A 45 days observational training program that gave exposure to the industrial environment and included visit to various plants like RHMP, Coke Oven, Steel Making Units, Blast Furnace which was a learning experience pertaining to the functioning of all the mentioned units.

1. BOKARO STEEL PLANT
SUBMITTED BY:- GAURAV VERMA
ID:-2012UMT1719
BATCH:-T-3
OBSERVATIONAL TRAINING AT
SAIL,BOKARO

2. Introduction
 Steel Authority of India Limited, Bokaro
(SAIL,Bokaro) is the fourth integrated plant in
the public sector- started taking shape in 1965 in
collaboration with the Soviet Union. The plant is
hailed as the country’s first Swedish steel plant,
built with maximum indigenous content in terms
of equipment, material ,etc..,. Its first Blast
Furnace started on 2nd October 1972 and 1st
phase of 1.7MT ingot steel was completed on
26th Feb. 1978 with the commissioning of the 3rd
Blast Furnace.

3. Products
 Bokaro is designed to produce flat product like hot rolled coils, hot rolled plates,
hot rolled sheets, cold rolled coils, cold rolled sheets, tin mill black plates
(TMBP) and galvanized plain and corrugated (GP/GC) sheets.
 Bokaro has provided a strong raw material base for a variety of modern
engineering industries including automobiles, pipe and tube, LPG cylinder, barrel
and drum producing industries.

4. INDEX
 Raw Material Handling Plant (RMHP)
 Coke Oven & By Product Plant (CO & BPP)
 Sinter Plant (SP)
 Blast Furnace (BF)
 Steel Melting Shop
 Hot Strip Mill (HSM)
 Machine Shop

5. RMHP’s Raw Materials sources

6. Raw Materials
Iron ore fines Iron ore lump
Lime Stone pallets
sinter
Hard coke

7. Raw material handling plant( RMHP )
 Basic functions:
 Receive different raw materials from various mines through wagons and their unloading & stacking
with the help of tipplers & stackers.
 Blend raw material by making layers in beds & cross section-wise cutting beds by re-claimer.
 Keep buffer stock to take care of irregularities and supply raw materials to different units as per
their requirements.
 Basic facilities:
 4 rotary wagon tipplers - 20 wagons/hr each
 7 twin boom stackers - 1200 t/hr each
 1 bucket wheel type reclaimer - 500 t/hr
 5 barrel type reclaimers - 1000 t/hr each
 2 transfer cars, 10 shuttle conveyors, 11 cranes, 8 telphers.
 A wagon can rotate from 0-172° during tippling process.
 Unlocking time provided for one railway rake = 4 hours
 Rate of unlocking = 59 wagon*65 tones/4hours = 950 tones/hour

8. WAGON TIPPLER

9. RMHP’s CUSTOMERS

10. Coke Oven & By Product Plant (CO & BPP)
 In Coke Oven Plant ,coal is converted into coke by heating the
prepared coal blend charge in the in the coke ovens in the absence of air
at temperature of 1000 -1100°c for period of 16 – 19 hours.
 The volatile matter of coal liberated during carbonization is collected in
gas collecting mains.
 Gas cooled from 800 to 80°c is draw to coal chemical plant by
exhauster .
 Residue coke is pushed out of the oven by pusher car through a guide
into coke bucket.
 The Primary by-product from crude coke oven gas are Ammonium
sulphate ,crude tar, crude Benzol and cleaned coke oven gas.
 The size of Blast furnace coke is +25 -80, Nut coke +15 -25, Coke
breeze +0 -15.

11. Production flow diagram

12. By Products
 PRODUCTS PRODUCED FROM BY PRODUCT PLANT.
 N G BENZOL
 N G TOLUENE
 XYLENE
 L S NAPTHA
 S B OIL
 PCM
 ROAD TAR
 COAL TAR WASH OIL
 EXTRA HARD PITCH
 HARD MEDIUM PITCH
 HOT PRESSED NAPHTHALENE

13. CAPACITY :- 2500 TONES
HEIGHT :- 38 METER
DIAMETER :- 12 METER
TOTAL NO. OF BATTERY:-8
NO OF OVEN IN A BATTERY:-69
HEIGHT:- 5 METER
LENGTH:- 15METER
CAPACITY :- 5000 TONES
SILO BATTERY WAGON PUSHER CAR CONVEYER BELT

14. Sinter Plant (SP)
 3 Sinter Machines: Capacity 6.25 million toNnes per annum
 Sintering is the process where incipient fusion takes place by combustion of Coke within
moving bed of loosely packed fines of mainly Iron ore, Coke & Flux so as to agglomerate into
a compact porous mass called Sinter.
 75-80% Sinter is being used in the burden of BF
 Area of each SiNter belt is 252 sq.M.
 Productivity of Sintering Band : 1.2 T/M2/hr.
 Three Sections
a) Raw Material SectioN
b) Stock Bin & Proportioning Section
c) Sinter Machine Section
A view of Sinter belt

15. Blast Furnace (BF)
 5 blast furnaces in BSL.
 Each of 2000 cubic meter useful volume and 2640 T/day
Hot metal capacity
 Hot metal temperature 1460-14800C
 BF productivity: 1.4 T/m3/day
 Capacity of B F 4.585 MT of hot metal per annum
 A top pressure of 1.60(maximum=1.80) bar
is maintained at upper zone of the blast furnace to utilize co,
which is comes out from blast furnace.

16. MATERIAL FLOW DIAGRAM FOR BLAST
FURNACE

17. Sintering Plant
BF1 BF2 BF3 BF4 BF5
Blast Furnace
300 T
Con-1
300 T
Con-2
Steel Melting Shop - 2
Steel Melting Shop - 1
130T
Con-1
130 T
Con-2
130 T
Con-3
130 T
Con-4
130 T
Con-5
Tandem Mill-1
Tandem Mill-2
Soaking Pit
ll
SPM 1 & 2
Hot Dip Galvanizing Line
Galvanized Sheet Shearing Line
Galvanized Sheet Corrugation Line
HR Coil
HR PLATE /
SHEET
CR Coil
CR Sheet GP Coil
Galvanized Corrugated
& Plain Sheet
Iron Ore
Fluxes
O H P
Continuous
Casting
Department
Reheating
Furnace
SAIL
Bokaro
Pig Casting Machine
H R C F
PROCESS FLOW
BF Coke
Coking Coal
Coke Breeze
PL-II
PL-I
A
N
N
E
A
L
I
N
G CRCF
COKE OVEN BATTERIES
DCR Mill
Slabbing Mill Hot Strip Mill
Iron Ore, Lime Stone
& Dolomite Fines

18. Steel Melting Shop
 SMS-I: 5 converters each of 100/130t capacity, 2 mixers each of 1300 t capacity (rated
capacity 2.5 MT/yr).
 SMS-II: 2 converters each of 300 t capacity, 2 mixers each of 2500 t capacity (rated capacity
2.25 MT/yr).
 Total capacity 4.5 MT of liquid steel.
 Oxygen of high purity(99.9 %) is blown into the converter from the top through water
cooled lance so as to remove the impurity of hot metal through oxidation.
 Impurities of Si, C& P are oxidised and forms slag with lime.
 Killed, semi-killed and rimming steels are made.
 SMS-II has got suppressed consumption system.
 Lining life :
 Sms-I=800-1000 heats
 Sms-II=2000-2500 heats

20. CONTINUOUS CASTING SHOP
 Two twin strand curvilinear casters with capacity to produce 2.16 MT of slabs
 Steel refining unit (SRU) with LF/LRF for treatment of steel before casting
 On-line slab cutting
 Steel killed with Al/Si to 2<5ppm + argon purging sulphur reduced <0.015%
 Slab size : thickness : 200, 225 & 250 mm
 width: 950-1850 mm
 Length: 9-10.5 mtr.
 Mgo lined tundish of 50 t capacity
 Tundish capacity = 50 t
 Slide gate system

21. Final product from continuous casting shop-- slab

22. Hot Strip Mill (HSM)
 Hot rolling involves plastic
deformation of a metal under
squeezing force (a pair of rolls)
above its re-crystallization
temperature.
 Designed to roll thin & wide strips
 Capacity: 3.955 MT of HR coils
 Rolling speed: 20 m/sec max.

23. Machine Shop
PLANER MACHINE GEAR CUTTING MACHINE

24. LATHE FORGING MACHINE

25. FORGING OPERATION

26. Conclusion
 My 45 days industrial attachment with SAIL Bokaro was one of
the most interesting, productive and instructive experience in my
life. Through this training, I have gained new insight and more
comprehensive understanding about the real industrial
working condition and practice. All these valuable experiences and
knowledge’s that I have gained were not only acquired through the
direct involvement in task but also through other aspects of the
training such as : work observation, interaction with collogues,
supervisor and other people related to the field. All students are
advised to be sincere, honest and punctual during the training
period.

27. THANK YOU