1800
3
*not working
Design parameters:
Parameter
BF #2 & 3
BF # 4
Blast Temperature
1100 c
0.7kg/cm2
0.7kg/cm2
Sinter charge
75%
75%
Furnace Productivity
1.3
1.3
1150 c
No. of cast/day
9-10
9-10
No. of tuyers
18
20
Blast period
60 minutes
60 minutes
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Basic Oxygen Furnace:
Hot Metal coming out of the Blast Furnace is collected in ladles and poured into mixers.
The mixers (2) serve the purpose of storing as well as homogenization of temperature
and composition. Coke oven gas is used here to maintain the temperature at 1260 o C.
the quantity of raw materials for producing one tonne of steel are as follows:
Hot Metal
1073 kg
Scrap
65.9 kg
Iron Ore
15.6 kg
Briquetted lime
10.6 kg
Calcined Lime
81.3 kg
Dolomite
31.3 kg
Fe- Mn
1.11 kg
Fe- Si
1.32 kg
Al
0.15 kg
Coke Breeze
3.27 kg
The shop has three converters each having a capacity of 110-130T per heat. The
converters were commissioned by Mannessmann Demag of Germany. Each converter
has its own lance system for blowing oxygen at high pressure so as to form an emulsion
on the surface of metal which increases the surface area to such an extent that
separation of impurities takes place very fast.
The oxygen blowing rate through the lance is 415 Nm 3/min. and the blowing pressure is
14.2 to 14.3 bars from top. The tap to tap time of BOF is approximately 57 minutes out of
which oxygen blowing time is 18 min. the gas obtained from BOF converter has a calorific
value of 2100 Kcal/Nm3 which acts as a fuel.
BOF has an online process monitoring system. The system uses VAX/VMS system which
works on the principle of virtual memory. The higher level of computerization caters to
the need of quick retrieval of data about operation parameters.
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Under traditional route, liquid steel is allowed to solidify into separate moulds and come
out as ingots, which are then rolled to get the billets. Continuous casting route bypasses
the steps of soaking and rolling in blooming and billet mill.
No. of strands/machines
Design Limit
80 -150 mm2
Casting Radius
6m
Heat Size
Casting time
85 min.
Shear
Molten steel is taken to ladle treatment section. The purpose of ladle treatment is to
homogenize the temperature and composition, floatation of non-metallic inclusions and
to facilitate active slag metal reactions. A dummy bar is inserted in the mould, up to 100
mm with the help of pinch rolls. The mould is surrounded by 4 mm water jackets through
which primary water is circulated internally. Primary cooling is thus done by
demineralized water. Other zones are kept cool by industrial water.
The billets formed are cut to proper lengths and are allowed to cool in air and then
packed and sent to stock yard.
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NLCP has got bunkers and conveyors for storage, handling and supply of fluxes to
converter shop.
ROLLING MILLS
The process of plastically deforming metal by passing it between rolls is known as
rolling.
TYPES OF MILLS:A. PRIMARY MILLS
Blooming & Billet Mill
B. FINISHING MILLS
Section mill
Skelp mill
Merchant mill
Wheel and axle plant
Semi
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Process:Soaking pit furnaces are used for reheating the ingots at 1280 o C. There are 20 soaking
pit furnaces with capacity 110T. Fuel used is CO and BF gases in the ratio of 1:4. The
reheating time is usually 1.5 times the Track Time. After soaking the ingots are lifted by
means of vertical ingot charger cranes for soaking. It is a two high charger reversible
type with two 2X3000 HP DC motors at the mills speed of 0/40/60 rpm.
Here 1200T shear is used to cut fish tail, and then the blooms are put in the bloom
transfer bank.
There is a two high reversible mill driven by 4500HP DC motor. The rolls are spring
balanced and driven with a speed of 0/80/120 rpm.
Major Equipments:
Blooming mill
Soaking Pits:
20 in numbers and of 3 types
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(a)
(b)
(C)
(d)
42 Blooming Mill
Front and back ends of blooms which develop fish tails are
sheared using1200T shear
32 Intermediate Mill:
700 T Shear:
Important Parameters:
(a)
Pit Time: This is the amount of time the ingots have to be placed in the
soaking pits. This is equal to 1.5 times the track time, which is around 3 to 4.5
hrs for hot ingots and around 12 hrs for cold ingots.
(b)
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Billet Mill
Blooms produced in Blooming Mill are further rolled into billets of various sizes. The
capacity of Billet Mill is 0.957 tonne per annum. The products of this mill are 50 mm
square to 125 mm square Billets and 140 to 240 mm * 75/80 mm skelp slabs.
Major Equipments:
(a) Mill Train:
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25
SKELP MILL
Skelp mill came up during the expansion of plant to 1.6 MTPA in late 60s. It was
designed and elected by a UK firm, Loewy Robertson Company Limited. Skelp is a
narrow section with bevel edge with included angle of 70 o. Mostly used for making
pipes and tubes. The annual capacity of this mill is 0.25 million tonnes.
Process:Skelp mill receives slabs from Billet Mill by rail transfer bogies. The slabs are taken on
to charging table from the bogie. The slabs are fed to a reheating furnace by a Ram
charger. The furnace is of side charge and side charging type. The furnace is fired by a
mixture of coke oven and Blast Furnace gas in a ratio of 1:1.
The furnace has a heating capacity of 60T/Hr. The slabs are sent to the mill section,
which consists of 11 horizontal strands and 6 vertical strands. These are arranged as
shown below:
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E1-H1-H2-H3-H4-H5-E3-H6-COBBLE SHEAR-LOOPING THROUGH-H7-E4-H8-H9-E5-H10E6-H11.
Where H refers to horizontal strands and E refers to vertical strands. The roughing mill
constitutes strands from E1 to H6 while H7 to H 11 constitute the finishing mill.
After rolling, the skelp or strip is coiled and the coil is dispatched to customers.
MERCHANT MILL
Merchant Mill takes billets of size 100 mm2 from CCP and produces ribbed TMT bars of
various diameters.
The capacity of Merchant Mill is 0.28 million tone per annum thermo mechanically
treated (TMT) ribbed bars of dia. 16, 18, 20, 22, 25, 28 mm.
Grade- IS2062
TMT 415, TMT 500, TMT 550, TMT HCRM
Input: billet of 100mm2 and 9m long
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Process:Reheating furnace has a two zone type arrangements for side charging and
discharging. The output of furnace is 70 TPH. Temperature inside the furnace is 1250
1300o C. Separating skids are used to placed the billets on the furnace charging table.
The mechanism consists of stationary and power operated carry over skids .The fuel
used is CO gas with 3000 BTU/ft3 of calorific value. The air for combustion is preheated
in metallic recuperators.
By using push-out bar, billets are discharged from the furnace to the first mill stand. For
this, there is a pinch roll arrangement near the furnace. A pendulum shear is located
between the pinch roll and first stand to cut the front end of the billets.
The mill has 13 horizontal stands in which 7 are roughing, 4 intermediate and 2 are
finishing stands. In between 7 & 8 stand, a crop cum cobble shear is provided to cut
front end of all the rolled stocks passing out of the 7 th stand. It is also used for cutting
the rolled stock into pieces in case cobble is formed.
Four 180 repeaters provided between 9 & 14 stands (13th stand is not there). These
repeaters are provided to reduce the overall length of the mill.
After the finishing mills Thermax carriages are situated for spraying water at high
pressure on the rolled bars (to impart required structure). There is a rotary shear, which
cuts the rod into the pre determined lengths, which are then accommodated in the
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cooling beds. After this the bars are cut to final sizes (as per customers demand) in the
Bar Shears and sent to dispatch area after bundling and strapping.
Apart from conventional rolling, Slit Rolling is also done where we get two rods parallel
from a single billet. (for section 16 mm rolling)
Major Equipments:
Reheating furnaces:
Capacity 70 TPH
To pull out and feed billets into the first mill stand
(b) Mill:
Stand no.
Drive
3, 4 & 5
400 HP DC motor
1 & 2, 6 to 9
500 HP DC motor
10 & 11
600HP DC motor
12 & 14
800 HP DC motor
Also used for cutting the rolled stock in case cobble is formed
in intermediate and finishing mill.
(d) Repeaters:
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3 in number
SECTION MILL
Blooms from blooming mill are taken and rolled in section mill to produce light and
medium structural like Joists, Channels and Angles. The capacity of Section Mill is 0.212
million tone per annum.
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Input -Blooms
Products:
Joists
Channels
Angles
Major Equipments:
(a) Reheating Furnace:
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2 stands of 24x68
Bottom rolls driven by 165 HP motor and Top rolls are friction
driven
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The present capacity is as follows:
Wheels:
42000 tonnes/annum
Axles:
16000 tonnes/annum
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Process:
This can be divided into two sections:.
(i)
Process of wheel making:
The 12 sided fluted ingots are sliced into number of blocks called cheese. After
physical inspection, blocks are heated in rotary hearth furnace for 6-8 hours to a
temperature of 1220 o C.
The heated cheeses are descaled and fed to 63/12 MN forging & punching
combination press. The block is subjected to upsetting, open die forging and punching.
After this, wheel blanks are heated in batch type holding furnace to 1150 o C. The wheel
is then rolled in a computerized wheel mill, where shaping of tread profile by a tread
roll, shaping of web portion by two web rolls and control of rim thickness by two edge
rolls is performed.
After rolling, the wheels are fed to a 20 MN Dishing press, where the form of the web
is charged from flat ring to that of a truncated cone sloping from boss to rim. This
prevents high internal stress during cooling and prevents warping of wheels. The wheel
is then feed to a marking press of 3 MN, where Sl. No., Year and Cast No. are stamped
on the back rim. The wheel is then subjected to heat treatment which includes
quenching and tempering to give hard rim and tough core. Next comes the machining
part, where rim face, boss face, rim blending, condemning glove, chucking glove are
machined by means of CNC machines.
Finally, the wheels are subjected to strength testing in the form of Ultrasonic
Test, Magnetic particle Test which are RITES certified.
Process of axle making:
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Square bloom from blooming mill made of killed steel is the raw material for axle.
These blooms are heated for 6-8 hours in continuous pusher type furnace after
inspection. Blooms are forged in a 7 tonnes hand operated axle forging hammer. The
process takes around 9-10 minutes and the finishing temperature is 850 o C. It is then
air-cooled.
Ultrasonic test is carried out, checking physical roundness of every axle is done.
Axle is then sawed and is first rough turned and then finish turned.
The axles are inspected for dimensional accuracy at every stage of the process
and for surface & diameter defects after completion.
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