This document provides details about a project report submitted for graduate apprenticeship training at Rashtriya Ispat Nigam Limited – Visakhapatnam Steel Plant (RINL-VSP). It includes certificates of approval for the project from supervisors at RINL-VSP. The project report focuses on providing a detailed report on the Raw Material Handling Plant at RINL-VSP, describing its various sections and equipment. It discusses the flow of raw materials and details various facilities for handling iron ore, coal, and other raw materials used in the steelmaking process.

1. RASHTRIYA ISPAT NIGAM LIMITED –
VISAKHAPATNAM STEEL PLANT
PROJECT REPORT
Dissertation Report Submitted in fulfillment for the award of Certificate of
Graduate Apprenticeship Training in Mechanical Engineering from RINL - VSP
Submitted To:
Department of
RAW MATERIAL HANDLING PLANT (RMHP), RINL - VSP
Submitted By:
Md Anzar Aman 012656
Under the Guidance of
D . J . R SRINIVAS
General Manager (Mech.)
Department of Raw Material Handling Plant (RMHP)
GRADUATE APPRENTICESHIP TRAINING
Under National Apprenticeship Training Scheme (NATS)
Instituted by Board of Apprenticeship Training / Practical Training
Ministry of Education, Government of India. Session: 2022 - 2023

2. GRADUATE APPRENTICESHIP TRAINING
Under National Apprenticeship Training Scheme (NATS)
Instituted by Board of Apprenticeship Training / Practical Training
Ministry of Education, Government of India
DEPARTMENT OF RAW MATERIAL HANDLING PLANT
CERTIFICATE
This is to certify that the work embodied in this Project, Dissertation Report entitled as “Detailed
Report on Raw Material Handling Plant (RMHP), RINL – VSP” being Submitted by Md
Anzar Aman [Trainee No. : 012656] in complete fulfillment of the requirement for the award of
“Graduate Apprenticeship Training” in Mechanical Engineering discipline to Rashtriya
Ispat Nigam Limited – Visakhapatnam Steel Plant, Visakhapatnam (A.P.) during the year 2022
-2023 is a record of bonafide piece of work, carried out under my supervision and guidance in the
Department of Mechanical Engineering, Raw Material Handling Plant, RINL – VSP.
Approved by
Mr. D. Mallikarjuna Rao Mr. D.J.R Srinivas
Dy. Manager (Mech.) General Manager (Mech.)
RMHP, RINL - VSP RMHP, RINL - VSP
Mr. A.K Dhawan
Head of Department
RMHP, RINL - VSP

3. GRADUATE APPRENTICESHIP TRAINING
Under National Apprenticeship Training Scheme (NATS)
Instituted by Board of Apprenticeship Training / Practical Training
Ministry of Education, Government of India
DEPARTMENT OF RAW MATERIAL HANDLING PLANT
CERTIFICATE OF APPROVAL
This dissertation entitled “Detailed Report on Raw Material Handling Plant (RMHP), RINL
– VSP” being submitted by Md Anzar Aman [Trainee No. : 012656] has been examined by us
& hereby approve for the complete fulfilment of the requirement for the award of “Graduate
Apprenticeship Training”, in Mechanical Engineering discipline to Rashtriya Ispat Nigam
Limited – Visakhapatnam Steel Plant, Visakhapatnam (A.P.), for which it has been submitted.
It is understood that by this approval the undersigned do not necessarily endorse or approve any
statement made, opinion expresses or conclusion draw there in, but the dissertation only for the
purpose for which it has been submitted.
DEPARTMENT AUTHORIZATION
Date:

4. GRADUATE APPRENTICESHIP TRAINING
Under National Apprenticeship Training Scheme (NATS)
Instituted by Board of Apprenticeship Training / Practical Training
Ministry of Education, Government of India
DEPARTMENT OF RAW MATERIAL HANDLING PLANT
CANDIDATE DECLARATION
I hereby declare that the Project dissertation work presented in the report entitled as “Detailed
Report on Raw Material Handling Plant (RMHP), RINL – VSP” submitted in the complete
fulfillment of the requirements for the award of “Graduate Apprenticeship Training”, in
Mechanical Engineering discipline to Rashtriya Ispat Nigam Limited – Visakhapatnam Steel
Plant, Visakhapatnam (A.P.), is an authentic record of our own work.
I have not submitted the completion of this report for the award of any other Training Scheme.
Trainee Name Trainee No.
Md Anzar Aman 012656
Date:
This is to certify that the above statement made by the candidates is correct to the best of my
knowledge.
Mr. D.J.R Srinivas
General Manager (Mech.)
RMHP, RINL - VSP

5. ACKNOWLEDGMENT
I am heartily thankful to the Management of Rashtriya Ispat Nigam Limited – Visakhapatnam
Steel Plant for providing me all the facilities and infrastructure to take up my Apprenticeship Training
to the final stage.
It is the constant supervision, moral support and proper guidance of our respected H.O.D Mr.
A.K Dhawan, RMHP Department, RINL – VSP, who motivated me throughout my Apprenticeship
Training Program.
I am also very thankful to Mr. D.J.R Srinivas, Deputy General Manager, RMHP Department,
RINL - VSP, for his constant support & motivation.
I express deep sense of gratitude & respect to my learned Trainer Mr. D. Mallikarjuna Rao, Deputy
Manager in RMHP Department of Mechanical Engineering, during all phases of my Training. Without
his enthusiasm and encouragement this dissertation would not have been completed. His valuable
knowledge and innovative ideas helped me to take the Training to the final stage. He has timely
suggested actions and procedures to follow for which i am really grateful and thankful to him.
I am thankful to all the RMHP Employees and other Non Technical staffs of Mechanical
Engineering, RMHP Department for their cooperation. Constant help, moral and technical support of
our RMHP Department each and every employees, who motivated us to complete the work. I express
my heartily thanks to all of them for their co-operation.I really admire the fond support of our L&DC
Team for their co-operation and constant help. It gives immense pleasure to acknowledge the
encouragement and support extended by them. Last but not the least i am extremely thankful to all who
have directly or indirectly helped me for the completion of my Apprenticeship Training Program.
Md Anzar Aman 012656

6. TABLE OF CONTENTS
S.NO TITLE PAGE NO.
COVER PAGE 1
CERTIFICATE 2
CERTIFICATE OF APPROVAL 3
CANDIDATE DECLARATION 4
ACKNOWLEDGEMENT 5
TABLE OF CONTENTS 6 – 11
LAYOUT OF RINL – VSP 12
INTRODUCTION OF RINL – VSP
 Overview
 The Journey of RINL
 Vision
 Major Sources of Raw Materials
 Major Units
 Main Products of VSP
 Core Values
 Genesis, Inception & Formation of Steel Plant
 Mission
 Objectives
13 – 15
 PRODUCTION DEPARTMENT
1.
1.1
 RAW MATERIAL HANDLING PLANT
Overview
The RMHP in any Organisation is needed
16 – 17
2.
2.1
2.2
2.3
2.4
 COKE OVEN & COAL CHEMICAL PLANT
Overview
Facilities
Salient Features
Capacity
Commissioning Dates
18 – 20
3.
3.1
3.2
3.3
3.4
3.5
 SINTER PLANT
Overview
 Sinter Plant – 3
New Technology
Facilities
Salient Features
Capacity
Commissioning Dates
21 – 23
4.
4.1
4.2
4.3
4.4
4.5
4.6
 BLAST FURNACE
Overview
 Blast Furnace – 3
Record Performance of Blast Furnace Department
New Technology
Features
Salient Features
Capacity
Commissioning Dates
24 – 26

7. 5.
5.1
5.2
5.3
5.4
5.5
5.6
 STEEL MELT SHOP & CONTINUOUS CASTING
Overview
 Steel Melt Shop – 2
 Continuous Casting Department
New Technology
Facilities
Characteristics of VSP Convertors
Salient Features
Capacity
Commissioning Dates
27 – 29
6.
6.1
6.2
6.3
6.4
 LIGHT & MEDIUM MERCHANT MILL
Overview
Facilities
Salient Features
Capacity
Commissioning Dates
30 – 31
7.
7.1
7.2
7.3
7.4
7.5
 WIRE ROD MILL
Overview
Facilities
Salient Features
Capacity
Product Mix
Commissioning Dates
32 – 33
8.
8.1
8.2
8.3
8.4
 MEDIUM MERCHANT & STRUCTURAL MILL
Overview
Facilities
Salient Features
Capacity
Commissioning Dates
34 – 34
9.
9.1
9.2
9.3
9.4
9.5
 SPECIAL BAR MILL
Overview
Facilities
Salient Features
Capacity
Product Mix
Commissioning Dates
35 – 36
10.
10.1
10.2
10.3
10.4
10.5
10.6
 STRUCTURAL MILL
Overview
Facilities
Salient Features
Capacity
Starting Material
Product Mix
Commissioning Dates
37 – 38
11.  SERVICE DEPARTMENTS 39 – 52
1. Mines
a) Madharam Dolomite Mine (MDM)
b) Jaggayyapeta Limestone Mine (JLM)
c) Garbham Manganese Mine (GMM)
d) Saripalli Sand Mine (SSM)

8. 2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
Calcining & Refractory Material Plant (CRMP)
Central Machine Electrical (CME)
Civil Engineering Department (CED)
Distribution Network Department
Electrical Repair Shop (ERS)
Electro Technical Laboratory
Energy Management Department
Engineering Shops & Foundary (ES & F)
a) Central Machine Shop (CMS)
b) Structural Steel Shop (SSS)
c) Foundary
d) Forge Shop
e) Utility Equipment Repair Shop (UERS)
Environment Management Department (EMD)
Field Machinery Department (FMD)
Information Technology (IT)
M & CR
Plant Design
Production, Planning & Monitoring Department
Quality Assurance & Technological Development (QA & TD)
Research and Development (R & D)
Refractory Engineering Department
Roll Shop and Repair Shop (RS & RS)
Safety Engineering Department (SED)
Spares Management Department (SMD)
Structural Engineering Department (St. ED)
Thermal Power Plant (TPP)
Traffic Department
Technical Improvement Cell
TQM – ISO Cell
Utilities Department
Works Contract Department
Water Management Department
Budget Plan & Control
Systems and Procedures
Personnel Department
Legal Affairs (LA)
Management Services (MS)
Training and HRD
Town Administration and Administration (TA)
Medical and Health Services (M & HS)
Marketing Department
Material Management Department
Finance and Accounts Department
Corporate Strategic Management

9. 42.
43.
44.
45.
46.
Design and Engineering Department (D & E)
Construction Department
Contracts Department
Project Monitoring Department
Vigilance Department
12. DETAILED REPORT ON RAW MATERIAL HANDLING PLANT 53 – 124
1. RAW MATERIAL HANDLING PLANT 53 – 57
1.1
1.2
1.3
1.4
1.5
1.6
The RMHP in any Organisation is needed
Raw Materials Flow Chart
Layout of Storage Yard
Augmentation of Iron Ore Storage
Function of RMHP
Section of RMHP
2. ORE HANDLING PLANT 58 – 62
2.1
2.2
2.3
2.4
2.5
Raw Materials – O.H.P
Materials Handling – O.H.P
Materials dispatch to O.H.P Customers
Expansion of O.H.P
Details of Equipments of O.H.P
3. WAGON TIPPLER 63 – 73
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
Description of Wagon Tippler Arrangement
Operational Description
Brief Items of Rotary Wagon Tippler
Purpose & Technical Parameter of Rotary Wagon Tippler
Electric Wagon Pusher Car
Types of Wagon Tippler
Types of Wagon
Design Layout of Tippler
Hydraulic Ore Tippler – 4
Why Hydraulics ?
4. ORE STOCK YARD 73 – 76
4.1 Machining Equipments used in Ore Yard
a) Twin Boom Stacker
b) Wheel on Boom Reclaimer
c) Blender Reclaimer
5. LUMP ORE CRUSHING PLANT (LOCP) 76 – 77
5.1
5.2
5.3
Crushing & Screening
Crushing & Screening Process Layout
Crusher Operation
6. IRON ORE SEPARATION AUGMENTATION (IOSA) 78 – 86
6.1 Process for separation of Iron Ore
7. PLANNING 87 – 88
7.1
7.2
7.3
Operational Planning Department
Electrical Planning Department
Mechanical Planning Department

10. 8. INDENT 88 – 90
8.1
8.2
8.3
8.4
8.5
Purchase Indent for following Department
Indents from Works Division
Budget Approval
Indent Raising
Purchase Action on Receiving Indent
9. STORES 90 – 92
9.1
9.2
9.3
9.4
Functions of Stores
Codification
Objectives of Codification
Advantages of Codification
10. AREA SHOP OFFICE (ARS) OF RMHP 92 – 94
11. COAL HANDLING PLANT (C.H.P) 95 – 99
11.1
11.2
11.3
11.4
Raw Material C.H.P
Materials dispatch to C.H.P Customer
Expansion of C.H.P
Details of Equipments of C.H.P
12. COAL STOCK YARD 99 – 105
12.1
12.2
Equipments of C.H.P
Machining Equipments used in Coal Stock Yard
a) Swivelling Boom Stacker
b) Wheel on Boom Reclaimer
c) Stacker cum Reclaimer
13. RING GRANULATOR (RG) 105 – 109
13.1
13.2
13.3
13.4
Crushing Principle of Ring Granulator Type Coal Crusher
Ring Granulator type Coal Crusher consists of following parts
Work involved during prevention maintenance of Ring Granulator type Coal Crusher
Boiler Coal Crushing & Screening
14. GANGAVARAM PORT LIMITED (GPL) 109 – 124
14.1
14.2
14.3
14.4
14.5
14.6
14.7
GPL Conveyors
Ore Conveyors Specification
Conveyor Component Specification
Conveyor Protective Devices
GEARS
a) Gear Terminology
b) Types of Gears
c) Advantages of Gears
d) Disadvantages of Gears
GEARBOX
a) How a Gearbox works ?
b) Gearbox : Speed Vs Traction
c) Types of Gearboxes
d) Industrial Gearboxes & It’s Uses
FLUID COUPLING
a) Main Parts
114 – 121
121 – 123
123 – 124

11. b) Fluid Coupling Working Principle
c) Types of Fluid Coupling
d) Advantages of Fluid Coupling
e) Disadvantages of Fluid Coupling
CONCLUSION 125

12.  LAYOUT OF RINL - VSP

13. INTRODUCTION OF RINL - VSP
 OVERVIEW
Rashtriya Ispat Nigam Limited, the corporate entity of Visakhapatnam Steel Plant is a
Navaratna PSE under the Ministry of Steel. Visakhapatnam Steel Plant fondly called Vizag steel. It is the
first shore based Integrated Steel Plant in the country and is known for its quality products delighting the
customers. It is a market leader in long products and it caters to the needs of diverse Industrial sectors. It is
the first Steel plant to be certified ISO 9001:2008 (presently2015), ISO 14001:2004 (presently2015),
OHSAS 18001:2007 and ISO/IEC 27001:2013 Standards. It is also the first PSE to be certified ISO
50001:2011 - Energy Management Systems and has acquired CMMI Level 3 Certification for s/w
development.
 THE JOURNEY OF RINL
 Formative Years
Relentless crusade by Shri Tenneti Vishwanadhan led to setting up of Vizag Steel
Plant. The site was formally inaugurated by the then PM Late. Mrs. Indira Gandhi, on 20th
January 1971.
 Marched towards glory with Soviet help
Detailed project report for 3.4 MT of liquid steel was preparedby M.N. Dastur
Company and GIPROMEZ of USSR (1985 – 1987).
 Maiden marl on the map of Indian Steel Market
First Casting of Hot metal into Pig Iron in 1989 – 90; Push cars made operational;
BF erection in progress, 1982 – 1983.
 Construction Site
First concrete pouring for expansion in 2006; Captive mines made operational.
 VISION
To be the most efficient Steel Maker having the largest single location shore based steel plant in
the country.
 MAJOR SOURCES OF RAW MATERIALS
S.No RAW MATERIALS SOURCES
1. Iron Ore Lumps & Fines Bailadila, Chattisgarh

14. 2. BF Lime Stone Jaggayyapeta, AP
3. SMS Lime Stone Dubai SMS Lime Stone Dubai
4. BF Dolomite Madharam, AP BF Dolomite Madharam, AP
5. SMS Dolomite Madharam, AP SMS Dolomite Madharam, AP
6. Manganese Ore Chipurupalli, AP Manganese Ore Chipurupalli, AP
7. Boiler Coal Talcher, Orissa Boiler Coal Talcher, Orissa
8. Imported Boiler Coal Indonesia Imported Boiler Coal Indonesia
9. Imported Coking Coal Australia / US Imported Coking Coal Australia / US
10. Medium Coking Coal (MCC) Kathara / Swang / Rajarappa / Kedla
11. Imported LAM Coke China Imported LAM Coke China
12. Quartzite Lump & Fines Local Quartzite Lump & Fines Local
13. Sand Sarepalli, AP Sand Sarepalli, AP
 MAJOR UNITS
DEPARTMENT ANNUAL CAPACITY UNITS (3.0 MT STAGE)
Coke Ovens 2,701 4 Batteries of 67 Ovens & 7 Mtrs. Height
Sinter Plant 5,256
2 Sinter Machines of 312 Sq. Mtr. grate
area each
Blast Furnace 3,400
2 Furnaces of 3200 Cu. Mtr. Volume each
Steel Melt Shop 3,000
3 LD Converters each of 133 Cu. Mtr.
Volume and Six 4 strand bloom casters
LMMM 710
2 Strand finishing Mill
WRM 850
4 Strand high speed continuous mill with no
twist finishing blocks
MMSM 850
6 STAND FINISHING MILL
 MAIN PRODUCTS OF VSP
STEEL PRODUCTS BY – PRODUCTS
Blooms Nut Coke Granulated Slag
Billets Coke Dust Lime Fines
Channels, Angles Coal Tar Ammonium Sulphate
Beams Anthracene Oil
Squares HP Naphthalene

15. Flats Benzene
Rounds Toluene
Re-bars Zylene
Wire Rods Wash Oil
 CORE VALUES
 INITIATIVE : Have a self – propelled & proactive approach.
 DECISIVENESS : Decide with speed & clarity.
 ETHICS : Be consistent with professional & moral values
 ACCOUNTABILITY : Take responsibility for actions.
 LEADERSHIP : Lead by example
 SPEED : Demonstrate swiftness and efficiency in everything we do
 MISSION
To attain 20 million ton liquid steel capacity through technological up-gradation, operational
efficiency and expansion; to produce steel at international standards of cost and quality and to
meet the aspiration of the stake holders.
 OBJECTIVES
 Achieve Gross Margin to Turnover ratio > 10%.
 Plan for finishing mill to integrate with 7.3 MT capacity and commission the same by 2017-
18.
 Achieve rated capacity of new & revamped units by 2017-18.
 Capture markets for high – end value added products by focusing on sector specific
applications and customer needs.
 Globalisation of operations through acquisition of mines and setting up of marketing network
abroad. I D E A L S.
 Diversify through operationalizing of Bhilwara Mines, setting up of Pelletization Plant, DRI-
EAF unit, Wheel & Axle Plants.
 Create high performance and safe work culture by nurturing talent and developing leaders.
 To grow in harmony with the environment & communities around us.
I
D
E
A
S
S
L

16. P. Dept. – 1 RAW MATERIAL HANDLING PLANT (RMHP)
1. OVERVIEW
Visakhapatnam Steel Plant is one of the most modern steel plant not only in the country but
also in the world. This has latest raw materials stacking and blending system. RMHP has the concept of
peripheral unloading which considerably reduces delay in taking over and handing over of rakes bringing
raw materials to the plant, there by increasing the availability of wagons. The Raw Material Handling
Plant is handling more than 24 million tons of various raw materials for 6.3 MTA
Raw Material Handling plant is meant for transporting materials from Raw Material yard /
Base mix yard to various units of the plant. The Major Raw materials required for Iron and Steel making
are Iron ore lump, Iron Ore fines, Sized iron ore, Flux limestone / dolomite, manganese, Quartzite coking
coal ( for Boiler operation & For Pulverized coal injection ) and coke. Lump iron ores, iron ore fines and
flux such as limestone and dolomite received by railway rake are unloaded in wagon tippler and stored
yard with the help of various stockyard machines.
Fig. 1.1 Overview of RMHP
Iron ore lump, flux such as limestone and dolomite, Coke is reclaimed by suitable stock
yard machine and are crushed in Ore crushing plant, Flux crushing plant and coke crushing plant
respectively to produce the size required. The above material is proportionately stacked by suitable
stacking machine in base mix yard and blended while reclaiming by blender reclaimer. The prepared base
mix is then transported to Sinter plant for sinter production. For feeding material to new Blast Furnace,
sized ore and flux are reclaimed by stock yard machine from respective yard and are transported by

17. conveyor. Sinter produced in sinter plant and coke from existing/new coke ovens is transported directly
to BF-3 stock house by conveyor. Purchased coke and necessary calcined lime from stock yard and new
lime calcining plant respectively are transported to SMS by conveyor. The waste product from the plant
is mainly dust and method of their disposal is through dust suppression system and inter plant
transportation.
1.1 The Raw Material Handling Plant in any organization is needed :
a) To have adequate storage capacity to store various raw materials depending up on the capacity of the
beds in the stock yard.
b) To blend raw materials, if needed, received from various sources, in order to supply homogeneous raw
materials.
c) To ensure methodical stacking and reclaiming of raw materials without mixing up of different raw
materials.
d) To process the raw materials and bring down the size to the size as required by the customer
departments to improve their productivity and product quality.

18. P. Dept. – 2 COKE OVEN & COAL CHEMICAL PLANT
2. OVERVIEW
Coal is converted into coke by heating the prepared coal blend charge in the coke ovens in the
absence of air at a temperature of 1000o
C-1050o
C for a period of 16/19 hours. The volatile matter of coal
liberated during carbonization is collected in gas collecting mains in the form of raw coke oven gas passing
through stand pipes and direct contact cooling with ammonia liquor spray. The gas cooled from 800o
C to
80o
C is drawn to Coal Chemical Plant by Exhauster. The residual coke is pushed out of the oven by pusher
car through a guide into coke bucket. The red-hot coke is taken to coke dry cooling plant for cooling. The
main by-product in the process of coke making is crude coke oven gas and this has a lot of valuable
chemicals. Coal Chemical Plant recovers Ammonia (NH3), Tar and Benzol from CO-Gas. The primary
by-products from Crude CO Gas are Ammonium Sulphate (NH4)2SO4, Crude Tar, Crude Benzol and
cleaned coke oven gas. The cooled coke from CDCP (Coke Dry Cooling Plant) is separated into 3
fractions, BF Coke i.e. +25-70 mm, which is sent to Blast Furnaces, Coke Breeze i.e. +0-15 mm, which is
sent to Sinter making and nut coke i.e., +15-25 mm, which is also used in the Blast Furnaces.
Fig. 2.1 Overview of Coke Oven
2.1 FACILITIES
 There are 5 batteries, each having 67 ovens.
 The volumetric capacity of each oven is 41.6 cubic metre.
 Dry Coal charge / Oven is 32 tons

19. 2.2 SALIENT FEATURES
 Largest and technologically unique Coke Oven Batteries in the country at the time of commissioning
 7 meter tall coke ovens batteries.
 100 % Dry Quenching of coke using Nitrogen gas.
 Power generation, from the waste heat recovered, at BPTS (Back Pressure Turbine Station).
2.3 CAPACITY
 Production capacity (for 5 Batteries) – 3.700Mt of BF coke per annum
2.4 COMMISSIONING DATES
 Battery No. 1 – 1st
Pushing – 06.09.1989
 Battery No. 2 – 1st
Pushing – 31.10.1991.
 Battery No. 3 – 1st
Pushing – 30.07.1992
 Battery No. 4 – 1st
Pushing – 12.04.2009
 Battery No. 5 – 1st
Pushing – 22.12.2020

20. Fig. 2.2 Overview of Coal Chemical Plant

21. P. Dept. – 3 SINTER PLANT
3. OVERVIEW
Sintering is an agglomeration process of fine mineral particles into a porous mass by incipient
fusion caused by heat produced by combustion within the mass itself. Iron ore fines, coke breeze,
limestone and dolomite along with recycled metallurgical wastes are converted into agglomerated mass at
the Sinter Plant, which forms 70-80% of iron bearing charge in the Blast Furnace. The vertical speed of
sintering depends on the suction that is created under the grate. At VSP, two exhausters are provided for
each machine to create a suction of 1500-1600 mm water column under the grate.
Fig. 3.1 Overview of Sinter Plant
 SINTER PLANT – 3
For meeting the requirement of new Blast Furnace-3 to produce 2.5 Mtpa Hot metal, One
number of Sinter machine of 400 sq.m is envisaged. The Raw materials required to produce Product sinter
are Base mix consisting of 100% iron bearing material including revert material including revert materials,
flux, coke, floating return fines and calcined lime which is fed into Blast Furnace-3. Considering 80%
sinter ratio in the burden of new Blast Furnace, the requirement of Sinter charge will be 3.25 Mtpa for
production of 2.5 Mtpa Hot metal.
Hence, new sinter will receive Base mix which will be prepared in bedding and blending yard
by mixing all iron bearing materials and about 80% of flux and fuel. Balance flux and fuel, as well as

22. calcined lime, will be added in proportioning section of Sinter plant. The facilities envisaged are
Proportionating system, Mixing and Nodulizing system, Sinter Machine section, Sinter cooler section,
Sinter stabilizing section and Waste gas system.
Fig. 3.2 Round Sinter Plant – 3
3.1 NEW TECHNOLOGY
 Circular Cooler
 Multi – slit burner
The benefits derived are being more energy efficient and utilization of heat recovered from Sinter
cooler to pre – heat the combustion due to which energy consumption is reduced has been incorporated in
the new Sinter Plant – 3.
Sinter produced in Sinter Plant will be supplied to the Blast Furnace through conveyor system.
3.2 FACILITIES
 Sinter Machine -1 with 378 M² grate area (after Modernization)
 Sinter Machine – 2 with 312 M² grate area
 Sinter Machine – 3 with 408 M² grate area
3.3 SALIENT FEATURES

23.  Base mix (homogeneous mixture of all raw materials) blending yard with six beds each of 1,10,000
tons storage capacity.
a) M/C – 1&2
 Sinter Machine – 1 (after modernization) is provided with Chamber type Ignition Furnace with roof
mounted energy efficient burners. Machine – 2 is provided with an ignition furnace of horizontal
burners.
 Sinter Bed Height 650 mm for M/C – 1 (after Modernization) & 500 mm for M/C – 2.
 Straight Line Sinter Cooler.
 Sinter Heat Recovery Power Plant (SHRPP) with a capacity of 20.6 MW electrical power generation
by utilizing waste heat recovered from Sinter Coolers of Machine 1 &2
b) M/C – 3
 Bed Height 700 mm.
 Chamber type Ignition Furnace with roof mounted energy efficient burners.
 27 m long extended hood with hot air supply through 4 feed points.
 Circular Sinter cooler with waste heat recovery system.
 Lime addition at Mixing and Nodulizing Section of Sinter Machine building.
3.4 CAPACITY
a) Production Capacity :
 Sinter Machine – 1 : 3.640 MT of Gross Sinter per annum (after Modernization)
 Sinter Machine – 2 : 2.85 MT of Gross Sinter per annum.
 Sinter Machine – 3 : 3.611MT of Gross Sinter per annum.
3.5 COMMISSIONING DATES
 Base mix preparation from RMB ( Raw Materials Bin) - 03.11.1989
 Machine – 1 commissioned (3.0 Mt stage) - 14.11.1989
 Machine – 1 Hot trials for commissioning (after modernization) - 08.08.2017
 Machine – 2 commissioned - 27.12.1991
 Machine – 3 Integrated trial run for commissioning - 04.07.2013

24. P. Dept. - 4 BLAST FURNACE
4. OVERVIEW
Iron is produced in the Blast Furnace by smelting iron bearing materials with the help of coke
and air. The solid charge materials like sinter, sized iron ore, coke etc. are charged in the vertical shaft of
the Blast Furnace from top and hot air blast is blown through tuyeres located at the bottom. The oxygen
present in hot air combines with the carbon of coke and generates heat and carbon monoxide (reducing
agent). The reducing gases, while ascending upwards comes into contact with the descending charge
materials. Eventually the charge gets reduced and hot metal, slag and BF gas are produced. Hot metal and
slag is tapped from tap hole. The Blast Furnace gas which comes out from top of the furnace is cleaned
and used as fuel in the plant.
Fig. 4.1 Overview of Blast Furnace
 BLAST FURNACE – 3
To achieve the desired hot metal production of 6.5 Mtpa, additional one number of BF is installed
with a capacity of 3800 Cu.M producing 2.5 Mtpa . The Raw materials required for manufacturing process
are Sinter, Sized ore, Quartizite, Coke and Injection coal. Raw materials and coke from stock yard are
transported to the stock house bunkers through junction houses. The main charging conveyor feeds the
burden into the Blast Furnace. Hot stoves deliver the hot blast into the Blast Furnace via bustle main and
tuyeres. Pulverized coal from coal grinding plant to coal distributor which distributes the coal into
individual tuyeres.
Inside Blast Furnace, the iron ore is reduced to form iron and slag, which collects at the hearth.
From there, Hot metal and slag is periodically tapped through tap holes. Hot metal is channeled via tilting
runners into torpedo ladle cars, which carries it away. Slag is granulated in the slag granulation plant,
dewatered and subsequently carried away by a conveyor to slag storage yard. The Blast Furnace top gases

25. enter into the dust catcher for primary cleaning and then to annular scrubber for final cleaning. The
facilities envisaged are Stock house and Charging system, Cooling elements and system, Cast House, Gas
cleaning Plant. Hot Blast stoves, Pulverized Coal Injection system, Slag Granulation and Stock House.
4.1 RECORD PERFORMANCE OF BLAST FURNACE DEPARTMENT :
 TECHNO – ECONOMICS :
Productivity 2.23 t/m³/day Feb ‘06
Power 51.31 kwh/thm Feb ‘06
Fuel Rate 509 kg/thm Jan ‘04
Heat Constant 450 Mcal/thm Apr ‘05
Nut Coke usage 56 kg/thm Mar ‘04
 PRODUCTION
 DAY PEAKS
Blast Furnace – 1 6820 Tons 23.03.06
Blast Furnace – 2 6805 Tons 21.03.06
Shop 13325 Tons 10.02.06
PCM Pouring 6723 Tons 31.03.93
 MONTHLY PEAKS
Hot Metal 374419 Tons Mar ‘06
PCM Pouring 107463 Tons Mar ‘93
Pig Iron Dispatch 110387 Tons Mar ‘94
G. Slag Dispatch 150942 Tons May ‘02
4.2 NEW TECHNOLOGY
 Pulverized Coal Injection
 Copper staves in high heat zones
 Hearth bottom cooling with water
The benefits derived are reduced coke consumption, improved productivity, improved process control &
better campaign life. The hot metal produced (7150 tons/day) at a temperature of 1500 degrees temp is
transported to Steel melt Shop by Torpedo Car.
4.3 FEATURES
 Three Blast Furnaces of 3800 m³ useful volume each.
4.4 SALIENT FEATURES
a) BF – 1&2
 New generation Paul – Wurth “Bell-Less” Top with conveyor charging
 BF Cooling element (Cast Iron Staves & Copper Staves)
 High heat zone copper staves

26.  Double compensator tuyeres, with PCI injection facility and extended tuyere platform.
 Circular type flat cast house with full castable runner system
 Hydraulic Drilling Machine, Mud Gun, Manipulators.
 Silence to bin pressure relief.
 New scrubber with annular gap element for better gas cleaning.
 HMI based control room.
 Equipped with above burden temperature Probes.
 Automation with PLC in BF -1 and PCS in BF – 2.
 Pulverized Coal Injection system
b) BF – 3
 New Generation Parallel Hopper Bell Less Top
 BF Cooling elements (Cast Iron Staves & Copper Staves)
 Flat Cast house Equipment (by TMT).
 INBA Slag Granulation system
 Annular Gap Scrubber
 Pulverized Coal Injection system
 Hot Stoves (internal combustion chamber)
 Automation with DCS
4.5 CAPACITY
 Production Capacity – 7.5 MT per Annum for shop
– 2.5 MT per Annum for BF – 1, 2 & 3 each
4.6 COMMISSIONING DATES
 Furnace – 1 – 1st
campaign since 28.03.1990 / 2nd
campaign since 30.07.2014
 Furnace – 2 – 1st
campaign since 21.03.1992 / 2nd
campaign since 21.10.2017
 Furnace – 3 – 1st
campaign since 24.04.2012

27. P. Dept. - 5 STEEL MELT SHOP & CONTINUOUS CASTING
5. OVERVIEW
Steel is made in steel melting shop in the refractory lined vessels called LD Converters by
blowing oxygen through the hot metal bath. While iron making is a reduction process, steel making is an
oxidation process. The oxygen reacts with impurities like carbon, silicon, phosphorous, Sulphur, etc.
present in hot metal to produce steel. No external fuel is required as the silicon & carbon releases huge
amount of heat energy. Also the carbon reaction releases large quantities of gas rich in carbon monoxide
along with huge amount of dust. The gases released from the converter are collected, cooled, cleaned
and recovered for use as fuel in the steel plant. The entire molten steel at VSP is continuously cast at the
radial type continuous casting machines resulting in significant energy conservation and better quality
steel. 100% Continuous casting on such a large scale has been conceived for the first time in India.
Fig. 5.1 Overview of Steel Melt Shop & Continuous Casting
 STEEL MELT SHOP – 2

28. Steel making capacity of the plant is correspondingly increased by utilizing higher availability
of Hot Metal. The Raw materials required for manufacturing process are - Hot Metal, Scrap, Flux, Ferro
alloys. New Steel melt shop comprises of two converters each of 150 cu.m capacity. Two Numbers of
Laddle Furnaces were envisaged to make the operation of the two converters independent of the
requirements of continuous casting machines thereby acting as buffer between the converter and the caster.
The steel temperature and steel chemistry will be homogenized in LF by inert gases and One
number of RH degassing system is envisaged for production of special grade with low gas content. There
are three numbers of six strand billet mill. Three casters are available for 200 days in a year and two casters
are available for 165 days in a year. Cast Billets will be fed to new Special Bar Mill and Wire Rod Mill.
A part of rolled billets will also be for sale. The other major facilities installed are Hot Metal
Desulphurization Plant, Scrap Handling system, BOF Gas cleaning Plant, Secondary Emission control,
Ferro-alloy handling facilities and Ladle & tundish preparation facilities.
 CONTINUOUS CASTING DEPARTMENT
VSP has six-4 strand continuous casting machines capable of producing 2.82 million Tones / year.
Blooms of size 250 x 250 mm and 250 x 320 mm. Entire quantity of molten steel produced (100%) is
continuously cast in radial bloom casters which help in energy conservation as well as production of
superior quality products. Facilities at continuous casting machines include a lift and Turn table for
ladles, Copper mould, oscillating system tundish, Primary & Secondary Cooling arrangement to cool the
steel bloom. Gas cutting machines for cutting the blooms in required lengths ( Av. 6 meters long ).
5.1 NEW TECHNOLOGY
 Convertor Shop – Combined Blowing, Secondary Fume Extraction system, Contour & Bath
level measurement : The benefits derived are reduced consumption of ferroalloys, better yield and
quality, cleaner environment and measurement of refractory lining.
 Continuous Casting Machines – Auto mould level control & 100% Billet casting : The benefits
derived are reduced in break outs and energy saving.
 LF & RH – Electro magnetic stirrer : The benefits derived are cleaner steel
5.2 FACILITIES
a) SMS – 1 :
 Three LD converters (modernized with increase in volume to 150 cum. Each along with DOG House
facility).
 6 nos. of 4 – Strand Continuous Bloom Casting machines.
b) SMS – 2 :
 Three LD Converters of 150 cum. Volume each.
 1 no. of 6 – Strand Continuous Billet – cum – Round caster.
 2 nos. of 6 – Strand Continuous Billet casters.
 1 no. of 5 – strand Continuous Billet – cum – Round caster.
 Hot Metal Desulphurization Plant (HMDP).
 DOG House.
 RH Degasser.
5.3 CHARACTERISTICS OF VSP CONVERTORS :

29. Capacity 150 Tones per heat blow
Volume 133 Cu. Meter
Convertor Sp. Volume 0.886 Meter Cube per Tone
Tap to Tap Time 45 Minutes – 60 Minutes
5.4 SALIENT FEATURES
 100 % Continuous casting of steel.
 Converters gas cooling, cleaning and recovery systems.
 Computerisation of the converter process.
5.5 CAPACITY
a) Production Capacity :
 SMS – 1 : Original Installed Capacity is 3.0 MT of Liquid Steel per annum & 2.82 MT of CC
Blooms per annum. After Modernization of all theb3 converters, capacity is enhanced to 3.5 MT of
Liquid Steel & 3.29 MT of CC Blooms per annum.
 SMS – 2 : 3.8 MT of Liquid Steel per annum & 3.7 MT of CC Blooms / Rounds per annum from
Converters – D , E & F.
5.6 COMMISSIONING DATES
 Converter – A – 1st
Heat – 06.09.1990 / 1st
Heat after Modernization – 16.03.2016
 Converter – B – 1st
Heat – 04.03.1991 / 1st
Heat after Modernization – 22.05.2017
 Converter – C – 1st
Heat – 25.07.1992 / 1st
Heat after Modernization – 27.10.2016
 Converter – D – 1st
Heat – 28.03.2014.
 Converter – E – 1st
Heat – 30.10.2013.
 Converter – F – 1st
Heat – 07.11.2016.

30. P. Dept. - 6 LIGHT & MEDIUM MERCHANT MILL
6. OVERVIEW
The cast blooms from continuous casting department are heated and rolled in the two
high speed and fully automated rolling mills namely Light & Medium Merchant Mill (LMMM) and
Medium Merchant & Structural Mill (MMSM). The billets produced in LMMM are further rolled in Bar
Mill / Wire Rod Mill (WRM). The finished products include wire rods & long products like
reinforcement bars, rounds, squares, flats, angles, channels, billets etc.
Blooms from Continuous Casting Division are rolled into billets, some of which are sold
and rest are sent to Bar Mill/WRM. The continuous two-line Bar Mill comprises of 8 Stand Double
Strand roughing train, 2 nos. of 4 Stand Single Strand intermediate train & 2 nos. of 4 Stand Single
Strand finishing train. Loopers are provided in between the finishing stands for tension free rolling in
order to obtain good surface quality and tolerances. Housings are of closed top type. Roll necks are
mounted in anti friction bearings.
Fig. 6.1 Overview of Light & Medium Merchant Mill
6.1 FACILITIES
a) Breakdown Mill
 7 Stand Break – Down Mill.

31. b) Bar Mill
 8 Stand Roughing Mill (2 Strand rolling).
 2 X 4 Stand Intermediate Mill (Single Strand rolling).
 2 X 4 Stand Finishing Mill ( Single Strand rolling).
6.2 SALIENT FEATURES
 Evaporating cooling systems in Rolling Mill furnaces.
 Computerised Rolling Mill.
 Tempcore cooling process facilitating high strength with good bendability and weldability.
6.3 CAPACITY
 A Mill of 0.88 MT per annum.
6.4 COMMISSIONING DATES
 Billet Mill – Trial Operation – 28.09.1990.
 Bar Mill – Trial Operation – 29.10.1991.

32. P. Dept. - 7 WIRE ROD MILL
7. OVERVIEW
WRM – 1 : The Mill is high speed 4 strand No-Twist continuous mill designed to produce
8,50,000 Tons of wire rod coils per year. Rolled billets of 125 mm x 125 mm square cross section, length
ranging from 9.8 m to 10.4 m and weighing approximately 1250 kgs are used. The mill is designed to roll
steel stock of 0.9% max. carbon content.
WRM – 2 : The Mill is designed to produce 6,00,000 tons per year of rounds in coil form. The
Mill is designed to roll low, medium and high carbon steel, case hardening steel, cold heading quality
steel, electrode steel, spring steel, bearing steel and free cutting steel. The mill shall use continuous cast
billets of 150 mm X 150 mm square cross section, 12 m length and weighing 2100 kgs approximately, are
used as input material.
The wire rod size will be in the range of 5.5 to 20 mm (dia). Provision is kept for the mill for
producing 7.7 ltpy depending on the market demand. The rolling mill will use the cast billets of size 150
x 150 mm having length of about 12 mtrs and rolled billets of size 125 x 125 x 9.7 to 10.2 mtrs. The mill
will roll Low carbon (85,000 tons/ yr), Medium carbon (93,000 tons/yr), High carbon (93,000 tons/yr),
Spring steel (25,000 tons/yr), Cold heading (1,34,000 tons/yr), Welding rod (85,000 tons/yr), Bearing steel
(25,000 tons/yr), Free cutting steel (35,000 tons/yr) and Case hardening (25,000 tons/yr).
The billet will be charged into 200 ton / hr capacity reheating furnace, one by one. The billets
after getting heated upto 1200 deg C will be discharged. The billets will be rolled down in the breakdown
mill and passed through pre-finishing mill. The finished product will come out of reducing and sizing mill
in coil form.
Fig.7.1 Overview of Wire Rod Mill
The Output of size wise product mix are :
 5.5 dia (mm) – 1,50,000 tons/yr.
 6.0 – 7.5 dia (mm) – 2,40,000 tons/yr.
 8.0 – 16 dia (mm) > 1,75,000 tons/yr.
 17 – 20.64 dia (mm) – 35,000 tons/yr.

33. 7.1 FACILITIES
a) WRM – 1
 7 Stand Roughing Mill (4 Strand rolling).
 6 Stand Intermediate Mill (4 Strand rolling).
 4 X 2 Stand Pre – finishing Mill (Single Strand rolling).
 4 X 10 Stand Finishing Mill (MORGAN BLOCK – Single Stand rolling).
b) WRM – 2
 6 – Stand Single strand Fast Roughing Mill.
 2 – Strand insulated Roller Table.
 6 Stand Intermediate Mill – I.
 4 Stand Intermediate Mill – II.
 2 X 2 pre – finishing train.
 2 X 8 – Stand No – Twist blocks.
 2 X 4 – Stand Reducing and Sizing Mill (RSM).
7.2 SALIENT FEATURES
 Highly automated and computerized Rolling Mill.
 Controlled cooling of Wire Rods, by ‘Stelmor’ process with Optimesh technology giving high
strength and good ductility.
 Closed loop control for laying temperature with Morgan pantented METCS (Morgan enhanced
temperature control system) in WRM – 2 to enhance Metallurgical properties.
7.3 CAPACITY
 WRM – 1 : 1.050 MT per annum.
 WRM – 2 : 0.60 MTT per annum
7.4 PRODUCT – MIX
a) WRM – 1
 Plain Rod – 5.5 mm to 12.7 mm diameter. However, sizes up to14 mm are also being
rolled presently.
 Rebar – 8 mm, 10 mm and 12 mm diameter in coil form.
b) WRM – 2
 Plain Road – 5.5 to 20.0 mm in step of 0.5 , Plain rod Dia 20.64 mm can be rolled in
future.
7.5 COMMISSIONING DATES
a) WRM – 1
 Walking Hearth Furnace – lighting up – 09.11.1990.
 Strand 1 & 2 trial operation – 16.03.1991.
 Strand 3 & 4 trial operation – 21.11.1990.
b) WRM – 2
 Integrated hot trial run for commissioning – 04.02.2014

34. P. Dept. – 8 MEDIUM MERCHANT & STRUCTURAL MILL
8. OVERVIEW
The Medium Merchant and Structural Mill (MMSM) is one of the modern rolling mills of
Visakhapatnam Steel Plant. This is a single strand continuous mill having production capacity of
8,50,000 tons per year. The important feature of this mill is that Universal beams (both parallel and wide
flange) have been rolled for the first time in India using Universal stands. Parallel flange beams have an
advantage over conventional beams because, for the same weight, the section is stronger and stiffer due
to greater moment of inertia and higher radius of gyration.
Fig. 8.1 Overview of Medium Merchant & Structural Mill
8.1 FACILITIES
 8 Stand Roughing Mill.
 6 Stand Intermediate Mill.
 6 Stand Finishing Mill.
8.2 SALIENT FEATURES
 Evaporating cooling systems in Rolling furnaces.
 Sophisticated, high speed rolling mills with computerized controls.
8.3 CAPACITY
 A Mill of 1.070 MT per annum
8.4 COMMISSIONING DATES
 Walking Beam Furnace 1 – Light Up – 22.11.1992.
 Walking Beam Furnace 2 – Light Up – 24.12.1991.
 Mill Inauguration – 28.03.1992

35. P. Dept. – 9 SPECIAL BAR MILL
9. OVERVIEW
The Mill is designed to produce 7,50,000 tons per year of plain rounds in straight length and in
coil form by using an input of Continuous cast billets of 150 mm x 150 mm x 12 m and weighing
approximately 2050 kgs. The mill is designed to roll medium and high carbon steel, case hardening
steel, cold heading quality steel, electrode steel, spring steel, bearing steel and free cutting steel.
The bar size shall be in the range of 16 mm to 40 mm. Provision will be kept in the mill for
producing 900,000 tons per year of special bar when the market demand increases. The mill will roll
medium and high carbon steel, case hardening steel, cold heading quality steel, electrode steel, spring
steel, bearing steel and free cutting steel.
The mill shall use continuous cast billets of 150 mm square size and 12 m length. Considering the
yield of 96% for losses due to scale, shear cropping, cobbles etc the requirement of billets for producing
750,000 tons of bar shall be about 781,000 tons.
Fig. 9.1 Overview of Special Bar Mill
9.1 FACILITIES
 6 Stand Roughing Train.
 6 Stand Intermediate Train.
 6 Stand Pre – Finishing Train.
 3 Nos. Stand Finishing Train (Sizing train).
 Pendulum sher, Flying shear 3 no.s and dividing shear.
 Controlled cooling facilities.
 Straight Form : Chain transfers, Cold Shear, Bundling Facilities and Strapping Machines.
 Coil Form : Garret coilers, Cooling conveyors, Hook conveyors, Compacting and Strapping
Machines.
9.2 SALIENT FEATURES
 Continuous Mill consisting of 21 stands of housing – less design.

36.  20 – 45 mm size in straight & coil form (Reduced wastage for end user).
 Free size rolling (Customized sizes with closed tolerances).
 Low temperature rolling for finer grain structure.
 Online automatic measuring measuring gauge for better quality control.
 Automatic bar Bundling & Strapping machines for packing of finished products.
9.3 CAPACITY
 0.75 MT per annum. The enhanced production capacity is 0.90 MT per annum.
9.4 PRODUCT MIX
a) Round Form Outputs :
 Round – 20 mm to 45 mm diameter (with a special provision to roll 16 mm to 18 mm).
 Coils – 2.0 tons (as per billet weight).
b) Straight Form Outputs :
 Straights – 12.0 m bundle with 6 straps.
9.5 COMMISSIONING DATES
 Mill : Commissioned on 3rd
Apr 2015.

37. P. Dept. - 10 STRUCTURAL MILL
10. OVERVIEW
The Mill is designed to produce 7,00,000 tones per year of structural section in straight
length in approximately 3733 rolling hours and 8,50,000 tones per year of structural sections in straight
length in approximately within 4533 rolling hours.an input of Continuous cast cold bloom of 200 mm x
200 mm x 12 m and weighing approximately 3760 kgs.
The Structural Mill shall be able to produce a wide range of products inclusive of plain
round, rebars, semis, besides structurals and product-mix of the mill shall have to be decided depending
upon the market demand and supply patterns at the time of implementation. Provision will be kept in the
mill for producing 850,000 tons per year of structurals when the market demand increases. The mill will
roll constructional steel conforming to standards of structural products.
The mill shall be operated in 3 shifts per day and 300 days in an year. Operation of about
5000 hours shall be considered for producing 850,000 tons per year at an average production rate of 170
tons per hour. The mill shall use continuous cast billets of 200 mm square size and 6 m length. Considering
yield of 92.0% for losses due to scale, shear cropping, cobbles etc, the requirement of billets for producing
700,000 tons of bar shall be about 761,000 tons.
Fig. 10.1 Overview of Structural Mill
10.1 FACILITIES
 Walking beam re – heating furnace, 200tph capacity with cold storage charge, and relevant charging
and discharging services.
 Furnace exit area with pinch roll and high pressure water static descaler.
 Exit furnace table for the feeding of continuous rolling mill.
 Continuous rolling mill composed of 17 rolling stand “housing less type” namely
1) Roughing mill composed of 7 stands arrange in H – V disposition.
2) Intermediate mill composed of 5 stands arranged either in H or H/V/U or H/U disposition.

38. 3) Finishing mill composed of 5 stands arranged either in H or H/V/U or H/U or H/V disposition.
 A crop type start/stop crank shear arranged after stand no. 7.
 A crop type start/stop rotary shear arranged after stand no. 12.
 Dividing shear for multiple length cut after stand 17.
 Double sided 90 m long cooling bed.
 Straightening machine.
 84 m long batching area.
 Three saw for cutting to length in each line.
 Stacking, strapping, weighting and collection stations.
10.2 SALIENT FEATURES
 Continuous Mill consisting of 17 stands of housing – less design.
 Mode Optimization for cut length of bars.
 On line automatic measuring gauge for better quality control.
 Automatic bar bundling & strapping machines for packaging of finished products.
 Basalt Rock Liner in the scale Flume tunnel to prevent wear out of the base of the tunnel.
 Minimum tension control and tension free (loop) control.
 Optimized roll pass design for all product.
 Start/Stop type flying shears along the mill for emergency chopping of rolled stock.
10.3 CAPACITY
 Mills : 0.70 MT per annum. The enhanced production capacity is 0.85 MT per annum.
10.4 STARTING MATERIAL
 Continuous cast cold bloom : 200 X 200 X 12,000 mm – weight 3,760 kg
10.5 PRODUCT MIX
 Beams : ISMB 100, 125, 150 mm ; ISJB 150, 175 mm ; ISLB 100, 125, 150 mm.
 Channels : ISMC 75, 100, 125, 150, 175 mm; ISJC 100, 125, 150, 175 mm.
 Angles : 55, 60, 65, 75, 80, 90, 100 mm.
 Flat : 70 to 180 mm (thickness : 8 to 30 mm).
 Special sections like
1) Squares : 45 to 80 mm
2) HE (columns with parallel Flanges) : 100 to 120 mm
3) IPN (Beams with tapered Flanges) : 100 to 180 mm
4) IPE (Beams with parallel Flanges) : 100 to 180 mm
5) TEE : 60 X 60 7 mm
6) Unequal angles : 80 X 50 , 90 X 60 , 125 X 75 mm
10.6 COMMISSIONING DATES
a) Mill : Hot trial commissioning on 30.04.2015 and production commencing from 15.02.2016

39. 11. SERVICE DEPARTMENTS
1. MINES
Brief about Captive Mines of Visakhaptanm Steel Plant
a) MADHARAM DOLOMITE MINE (MDM)
MDM is located at Madharam village in Singareni Mandal of Khammam District, A.P. The
mining lease is for exploitation of Dolomite covering an area of 384.46 Hectares for about 20 years. The
lease area is a captive source for Rashtriya Ispat Nigam Ltd (RINL) / Visakhapatnam Steel Plant (VSP)
for use of Dolomite in its Iron and Steel making processes. The capacity of the mine is to produce
7,80,000 tonnes of Dolomite per annum. It is an open cast mechanized mine of VSP to cater to the
requirement of Dolomite.
b) JAGGAYYAPETA LIMESTONE MINE (JLM)
Jaggayyapeta Limestone mine (JLM) is located 5 Km south – West of Jaggayyapeta
connected by a black – top road in Krishna District, A.P. This is a captive mine of VSP to cater to the
requirement of BF Grade Limestone of VSP. This mine is an open cast mechanized mine with a capacity
of 4,50,000 tonnes of BF Grade Limestone per year. The Limestone reserve of 130 million tones is
occurring in the area.
c) GARBHAM MANGANESE MINE (GMM)
Garbham Manganese mine (GMM) is a captive source for manganese ore for VSP. It is
located 16 Km away from Garividi connected by the black – top road in Merakamududam Mandal,
Vizianagaram District, A.P. There are two mining leases adjacent to each other covering an area of
264.54 Hectares. The present reserve of Manganese is 7,03,760 tonnes as on 01.01.2008 with a life of 46
years producing 15,000 tonnes per annum. The annual production ofthe mine is @ 16,000 tonnes.
d) SARIPALLI SAND MINE (SSM)
This is a captive source for catering to the requirement of Silica sand for VSP. This is located
in Champavati River near Nellimarla Mandal of Vizianagaram District, A.P. The sand is transported
from this mine to VSP. The totalreserve of sand is 3,20,000 tonnes.
2. CALCINING & REFRACTORY MATERIAL PLANT
CRMP consists of two units - Calcining Plant & Brick Plant. In calcining plant, Limestone &
Dolomite are calcined for producing Lime & Calcined Dolomite which are used for refining of steel in
the converters. In Brick Plant, bricks and refractory masses are produced, which are used in the Steel
Converter as working lining.
3. CENTRAL MAINTENANCE ELECTRICAL (CME)
Maintenance of all H.T motors, L.T motors and DC motors of above 200KW. There are 810
such large rotating electrical machines spread through out the plant including 3 Nos. of 60 MW Turbo -
Generators, 1 No of 67.5M TG in TPP, 2 nos of Back Pressure Turbo Generators of 7.5 MW each and 2
Nos. of Gas Expansion Turbo- Generator of 12 MW each. The service provided are as mentioned below.

40.  Repairs, Maintenance and condition monitoring of all rotating Electrical machines of the plant. The
job includes transportation, Overhauling and re-erection with precision alignment.
 Maintenance of Electrics of all street lights, Tower lights and Weigh Bridges through out the plant.
4. CIVIL ENGINEERING DEPARTMENT
 Inspection of all Civil Buildings in the plant.
 Attending Civil Maintenance jobs in various zones of the plant
 Road repair works
 Laying of additional roads…….. RCC / BT Roads
 Attending special jobs during Capital Repairs / Shutdowns.
 Repainting of Equipments in various zones of the plant
 Horticulture / Development of parks
 Cleaning of storm water drains / Box drains, diversion channel
 Upkeep of Toilets in buildings / shops of the plant
 Preparation jobs for VIP visits
 Ash Pond maintenance jobs
 Survey jobs
 Special jobs: Core cutting in concrete structures, Pressure grouting, Roof treatment, Anti - terminate
treatment etc.
 Civil jobs for infrastructure: Scooter sheds / Rest rooms, office room extension etc.
 Security related jobs: Maintenance of Boundary wall Watch towers, peripheral road
5. DISTRIBUTION NETWORK DEPARTMENT
Distribution Network (DNW) Department deals with receipt, transmission of electrical power
at 220KV level and distribution of power at 33 KV, 11 KV and 6.6 KV level. Operation and
maintenance of power handling equipment under DNW at 220 KV, 33 KV, 11 KV & 6.6 KV levels,
maintenance of TPP 220 KV equipments and maintenance of other shop’s 33 KV, 11 KV, 6.6 KV
equipments (except operations of 220 KV, O&M of 33 KV, 11 KV, 6.6 KV equipment at TPP & other
shop HVMCC board with Vacuum Contactors, other Vacuum Contactors) are under DNW purview.
DNW department also coordinates with AP Transco and APEPDCL for import of power.
6. ELECTRICAL REPAIR SHOP (ERS)
ERS is a central repair shop to carry out repair activities like overhauling, rewinding, testing
etc., of various types of AC Motors, DC Motors, HT Motors, Submersible pumps, Distribution
transformers, Welding Machines, Control Transformers, Lifting magnets, Coils etc., of the plant.
The Main Functions of ERS are:
 Overhauling of motors
 Rewinding of motors, magnets, transformers, pumps, coils etc.
 Testing of Electrical equipment
 Emergency Site Repairs

41.  Performance assessment of electrical motors
7. ELECTRO TECHNICAL LABORATORY
ETL Department supports the electrical sections of different production shops all over the
plant in maintaining electronics pertaining to Drive automation, Programmable Logic Controllers, Crane
Drives, Uninterrupted Power Supplies, Electrostatic Precipitators, Special Machines like CNC Machines
etc.
The following are the main activities :
• Preventive Maintenance and trouble shooting of the concerned electronics.
• Procurement of spare electronic modules.
• Repair of defective electronic modules.
• Aid the up gradation of obsolete electronics in preparation of specifications and commissioning.
8. ENERGY MANAGEMENT DEPARTMENT
EMD deals with handling and distribution of gaseous by-product fuels (BF Gas, Coke Oven
Gas, LD Converter Gas) and other utilities such as Steam, Compressed Air, Instrumentation Air,
Nitrogen Chilled Water, Oxygen, Demineralised Water, Argon, Acetylene and Fuel Oil in the plant
besides conducting various thermo technical studies and reviewing energy consumption regularly. It also
looks after gas safety aspects in the plant.
9. ENGINEERING SHOPS & FOUNDARY (ES & F)
Engineering Shops & Foundry department is set up to meet the requirements of spares, repair
of assemblies and reclamation of various jobs of different departments.
This complex consists of :
a) Central Machine Shop (CMS)
b) Steel Structural Shop (SSS)
c) Foundry
d) Forge Shop (FS)
e) Utility Equipment Repair Shop (UERS).
a) CENTRAL MACHINE SHOP (CMS)
In Central machine shop, various spares like Gears, Shafts, Crusher liners, hammers,
machined castings and fabricated jobs are made. In addition to the manufacturing spares, assembly and
repair jobs like gear boxes, Crusher, bearing housings, stands of SMS are taken up. Over 100 major
machines including lathes, milling, Plano milling, boring, slotting, shaping, grinding etc. are available to
take up machining of spares. 2 presses of 630 ton, 315 ton and dynamic balancing machine of 25 ton
capacity, are provided at CMS for repair of assemblies.
b) STEEL STRUCTURAL SHOP
At Structural shop of ES&F, structural jobs of various departments like coke bucket, ladle,
SRC body, Wagons, Shells, ducts etc. are being fabricated or repaired as per the requirement of

42. departments. The equipments available are Bending machine-25mm capacity, Shearing machine - 25mm
capacity, CNC profile gas cutting machine, welding machines, gas cutting sets, other tools and tackles.
c) FOUNDARY
In Foundry, castings of Iron, steel and non-ferrous are produced based on the projection of
customer departments. 8 ton Arc furnace, 2nos of 5ton Induction furnaces and 1 ton crucible furnace for
non-ferrous jobs and sand plant for preparation of sand for moulds are available for making castings.
Major jobs like Hot metal runners of 10 tons weight , Bottom funnel(5 ton), Emergency containers(7
ton), lower mantle and Bowl liners(3 tons each) etc are produced.
d) FORGE SHOP (FS)
In Forge shop, preparation of raw materials for shafts, coupling flanges, gears etc and also of
forge shapes such as crusher hammer heads, V -hooks, drill rods with the help of 0.5 ton, 2 ton, 3 ton
pneumatic hammers, manipulators, heating furnaces is carried out.
e) UTILITY EQUIPMENT REPAIR SHOP (UERS)
In Utility Equipment Repair Shop, repair of ventilation equipments, valves, fans and impellers
is carried out. Equipments like shearing machine, bending machine, presses, lathes etc are provided to
take up different repair and manufacturing activities.
10. ENVIRONMENT MANAGEMENT DEPARTMENT (EnMD)
The environmental parameters related to ambient air, stacks, effluents, work-zone environment,
sound, waste management, sub-soil water, marine water and the fugitive emissions (from the coke oven
batteries) are regularly monitored by the Environment Management Department (EnMD) as stipulated
under consent conditions and statutory orders from APPCB/CPCB/MoEF. All these monitoring
activities are carried out as per frequency prescribed by the APPCB/CPCB/MoEF and compliance with
all norms is ensured.
11. FIELD MACHINERY DEPARTMENT (FMD)
FMD deals with operation and maintenance of Heavy Earth Moving Equipment, Material
Handling Equipment like Cranes, Fork lifts, Tractor trailers and Vehicles. Our equipments are utilized
for material transportation, maintenance jobs, house keeping etc. FMD is one of the critical service
department, whose services are directly involved in operational activities at many production
departments like Coke Ovens, Sinter Plant, Blast Furnace, Steel Melting Shop etc.
In addition to the above, vehicles and fire tenders of VSP / CISF are maintained by FMD.
12. INFORMATION TECHNOLOGY (IT)
 Formulation of Organizational IT-Policy, IT-Security Policy and IT-Vision.
 Identification of IT enabled projects for various processes and implement them.
13. M & CR
a) Functions :
 Modernization of major plant equipment (BF-1&2, SMS Converter shop, Sinter

43. machines-1&2 etc.) through “Revamping, Up gradation and Capital repairs” as per
sustainability and roll on plan of VSP.
 To execute the modernization of major plant equipment with support of works
department and concerned contractor / agency.
b) Duties :
 To finalize technology and design in construction with D&E, works department for modernization or
major plant equipment.
 To finalize contracts in consultation with project contracts department for modernization of major
plant equipment.
 To execute the modernization of major plant equipment with support of works department and
concerned contractor / agency.
14. PLANT DESIGN
 Major functions of this unit are
 Development of detailed Manufacturing Drawing and Replacement Specification drawings
 Suggesting New Designs and detailing by doing elaborate engineering study and Analysis
 Standardization
15. PRODUCTION, PLANNING AND MONITORING DEPARTMENT
 Formulation of Annual and Monthly Production Plan.
 Analyzing Plant performance against targets on a periodic basis and put up for information.
 Formulation of techno – economic norms and reviewing the same against targets periodically.
 Raw material requirement projection of Coal, Ore and fluxes.
 Preparation of MIS on Inward and outward traffic w.r.t. incoming raw materials and outward
dispatches.
16. QUALITY ASSURANCE & TECHNOLOGICAL DEVELOPMENT
(QA & TD)
The QA & TD dept. has been set up to take care of activities pertaining to Quality Control of
Raw Materials, Semi finished products and finished products. The QA & TD labs are provided at major
department like CO&CCP, SP, BF, SMS, Rolling Mills etc., in addition to Central Laboratory. The
department monitors the process parameters for production of quality products. QA & TD carries out
analysis, testing and final inspection including spark testing of finished products and assigns grades to
them.
17. RESEARCH AND DEVELOPMENT (R & D)
R&D Department started functioning from 2005 in RINL. This department takes up various
improvement projects related to the areas given under:
 Pursuing innovative and path breaking technologies to create a vibrant, viable and sustainable future
for RINL

44.  Developing technologies to enrich raw materials of lean variety
 Product development to meet ever increasing demands on steel quality
 Meeting the challenges of energy and environment
 Create knowledge through basic research in the area of Iron and Steel
 Improve the technological capability of the human resources through interventions like exposure to
information, advanced knowledge and new technologies
R&D projects are carried out internally and jointly with the help of external agencies viz., research
organizations and academic institutions like IITs, NITs, CSIR laboratories, Universities etc.
18. REFRACTORY ENGINEERING DEPARTMENT
In Visakhapatnam Steel Plant the pyrometallurgic processes involved from Raw Materials
Processing to Finished Products units, everywhere Refractory material is involved. Refractory
Engineering Department plays it’s role by maintaining the refractories in furnaces, kilns and vessels
required for different operations of steel making process. In order to augment timely production, the
main objective of RED is to make pyrometallurgic machines / equipments available in time with
prolonged service period.
RED section are scattered in all the major production units (viz., SP, TPP, BF, SMS, Roiling Mills,
ES&F etc.).
1. The central section is located at CRMP & RED Area Shop Office Building. The main functions of
RED are:
• To plan & procure the refractory required during regular maintenance and capital repair of all types of
furnaces, kilns and vessels in steel making
• To carry out all the refractory repair & maintenance including regular and running repairs and also
capital repaint
• To arrange for supervision, inspection and corrective action of vital equipments.
a) like LD converter, Steel ladle, Tundish in SMS round the clock
b) TLC, Open top ladle of BF
c) Furnaces of CRMP, ESF & Rolling mills.
Round the clock supervision of capital repair of furnaces of rolling mills, hot blast stoves, Mixer,
CRMP.
19. ROLL SHOP & REPAIR SHOP (RS & RS)
Roll shop & Repair shop is in the complex of Rolling Mills catering to the needs of mills in
respect of roll assemblies, guides few Maintenance Spares and roll pass design. Geographically this
dept. is in three areas as Roll shop-1, Roll shop-II and Area Repair Shop. The main activities of this shop
is Roll pass Design, grooving of rolls, assembly of rolls with bearings, preparation of guides and their
service and manufacture / repair of mill maintenance spares.
For the first time in the country, VSP has adopted CNC technology for grooving of steel
rolling mill rolls. High constant respective accuracy, higher productivity, use of standard tool for any
groove turning, elimination of the use of different templates, easier to incorporate groove modification
etc., are some of the advantages of CNC lathes over the conventional one.

45. 20. SAFETY ENGINEERING DEPARTMENT
Safety Engineering Department advises and assists the management in the fulfillment of
obligation concerning prevention of accidents and maintaining a safe working environment. SED
imparts safety training as well as refresher safety training to the regular employees as well as contractor
workers. SED conducts safety inspections, safety audits, mock drills and co-ordinate with the
departments for corrective actions in respect of unsafe conditions and unsafe actions. SED conducts
safety campaigns and safety competitions amongst the employees to promote safety. SED ensures that
high quality safety appliances are procured and issued to the employees. SED coordinates and liaison
with AP Factories departments.
21. SPARES MANAGEMENT DEPARTMENT (SMD)
SMD is a nodal agency between Works and Materials Management department:
2. The main functions of SMD are:
 Rationalized spares are procured by SMD department viz., Bearings, Electrodes, Conveyor belts, Idlers,
LV Switchgear, Cables, etc., to cater the needs of various departments.
 All the indents and Technical recommendations viz., Operation, Mechanical, Electrical,
Instrumentation, Refractory etc., are processed thro’ SMD department for procurement of spares thro’
Materials Management department.
 SMD department controls Inventory of spares, indenting & consumption budget.
22. STRUCTURAL ENGINEERING DEPARTMENT (St. ED)
The main objective of Structural Engineering Department is to maintain Steel structures
located inside the plant area including Boundary Lighting Towers & Watch Towers and the main
functions are as below:
 Inspection of all steel structures and chimneys as per schedule of inspection and inspection of roof
sheeting works as per schedule of inspection.
 All units of every zone are inspected at least once in a year. Critical units like CDCP’s of C&CCD,
Service benches of C&CCD are inspected twice in a year. Inspection of roof dust cleaning of
identified units of CRMP, SP, & SMS is being done four times in a year.
 Repair / Replacement of damaged steel structures and sheeting in various zones inside the plant area.
 Arresting roof leakages in all structural buildings inside the plant area.
 Re-painting of ODPL pipe lines and repainting of structures as a Preventive Maintenance.
 Removal of dust from roof and gutters of different units.
 Preparation jobs for VIP visits.
 Special Jobs: Providing polycarbonate sheets as energy conversion in all zones.
 Infrastructural Jobs: Providing scooter sheds, Rest Rooms, storage racks etc.
 Security related jobs: Maintenance of watch towers and Flood light towers inside the plant area.
23. THERMAL POWER PLANT
The average power demand of all units of VSP when operating at full capacity will be
around 230 MW. The captive Generation capacity of 286.5 MW is sufficient to meet all the plant needs

46. in normal operation time. In case of partial outage of Captive Generation Capacity due to brake down/
shutdown/ or other reasons, the short fall of power is availed from State Grid.
The Captive Generation capacity comprises of :
 TPP : 247.5 MW (3 X 60 MW + 1 X 67.5 MW)
 Back Pressure Turbines (C&CCD) : 2 X 7.5 MW
 Gas Expansion Turbines (BF) : 2 x 12 MW
Power plant also meets the Air Blast requirement of Blast Furnaces through 3 Turbo Blowers each of 6067
NM3/Min capacity.
In addition to the above, Power Plant also supply process steam, DM Water, Chilled Water, Soft Water to
various units of VSP.
24. TRAFFIC DEPARTMENT
VSP has a well planned rail network with Yards / Stations, Locos and Wagons which are
maintained by Traffic department. For the convenience of Operational activities, the rail network is
divided into six yards / stations and each yard has specified functions attached to it.
VSP has the distinction of having peripheral yard concept to improve the turn – round time of wagons
and to avoid duplicating of the rail facilities by Railways and VSP. All the Raw-material rakes are
delivered by Railways directly at Pre-tippler lines.
The main functions of Traffic department are to carry out in-plant rail movements like handing over of
empties to Railways after tippling, transportation of Hot metal from BFs to SMS / PCMs, taking over of
empty rakes from Railways and distribution to various loading points and after loading of the finished
products and weighment handing over of load rakes to Railways.
25. TECHNICAL IMPROVEMENT CELL
TIC functions as nodal agency for coordinating and monitoring the various activities as
envisaged in company procedure for processing and implementing of AMR schemes.
26. TQM – ISO CELL
 Ensuring the implementation and maintenance of Quality Management System requirements for ISO
9001 : 2008.
 Liaisoning with certifying agency for conducting audits for Quality Management System,
Environment Management System, Occupational Health & Safety Management System and Energy
Management System.
 Conducting Internal Audits for Quality Management System, Environment Management System,
Occupational Health & Safety Management System
27. UTILITIES DEPARTMENT
Utilities dept. Consists of :
1. Air Separation Plant, designed to produce and meet the consumer requirements of gaseous oxygen,
Nitrogen and Argon through pipe lines and through gas cylinders.

47. 2. Compressor Houses – 1 & 2, designed to produce and meet the consumer requirements of Plant air
and Industrial grade dry air.
3. Chilled water plants – 3 & 4, designed to produce chilled water for meeting the consumer air
conditioning requirements.
4. LPG is being procured and distributed through pipe lines for CCD & Engineering Shops and for
maintenance agencies through cylinders. DA gas is being procured and distributed for Billet cutting
at MMSM & for critical maintenance agencies through cylinders.
28. WORKS CONTRACTS DEPARTMENT
 Processing for and obtaining administrative approval on receipt of contractual proposal from
indenting departments, tendering and awarding of work.
 Convening tender Committee meetings and preparing recommendations for awarding work.
 Preparing COM / Board Note for decisions at those forum.
 Participating in Claims and Arbitration proceedings and legal cases pertaining to contracts.
 Registration of agencies under various categories & classes of works regularly.
29. WATER MANAGEMENT DEPARTMENT
Water Management Department basically caters water needs throughout the plant for
various processes of making Steel and drinking water inside the plant and Township. It consists of 30
pump houses, 8 treatment plants, 4 Overhead tanks, 22 cooling towers, 10 sewage pump houses, STP &
ETP. Its prime functions are as follows:
 Receipt of Raw water from State Government, Treatment and distribution of Makeup water and
drinking water in & Township.
 Operation and Maintenance of Various Recirculating Pump houses, Cooling towers, Treatment
plants, pipe line tunnels etc.
 Maintenance of underground Makeup and Fire & Drinking water network.
 Operation and Maintenance of Effluent Treatment Plant & Sewage treatment plants and pump
houses.
 Recovery of township sewage water through Ultra Filtration process and reuse in plant as make
water.
30. BUDGET PLAN AND CONTROL
 Identification of Budget requirement under various heads.
 Control of the Budget and Spares, Consumables & Raw Materials Inventory.
31. SYSTEMS AND PROCEDURES
 Streamlining the contract management system to ensure consistency of approach and adoption of
sound principles of contract management.
 Monitoring pollution control activities of the Plant and interaction with the State and Central
Pollution Control Board.
32. PERSONNEL DEPARTMENT

48. Personnel Department (Corporate Personnel, Central Employee Relations and Plant
Personnel)
 Manpower Planning
 Employees induction
 Service matters, policy & rules
 Industrial relations
 Employees welfare
 Corporate Social Responsibility (CSR)
 Replies to parliamentary questions
 Official Language implementation
33. LEGAL AFFAIRS (LA)
 Legal Affairs deals with all legal matters including arbitration, coordination with Standing Councils,
Legal Advices etc.
34. MANAGEMENT SERVICES (MS)
 Quality Circle
 Suggestion Scheme
 Incentive Scheme
 Reward Scheme
 Procedural Orders etc.
35. TRAINING & HRD
 Leadership Training
 Training on Motivation and Attitude
 Team Building
 Skill Training
 Induction and Orientation
 Plant Practice Lectures
 Basic Engineering Lectures
 Plant Specialized Training
 Management Development
 On the Job Training
 Multi Skilling / SUPW and Mentoring
36. TOWN ADMINISTRATION & ADMINISTRATION (TA)
 Matters relating to Land & State

49.  Civil Maintenance
 Electrical Maintenance
 Water Supply
 Roads and Drain Maintenance
 Horticulture and Afforestation
 Peripheral Development and
 Public Health in Township (Ukkunagaram)
 Interact with District Authorities for various welfare activities, land acquisition matters etc.
37. MEDICAL & HEALTH SERVICES (M & HS)
The Medical & Health Services Division of RINL consist of Visakha Steel General
Hospital (VSGH) & Peripheral Units viz. Pedagantrya Health Centre (PGHC), Health Centre – II,
Occupational Health Services & Research Centre (OHSRC), Emergency Unit – I & II and Hospitals in
Mines –Jaggayyapeta Limestone Mines and Madharam Mines. The special features of Visakha Steel
General Hospital are:
 Full fledged Modern American Designed ICU and MBU capable of treating 6 patients at a Time
 Full fledged Modern Radiology with Central A/c systems
 Well equipped Path. Lab with Blood bank facility
 Cluster type Wards & Casualty with Central Nursing Station
 Modern Operation Theatre comples with Shadowless cold lights and 100% bacterial free A/c system
38. MARKETING DEPARTMENT
VSP has 23 no of Branch Sales Offices all over India and five Regional Offices viz. North
Delhi, South - Chennai, West - Mumbai, East - Kolkata and Andhra - Visakhapatnam. Main Activities of
the Marketing are as follows :
 Collecting Market feedback and Customers requirements for the preparation of Annual Sales Plan in
coordination with Works Department, for the sale of Pig Iron, Steel and Byproducts.
 Preparation of Marketing Policies.
 Finalization of MOUs, Spot sale agreements etc, in Domestic and Export Markets.
 Preparation of Monthly Rolling Plans in coordination with Works Department for meeting the sale
commitments.
 Processing of Materials like straightening of coils, cutting, bending, bundling, packaging etc. at the
plant premises and in the branches to meet customers requirements.
 Dispatch of products to various stockyards by road or rail or to customers from the plant on direct
dispatch basis.
 Operation of the contracts for transportation of products by road and stockyard
handling/consignment agency contracts for domestic sales, stevedoring contracts and third party
inspection agency for exports.
 Sale of products at branches, Headquarters and on direct dispatch basis to the customers in domestic
markets and on Ex-works and fob Visakhapatnam basis in exports subject to tying up of commercial

50. and financial terms and conditions. Ensure documentation as per the procedures and as per the
statutory requirements.
 Rendering after sales services, obtaining customer feedback and Customer Relations Management.
 The details/information on the following aspects of Marketing are available in www.vizagsteel.com,
Marketing Module.
a) Rolling Plan
b) Products
c) Prices
d) Exports
e) Network
f) Customer Relation
 Further, five Consignment Sale Agencies are also functioning at Jamshedpur, Raipur, Pondicherry,
Jammu and Guwahati.
39. MATERIALS MANAGEMENT DEPARTMENT
 Procurement of all materials such as Raw-materials, Spares and consumables required for the entire
Plant Operations.
 To enter into long term agreements for supply of major & minor raw-materials with indigenous and
imported suppliers.
 To affect economy in the cost of materials by Purchasing materials of the right quality, in the right
quantity at the right time from the right source at the right place.
 To arrange inspection of materials prior to handing over to Production Units to ensure quality
materials only are issued to Production Units.
 Storage of materials & issue the same to the Production Units as per their requirement.
 To develop and encourage ancillary industries so that the availability of the materials at right time is
ensured.
40. FINANCE & ACCOUNTS DEPARTMENT
 Corporate Treasury Functions - Arrangements for Long term & Short term Funds, Working Capital,
Submission of periodical reports to Banks as required, Strategies for Long term / Short term
investments.
 Accounting of all monetary transactions and preparation of Financial statement of the company,
statutory compliance of Taxation, Company Law & Provident Fund and getting them audited as
required under Companies Act / relevant Act.
 Maintaining records w.r.t. to the cost of products in line with the Cost Accounting Records & Rules
Prescribed.
 Release of payments to suppliers / providers of goods and services.
 Release of salaries & allowances to the employees of the company.
 According concurrence / consultation to the proposals for investments & expenditure as per the
extant policies, procedures and the Delegation of Powers.

51.  Organising for payment of Central Excise, Sales Tax, Income Tax & other statutory payments as per
the provisions of the respective acts.
 Internal Audit (including ERM audit), Stock Verification as per the requirement of the company.
 Ensuring timely Statutory Audit and Govt. Audit for the Company’s accounts and attending to
proprietary audit points by Govt. Audit.
 Generation of various MIS reports relating to Finance function of the Company for enabling
Management to take timely decision.
41. CORPORATE STRATEGIC MANAGEMENT
CSM is a “think tank” of the organisation. The Deparment is engaged in formulation of VMO
(Vision, Mission & Objectives) of the organisation and developing the strategy to achieve VMO. It has
various wings which inter-alia includes Knowledge Management Cell (KM Cell). It has also developed
the Corporate Plan of RINL. It takes up strategic tasks of the organisation.
42. DESIGN & ENGINEERING DEPARTMENT (D & E)
 Liaisoning with Consultants and Government Authorities in connection with designs, specifications,
approval of drawings and liaisoning work for various types of clearances.
 Preparation of drawings, design and specification for AMR and Non-AMR jobs.
 Assisting indenting departments in technical discussion with parties and preparation of technical
recommendation.
 Layout clearances of various facilities coming in the Plant and Township.
 Operation of Consultancy contracts.
43. CONSTRUCTION DEPARTMENT
 Exercising supervision of work at site both for quality and quantity checks.
 Preparation of contractors bills, processing of extra items and closure of contracts.
 Liaisoning with suppliers, MM department, Design & Engineering Department and Stores in
connection with progress of work at site.
 Arranging PAT/FAT will all concerned departments like works, design, consultants and suppliers in
terms of contract and handing over the unit to works department for operation.
44. CONTRACTS DEPARTMENT
 Awarding of contract from the point on receipt of administrative approval from indenting
departments.
 Conducting commercial discussions with parties.
 Arranging Tender Committee meetings and preparing recommendations for awarding work.
 Preparing COM/Board Note for decisions at those form.
 Participating in claims and arbitration proceedings.
45. PROJECT MONITORING DEPARTMENT

52.  To monitor the physical and financial progress of all the works executed by Construction department.
 To monitor the progress of works executed by D&E as well as Contracts department.
 Preparation of various types of reports for information of Government and different level of
Management.
 Interaction with departments and consultant for updating the schedules and networks for Project
Monitoring.
46. VIGILANCE DEPARTMENT
Vigilance Department of RINL, set up in accordance with the Central Vigilance
Commission (CVC) Act 2003, is headed by the Chief Vigilance officer (CVO). The CVO acts as a link
between the organization and the CVC.
Functions of the department can be broadly divided into three areas, viz. (i) Pro-active / Preventive
vigilance; (ii) Punitive vigilance; and (iii) Collecting intelligence about the corrupt practices / acts
committed or likely to be committed in the organization through Surveillance and Detection.
At micro level, the Activities of vigilance Department include inter-alia timely investigation and
disposal of complaints, monitoring and advising the Disciplinary Authorities for timely disposal of
disciplinary cases initiated based on vigilance cases, putting up to the authorities concerned periodic
reports in the prescribed timeframe, coordinating with the CVC, Administrative Ministry and the CBI
for effective vigilance administration, implementation of anticorruption initiatives through awareness
drives etc.

53. 12. DETAILED REPORT ON RAW MATERIAL HANDLING PLANT
1. RMHP
Visakhapatnam Steel Plant is one of the most modern steel plant not only in the country but
also in the world. This has latest raw materials stacking and blending system. RMHP has the concept of
peripheral unloading which considerably reduces delay in taking over and handing over of rakes
bringing raw materials to the plant, there by increasing the availability of wagons.
The Raw Material Handling Plant is handling more than 24 million tons of various raw
materials for 6.3 MTA.
Raw Material Handling plant is meant for transporting materials from Raw Material yard /
Base mix yard to various units of the plant. The Major Raw materials required for Iron and Steel making
are Iron ore lump, Iron Ore fines, Sized iron ore, Flux limestone / dolomite, manganese, Quartzite
coking coal ( for Boiler operation & For Pulverized coal injection ) and coke. Lump iron ores, iron ore
fines and flux such as limestone and dolomite received by railway rake are unloaded in wagon tippler
and stored yard with the help of various stockyard machines.
Iron ore lump, flux such as limestone and dolomite, Coke is reclaimed by suitable stock yard
machine and are crushed in Ore crushing plant, Flux crushing plant and coke crushing plant respectively
to produce the size required. The above material is proportionately stacked by suitable stacking machine
in base mix yard and blended while reclaiming by blender reclaimer. The prepared base mix is then
transported to Sinter plant for sinter production. For feeding material to new Blast Furnace, sized ore and
flux are reclaimed by stock yard machine from respective yard and are transported by conveyor. Sinter
produced in sinter plant and coke from existing/new coke ovens is transported directly to BF-3 stock house
by conveyor. Purchased coke and necessary calcined lime from stock yard and new lime calcining plant
respectively are transported to SMS by conveyor. The waste product from the plant is mainly dust and
method of their disposal is through dust suppression system and inter plant transportation.
1.1 The Raw Material Handling Plant in any organization is needed :
a) To have adequate storage capacity to store various raw materials depending up on the capacity of the
beds in the stock yard.
b) To blend raw materials, if needed, received from various sources, in order to supply homogeneous raw
materials.
c) To ensure methodical stacking and reclaiming of raw materials without mixing up of different raw
materials.
d) To process the raw materials and bring down the size to the size as required by the customer
departments to improve their productivity and product quality.

54. 1.2 RAW MATERIALS FLOW CHART

55. 1.3 LAYOUTS OF STORAGE YARD

56. 1.4 AUGMENTATION OF IRON ORE STORAGE
1.5 FUNCTIONS OF RMHP
a) Receiving - Raw Materials from different Sources
b) Processing - Iron Ore Lump & Boiler Coal
c) Storing - Raw Materials in Stock Yard Beds & Hoppers
d) Supplying - raw Materials to customer departments as per their demand
a) Receiving Raw Materials :
 Received through rail route (open wagons), by road (Trucks) and by high seas (Ship /
Vessels).
 Through Rail route : Iron Ore, BF Limestone, BF Dolomite, Boiler Coal, Coking Coal
etc.
 By Road : Quartzite, River Sand, Manganese Ore etc.
 By High Seas : Coking Coal, Limestone (SMS Grade)
b) Processing :
 Iron Ore Lumps are Screened and Crushed in OHP and Stored & dispatched to Blast Furnace
(BF).
 Boiler Coal is Screened & Crushed in CHP and dispatched to Thermal Power Plant (TPP).

57. c) Storing Raw Materials :
 Wagons are unloaded by Wagon Tipplers.
 Trucks are unloaded in Ground Hoppers.
 Materials are carried to and Stacked in different beds in Stock Yard by set of conveyors.
 Materials are Stored in different beds of Stock Yards allocated for Ore and Coal.
d) Supply / Reclaiming of Raw Materials :
 The Raw Materials are reclaimed and sent to customer departments with the help of Reclaiming
Equipment and sets of conveyors.
1.6 SECTIONS OF RMHP
a) Ore Handling Plant (O.H.P) :
 Wagon Tipplers
 Track & Ground Hoppers
 Stock Yard & Equipment
 Screening and Crushing
 Reclaiming routes to Customers
 Ore control rooms
 Drier
 IOSA (Iron Ore Stock Yard for Augmentation)
b) Coal Handling Plant (C.H.P) :
 Wagon Tipplers & GPL Conveyors
 Track & Ground Hoppers
 Stock Yard & Equipment
 Screening and Crushing
 Reclaiming routes to Customers
 Coal Control Room
MAJOR RAW MATERIALS

58. 2. ORE HANDLING PLANT (OHP)
2.1 RAW MATERIALS – O.H.P
2.2 MATERIALS HANDLING – O.H.P
2.3 MATERIALS DISPATCH TO O.H.P CUSTOMERS
Material Size Colour Source
Iron Ore Fines -10mm Flash Red Bacheli/Kirandul Gua
Sized Iron Ore 10 to 40mm Flash Red Bacheli/Kirandul
Iron Ore Lump -150mm Flash Red Bacheli/Kirandul
Lime Stone (BF Grade) 6 to 40mm Yellow /grey Jaggayya Peta
Dolomite (BF Grade) 6 to 80mm Light grey Madharam
Lime Stone (SMS Grade) -50mm Grey UAE/Oman/Jaisalmer
Dolomite (SMS Grade) -50mm Yellow Madharam
CRMP L/S Returns -25mm Grey CRMP
LD Slag (Sinter Plant Grade) -10mm Grey SMS
LD Slag (SMS & BF Grade) 10 to 30mm Grey SMS
Material Size Colour Source
Sand/Quartzite Fines -3mm Yellow/Brown Vizianagaram
Quartzite Lump 10 to 30mm Yellow/ Brown Vizianagaram
Mn Lump 10 to 40mm Black Vizianagaram
Pellets 20mm Flash Red Kudremukh
Sinter 7 to 40mm Shiny Black Sinter Plant
Coke 10 to 60mm Black China/ Russia
Department Material Tons/Day (Average) Qty (Tons)/Annum
Sinter Plant Iron Ore Fines 15,000 56,08,000
Lime Stone 1,500 5,71,000
Dolomite 2,000 7,25,000
LD Slag 300 1,09,500
Sand/Quartzite Fines 200 61,300
CRMP L/S Returns 400 1,44,000
Blast Furnace Sized Iron Ore 5,900 21,57,000
LD Slag As per requirement ----
Mn Lump As per requirement 8,700
Sinter/Pellets As per requirement ----
Quartzite Lump As per requirement 8,400
Dolomite 200 60,000

59. 2.4 EXPANSION OF ORE HANDLING PLANT
a) TIPPLING & STACKING ORE HANDLING PLANT
No. of
wagon
Tipplers
No. of
Wagon
Pusher
cars
Device for Tippling
of Last -4 wagons
No. of
Tippling
streams
Capacity
TPH
Existing 3 6
3-No’s of In haul
shunting device
3 1200
Expansion 1 2
2-No’s of dummy wagons
for each Wagon Pusher
will be attached
permanently
1 1550
Augmentation 1 2
2-No’s of dummy
wagons for each
Wagon Pusher will be
attached permanently
1 1550
b) CONSUMPTION OF ORE & FLUX AREA OF RMHP (EXISTING &
EXPANSION)
Material
Existing Expansion
Per Day Consumption Per Day Consumption
Iron Ore Fines 12270 10230
Iron Ore Lump 6800 7575
Sized Iron Ore 5440 4760
BF – Dolomite 1500 1033
BF – Lime Stone 1100 1033
SMS – Lime Stone 1300 1600
SMS - Dolomite 500 500
c) RAW MATERIAL REQUIRED IN O.H.P PER DAY
Material
Existing Expansion
Sinter/Sized Iron Ore 400 1,20,000
LD Slag As per requirement ----
Coke If required 6,000
CRMP Imported Lime Stone
Dolomite
2,200
800
8,31,000
2,40,000

60. Tons Rakes Tons Rakes
Iron Ore Fines 12270 3.5 22500 6.5
Iron Ore Lump 6800 1.8 14375 3.9
Lime Stone for SP 1100 0.3 2133 0.6
Dolomite for SP 1500 0.4 2533 0.7
Lime Stone for SMS 1300 0.4 2900 0.9
Dolomite for SMS 500 0.2 1000 0.3
Total 23470 6.6 43441 12.9
d) ORE & FLUX STOCK YARD

61. e) ORE & FLUX YARD AFTER 6.3 MTPA EXPANSION

62. f) RECLAIMING STREAM OF ORE & FLUX
Description
BF Circuit SP Circuit CRMP Circuit Drying Station Capacity
Capacity in
Ton
No. of
Streams Capacity
No. of
Streams Capacity
No. of
Streams Capacity
No. of
Streams
Existing 1200
TPH
1
1200
TPH
1
450
TPH
2 50 TPH 1
Expansion
800
TPH
1
1200
TPH
1
2.5 DETAILS OF EQUIPMENTS OF O.H.P
ORE HANDLING PLANT
S.NO Description of
Equipment
Existing Expansion IOSA AMR Total
1
Conveyors
Quantity 90 79 29
− 198
Length Kms 39 23 19
− 81
2 Wagon Tippler 3 1 1
− 5
3 Wagon Pusher 6 2 2
− 10
4 Dummy Wagons − 4 4
− 8
5 Apron Feeders 6 2 2
− 10
6 Twin Boom Stacker 5 1 1
1 8
7 Wheel On Boom Reclaimer 3 1 1 0 5
8 Blender reclaimer 3 1 1 1 6
No. of days of Stock envisaged by considering Existing, Expansion & Augmentation yard is 30 - Days
Material Storage Days of storage as per current practice Augmentation: Additional
storage envisaged
Total
Iron Ore Fines 13 17 30
Iron Ore Lumps 12 18 30

63. 9 Transfer Car 1 * 1
− 2
10 Cone Crushers 3 3 −
− 6
11 Vibrating Screens 5 5 −
− 10
12 Tailor Unloaders 6 2 2
− 10
3. WAGON TIPPLER
3.1 DESCRIPTION OF WAGON TIPPLER ARRANGEMENT
The wagon tippler consists of gears and units, listed in the general drawing specification 01-PRH1-02-M-
0001.
The rotor is set on the roller supports where it rotates about the horizontal axle. It consists of three ring
disks. These disks on the sides are linked with the beams, and from the bottom side of the left and the
right beam they are connected with the stationary platforms. Due to this the rotor is rigid metal work.
For moving the open wagon into the rotor and stopping it in the required position the rail-road rails and
friction brake devices are installed on the platform.
Inside the rotor a mobile resting wall is set on the levers. The levers are arranged so, that make
parallelogram gears, providing the wall with the ability to fix the open wagons of different width, making

64. flat-parallel motion.
The wall in its turn consists of two parallel set beams hinge – connected.
The wall is moved by the hydraulic cylinders making the whole unit of the hydraulic drive. The eight
cylinders (four on each beam) bring the wall into motion. Each cylinder has a pilot controlled check
valve that locks the cylinder piston space after the open wagon fixing and shutting off the control valve.
On the rotor side beams two clamps are located on each side which fix the unloaded open wagon along
its upper binding.
The clamps consist of horizontal beams, whose support surfaces are lined with rubber plates to prevent
damages of the open wagons. Each beam is hinge connected with two pairs of levers that make the
parallelogram gears. The free ends of the levers are fixed in the hinge supports of the side beams.
Each clamp is moved with the help of two hydraulic cylinders, one side of which is fixed through a hinge
bearing on the side beam of the rotor, the other side is fixed as well, on the load-bearing levers. Each
cylinder has also a pilot controlled check valve, locking to the rod space of the cylinder after the open
wagon fixing and shutting off the control valve.
On the clamps (right), located on the side of the material unloading, are set the fields for the replacing
unloaded material onto the bin grate, apart from the rotor, during start age of unloading.
On the resting wall are located also three vibrators for the forced surface conditioning of the open wagons
from the material sticked to the walls and the floor.
The vibrator unit is an arm with a vibrating beam and the vibrator HB11-50 fixed on it. The arm is hinge
attached to the resting wall with an axle and is pressed to it with springs. During the fixation of the
vibrating beams are pressed out of it, staying pressed to the walls of the open wagon and this provides the
contact of the vibrating beam with the open wagon.
As the resting wall is put on the mobile levers, rested on the hinge bearings, it has undesirable level of
freedom (ability to move lengthwise). To fix it and to prevent from possible movements lengthwise,
between the disks and the face surfaces of the wall roller rests are set.
Two separate tilting drives (left and right) are basic gears of the wagon tippler. Each drive has one drive
gear wheel. The drives are not connected with a rigid shaft; its functioning made by the metal
construction of the rotor that provides necessary rigidity and strength even when one drive operates. The
drives are supplied with shoe brakes with electromagnets of the direct current, and with additional
mechanical fixation of the drive couplings, in case of necessary rotor stopping in an intermediate position
for clearing the open wagons manually.
The rotor rests on the roller supports through the circular rails (tyres). Each support has four rollers,
connected in pairs with balance beams, hinge rested on the general frame. The rollers of the one outer
support are made two – flanged, the others are unflanged. All of them are made of the high – strength
steel 65T and designed for a long term of operating without a change.
Together with the wagon tippler the electro – mechanical fixing arms in the starting position are also
delivered. They are located on the foundations between the rails of the approach ways on the both sides
of the wagon tippler.
The purpose of the fixing arms is a strict alignment of the rails of the approach ways of the platform rails,
and also protecting of the rotor from a casual turning during moving open wagon into it. The fixing arm
consists of the fixing rod with a roll moving in four rolls fixed on the general frame. The fixing rod is put
into motion with a screw ending drive the IIBM type.
 Peripheral unloading system is the specialty of VSP
 18 to 20 Wagons tippled per Hour.
 The tippling process also depends on the availability of stacking streams (stackers, conveyors)

65.  The Wagons are placed in the Tippler with the help of PUSHER CARS.
 Each Wagon Tippler has two pre – tippling lines and one pusher car in each line which are operated
with power supplied from DSL / bus bars.
 Each pusher car has six axles each having a motor of 37 KW capacity and aided with electro –
magnetic brakes.
3.2 OPERATIONAL DESCRIPTION
The wagon tippler operates in the following way :
1. Purposed for unloading open wagons are moved to the wagon tippler with a pusher and one by one
are placed on its platform. Putting the open wagon to a certain position on the platform is made by the
engine – driver assistant visually on the equal distances from the symmetry of the platform;
2. The engine drive of the wagon tipper, after getting the allowance instruction of the assistant, sends
the command to the gears for tipping over. At this moment automatically, in a certain order, unfixing
of the rotor takes, then the clamps lowering, the wall moving, and (after the hydraulic drive operate
finishing) the drives switching as well. The drives of the tippler provide a smooth starting and
smooth stopping of the motor in the rotor in the extreme positions. The wagon tippler construction
makes it possible to turn the rotor to the angle of 175°, to stop it if it is necessary in any intermediate
position.
3. After the rotor is stopped in the tippled over state the vibrators are switched on automatically. The
operating period of the vibrators can be regulated and changed in the interval of 0….10 sec.
4. After unloading of the open wagon the tipping over drive motors are switched to the reverse motion,
and all the gears moving are repeated in the reverse order (the motor returns to the starting position,
the clamps are lifted, the wall is removed, the rotor is stopped). And besides, the switching on of the
clamps takes place at the movement when the rotor turns to 90° as minimum, and the wall removing
is made after the full stop of the rotor.
5. After the rotor returns to the starting position the next open wagon is moved by the pusher and
simultaneously the open wagon pushes off an empty one.
6. In case of not full dump of the open wagon the tipping over procedure is related. And in case of
necessity the cleaning is made manually, and the wagon should be stopped over 90°, the drive is
braked the drive pulleys are stopped, and also the safety measurements for the personnel should be
observed.
3.3 BRIEF ITEMS OF ROTARY WAGON TIPPLER
1. 3 – Rotor Disc
2. Resting Wall
3. Hydraulic Clamp Arrangement
4. Vibrator Units for discharge the total material
5. Rail Alignment System
6. Dust Suppression System
7. Lubrication System
8. VVVF Drives with 30 KW Motor each
9. CCVM System to locate the Wagon in proper position

66. 10. Electromagnetic Brake Arrangement
3.4 PURPOSE & TECHNICAL PARAMETERS OF ROTARY WAGON
TIPPLER
The Wagon Tippler can be used in the coal and raw material handling storage of the intended iron and
steel works, Thermoelectric station as well as in the river and seaports to transfer the granular material
from the railway trains. Technical data and service condition of the wagon tippler are as followings :
Turning angle of the Rotor 175°
Time of open Wagon unloading (Direct and reverse motion) 63 - 75 seconds
General mass with the freight Up to 110 tone
Height from the rail head 2250 - 3735 mm
Width 3078 - 3500 mm
Length according to the Automatic Couplers axles 10715 - 13729 mm
Kind of the Current Alternating Current (AC)
Voltage 415 V
Frequency 50 Hz
Installed Power 88 KW
Overall dimension of the Wagon Tippler – Length X
Width X Heigth
16700 X 9620 X 8720
Expiry operation term before the first overhaul 5 Years
The norms operation term 20 Years
Climate made design T2
Type Rotary Gravity Clamping
Rail Guage 1676 mm (5’ 6” Broad Gauge)
Carriage track 1360 mm gauge
(optional)
Tippling Time per Cycle ( Forward – 30 seconds , Pause – 10
seconds , Backwards – 20 seconds )
Total 60 seconds
Overall dimension of tippler (L – 19800 mm, B – 9600 mm, H
– 8505 mm, L of platform – 16700
mm)
Loading equalizing roller support 3 Nos.
Total no. of rollers 12
Diameter of roller 750 mm
Width of roller working surface 115 mm
Reduction Gear Boxes 2 nos. of Helical Gear Boxes,
Reduction Ratio 40
Open drive Spur straight tooth Reduction ratio
14
Brakes 2 Nos. D.C. Electromagnetic
brakes dia. 500 mm
Prime Motors 2 Nos. slip ring induction motors