Overview of Bokaro Steel Plant

byV. K. GAHLOTAGM (HRD)

Background

• Fourth Integrated Steel Plant in Public Sector,well known as Swadeshi Plant, maximum indigenisation in equipment,materials & know-how

• Originally incorporated as a Limited Company on 29.01.64

• Collaboration agreement with Soviet Union (USSR) on 25th Jan, 1965 ( SAIL Foundation Day)

• After formation of SAIL on 24th January 1973, merged with SAIL on 01.05.78

• Collaboration with the then USSR

• Total area 33,045.35 acres

• Flat Product : HR Coil, HR Sheet, CR Coil, CR Sheet, TMBP, GP&GC

Background• Capacity

– First Phase : 1.7 MT of ingot steel– Second Phase : 4.0 MT of ingot steel– After modernization : 4.5 MT of liquid steel– Enough scope for further expansion (Plan for 7

MT)

• Milestones– Start of construction : 06.04.68– Start of hot metal production : 02.10.72– Completion of 1.7 MT stage : 26.02.78– Completion of 4 MT stage in phases– Start of last modernization : 23.07.93 (completed

in 1997)– Next modernization for 7 MT : Evaluation Process

started

Basic Information Location : Southern bank of ; approx. 50 kms from Dhanbad and 140 kms

each from and Latitude : 230 39' Longitude : 860 09' Altitude : 210 metres (average) varying from 195 to 224 metres Climate : Extreme Annual Rainfall : Average 157 cms; Maximum 195 cms Temperature : Maximum 48½0 Celsius

: Min. 2½0 Celsius Wind direction : South-West to North-East Type of Soil : Loamy up to 1 to 2 metres, sandy soil below that Total land area : 33,045.35 acres Plant, Slag-dump, Cooling

Ponds, Ancillaries, Marshalling Yard

: 17,208.01 acres

Township(including Airstrip) : 10,114.53 acres Garga Reservoir : 3,886.87 acres Railways : 1,835.94 acres

Township

• Located on the southern bank of damodar on North Parasnath Hills

• Area 10,114.53 acres• 10 Sectors • Various amenities in neighbourhoods

– City Centre, Shopping Centres, Schools, Park, Play ground

– 37,472 permanent houses / hostels (incl. 4773 leased out)

• Various types of residential units– A, B , C/C-D , D & E/EF/F

• Maintenance post in each sector• Community Centre / Kalyan Mandap in most of the

sectors

Education• BSL run 42 schools (21 CBSE & 21

affiliated to JSSEB) having around 1200 teachers and 31,000 students

• No fee in JSSEB schools & nominal fee in CBSE schools

• State run 4 schools / colleges and private run 31 schools / colleges with 31,750 students

• Exemplary performance of students in various exams CBSE, ICSE, Engineering, Medical, Management, Civil Services etc.

Medical• 910 bed Bokaro General Hospital with various specialized Units

like Emergency Ward, Intensive Coronary Care, Dialysis, Intensive Burn, Physiotherapy, Rehabitation, Special Baby Care, Nuclear Medicine, Cancer Therapy, CT Scan, ultra modern operation theater, Neuro Surgery etc.

• 10 Health Centre and 4 Primary Health Centres in peripheral areas

• Occupational Health Services Centre inside Plant premises

• A team of around 200 skilled doctors and over 1000 paramedical staff

• Recognition by

– Indian Medical Council for imparting training to Housemen & Interns

– Nursing Council of India for training of Student Nurses

– National Board of Examinations, New Delhi as a Centre for imparting Post-graduate training

Enrichment of Life• Bokaro Ispat Pushtakalaya with a collection of

over 40,000 books.• 6 sector libraries besides central and technical

libraries.• City park with boating facility and lake view

restaurant.• J.N. Biological Park• Welfare Schemes: Family Benefit Scheme,

Group Insurance Scheme, Co-operative Credit Societies

UTILITIES & SERVICES

WATER SUPPLY - GARGA DAM & TENUGHAT DAM

POWER SUPPLY

DVC CHANDRAPURA - 200MVA (Contract)

Bokaro Power Supply Co. Ltd.

- 1 x 12 MW (back pressure)

2 x 55 MW

3 x 60 MW

Total Road length 392 Kms.

Sintering Plant

BF1 BF2 BF3 BF4 BF5

Blast Furnace

300 TCon-1

300 TCon-2

Steel Melting Shop - 2Steel Melting Shop - 1

130TCon-1

130 TCon-2

130 TCon-3

130 TCon-4

130 TCon-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

ReheatingFurnace

SAILBokaro

Pig Casting Machine

H R C F

PROCESS FLOW

BF Coke

Coking Coal

Coke Breeze

PL-II

PL-I

ANNEALING CRCF

COKE OVEN BATTERIES

DCR Mill

Slabbing Mill Hot Strip Mill

Iron Ore, Lime Stone & Dolomite Fines

Commissioning dates and Capacity of Major Units

Unit Date of Commissioning

Number Capacity (MT)

Product

Agreement with UUSR 25 Jan, 1965

Coke Ovens Sep'72 – Dec'85 8 Batteries of 69 Ovens 3.48 BF Coke

Sinter Plant Sep'72 – Dec'82 3 Machines of 252 m2 area 6.20 Skip sinter

Blast Furnaces Oct'72 - Jun'85 5 furnaces of 2000 m3 volume 4.585 Hot Metal

Steel Melting Shop I Jan'74 – Dec'78 5 LD converters of 130 T 2.20 Ingot Steel

Steel Melting Shop II Jun'83 - Jan'85 2 LD Converters of 300 T 2.25 Liquid Steel

Continuous Casting Sep'97 - Mar'98 2 Double Strand casting m/c 2.16 Cast Slab

Commissioning dates and Capacity of Major Units

Unit Date of Commissioning

Number Capacity (MT)

Product

Slabbing Mill Dec'74 8X4 Soaking pits of 160 T & one 1250 mm universal Slabbing Mill

1.90 Rolled slab

Hot Strip Mill Dec'75 4 reheating Furnaces, 5 roughing & 7 finishing stands

3.36 HR Coil

Hot Rolled Coil Finishing

Jan'76 2 Shearing line 1.1 HR Plate/Sheet

Cold Rolling Mill 1 Jun'77 Pickling Lines, Tandem Mills Saleable CR

Cold Rolling Mill 2 Sep'91 Annealing Lines, Skin Pass Mills-2, Temper/DCR Mill-1, Shearing lines-5, Slitting lines-3 & Hot Dip Galvanising Complex -1

1.66 Product CR coils/Slit coil/ sheet, slit coil, Black Plate,

GP&GC

Raw Materials coming from Mines

Wagon Tippler – Tippling a wagon

ORE HANDLING PLANTBasic 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 5 Barrel Type Reclaimers - 1000 T/Hr each 1 Bucket Wheel Type Reclaimer - 500 T/Hr 2 Transfer Cars, 10 Shuttle Conveyors, 11 Cranes, 8

Telphers

Sources of Raw Material

Material No. of Beds

(240 M)

Stock

No of Days

Source

Iron Ore Lump 4 24 Kiriburu, Meghataburu, Bolani, Barsua

Iron Ore Fines 6 16 Kiriburu, Meghataburu, Bolani, Gua

Lime Stone

BF Grade

4 13 Bhawanathpur, Khanabanjari, Purnapani

Lime Stone

SMS Grade

2 ½ 21 Kuteshwar, Jaisalmer, Nanwara

Dolomite Lump 16 Bhawanathpur Birmitrapur, Tulsidamar, Sonakhand

Dolomite Chips 50 Bhutan, Salwari

Sources of Raw Material

Material No. of Beds

(240 M)

Stock

No of Days

Source

Manganese Ore ½ Barbil, Banspani

Imported Coal Autralia, NewZealand , Haldia, Paradeep, Vizag

Prime Coking Coal 46 Dugda, Munidih, Jamadoba, Belatand

Medium Coking Coal Silos Kathara, Kedla, Rajrappa, Mahuda, Swang

Coal Middlings for Power Plant 38 M high, 12mm dia

2500T 7 Kathara, Rajrappa, Kedla, Swang, Giddi, West Bokaro, Kargali, Mahuda, Dugda, Katrasgarh etc.

Coke Oven Battery

Quenching of Coke

Coke Ovens• 8 Batteries of 5 meter height, 69 Ovens each• The process of coke making consists of destructive distillation of coal in

absence of air. The phenomenon is called high temperature (above 12000c -13000c carbonisation of coal

• Volatile matters are driven out leaving behind the residue called COKE• By-Product Plant: - Gas Condensate Section - Ammonium Sulphate Plant - Benzol Recovery Plant - Tar Distillation Plant - Sulphuric Acid Plant• Desired Analysis vs Indian Coals:

Desired Analysis

Indian Coals Imported Coals

Ash% < 16 19-24 3-12 (Av 9)

Volatile Matters%

> 25 24-26 19-28 (Av 23)

Moisture% 7-9 7-8 8-11 (Av 9)

Sulphur% < 0.05 0.56 < 0.05

Phosphorus% < 0.05 0.09 < 0.05

Material Flow Diagram : Coal & Coke

Coking CoalFrom

Various SourceWagons Coal Handling Plant

Coke Sorting Plant Coke Battery ( 8 Nos.)

Blast FurnaceCoke

+ 25 -80 mm

NutCoke

CokeBreeze-15 mm

Blast Furnace

Coke Oven Gas

By Product Plant

Sinter PlantSold

By-Product PlantIt consists of : • Gas Condensate Section • Ammonium Sulphate Plant• Benzol Recovery Plant• Tar Distillation Plant • Sulphuric Acid Plant

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

All by products of By Product Plant are sold through e- auction.

Tech-economic factors

CO Gas yield : 325.0 Nm3 / TDC

Coke Rate --- : 505.0 Kg / THM

Sp. Heat Consumption : 0.583 Gcal / TDC

Sp. Power consumption : 29.50 KWh /Ton of BF Coke

Ammonium Sulphate yield : 10.50 Kg/ TDC

Crude Tar yield : 30.80 Kg/ TDC

A view of Sinter belt

Sintering Plant• 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 Siter belt is 252 sq.m.• Productivity of Sintering Band : 1.2 T/M2/hr• Three Sectionsa) Raw Material Sectionb) Stock Bin & Proportioning Sectionc) Sinter Machine Section

Cleaned Water

Hot Rolling Mill Refractory Mat Plant Ore Handling Plant Coke Ovens

Raw Mat Section

Iron OreFines, LimeStone,Dolomite, Sand

Stock Bins

LimeStone Fine ,Coke Fine, Dolomite Fine

Lime Dust Fine

Waste Bins Section

Lime Dust Coarse

Mill Scale Coke Breeze

Mill Scale, Flue Dust, Lime Dust Coarse Mixed Raw Charge

Palletizing/Balling Drums

Raw Charge(Moist & Balle)

Sinter Machine Building

Blast Furnace Deptt

Slime Thickening

SectionLime Sludge

Hot Sinter Return

Cold Sinter Return

Sinter

Material Flow Diagram

Sintering Plant

Return Sinter to Stock Bin

Flue dust to waste bin

Screened coke return to raw material section

Raw material sinter

Technical Specifications of some critical equipments

Sl.no Name Quantity Capacity Installation Area01 Hammer crushers

05 250 ton/hour Raw material

02 Coke crusher 08 16 ton/hour Raw material03 Flux Screen 10 150 ton/hour Raw material04 Sinter Machine 03 300-450 ton/hour M/c building05 Sinter area 252 square metre M/c building06 Pallets 130 in each m/c M/c building07 Vacuum chambers 26 in each m/c M/c building08 Exhausters 6nos(2nos/m/c) 12000 m3/minute M/c building

Technical Specifications of some critical equipments

Sl.no Parameters Norms Actual in 2007-08

01 Specific fines consumption 1093kg/t of hot metal 1025kg/THM

02 Specific flux consumption 255 kg/THM 244kg/THM

03 Specific Coke consumption 85 kg/THM 86kg/THM

04 Specific Power consumption 45KWH/Tgross sinter 48.33KWH/TGS

05 Specific Heat consumption 0.024Gcal/TGS 0.025Gcal/TGS

A view of Blast Furnace

A Closer view of Blast Furnace

Blast Furnace• The iron oxide of ore and sinter is reduced to iron with

the help of carbon monoxide & Coke• Functions of coke in BF are manifold. It provides strong

porous bed to burden and supplies the heat load. Part of the heat load is supplied by the hot air blast

• 5 Furnaces each of 2000 cubic meter useful volume and 2640T/day HM capacity

• All furnaces have Bell-less Top charging System for continuous charging & better distribution of charge

• Coal Dust Injection in Fce.# 4 & 5• CHSGP in Fce. # 4 & 5• Capacity of B F 4.585 MT of Hot Metal per annum• Hot Metal Temperature 1460-14800C• BF Productivity: 1.4 T/m3/Day• Coke Rate 520 Kg/THM

MATERIAL FLOW DIAGRAM FOR BLAST FURNACESintering

Plant

Dust catcherIn BF

Gas Cleaning Plant

RM & MHP

SP

ProcessSteam

Net work

Stove of BF

ChargingSection

ofBlast

FurnaceCoke Ovens

ForSale

Pig Casting M/C

ForDistribution

Mixer of SMS

IMF

Slag DumpYard

TBS

BFCHSG/SGP

Blast Furnace

Hot Metal

Iron Ore Lime Stone

Mn Ore

Sinter

Coke

Slag Granules for Sale

Raw BF gas Flue Dust

Cleaned BF Gas

Partially Cleaned BF Gas

Iron Ore(Lump)

Lime Stone, Mn Ore, Quartzite

Sinter

Coke

Cold Pig

Process Steam

Hot airCold air

Slag

Quartzite

Hot Metal being charged into the converter

BF

SSD

RMP

FAS

HOT METAL

O2 Plant

BMS

SCRAP

LIME

IRON Ore, BAUXITE, Mn Ore, Lime Stone

Fe-Mn, Fe-Si

99.5 % pure O2

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 suppresed consumption system

• Lining life : SMS-I = 800 – 1000 heats

SMS-II = 2000 – 2500 heats

Concast Slab coming out of Caster

Continuous Casting Shop

• Two Twin strand curvilinear casters with capacity to produce 2.16 MT of Slabs

• Steel Refining Unit (SRU) with LF/LRS for treatment of steel before casting

• On-line slab cutting • Steel Killed with Al/Si to O2<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• Slab Produced

- Mild Steel : DD, EDD, Bioler Plate etc.- Low Alloy Steel : LPG, WTCR, SAILCOR & API grades

Slabbing Mill• 12 groups of Soaking pits with each group

having 4 pits ; total 48 pits wherein ingot are heated to a temperature above 13000C

• On line hot & cold scarfing M/c for surface scale/defect removal

• One 1250 mm Roll dia 2-high Reversible Universal Mill to produce slabs of thickness 150-300 mm, width 950-1850 mm and length 2.5 – 10.5 mtr.

• 2800 Ton Hydraulic Shear (6 cuts/min)• 4MT Capacity (Rolling Rate 600-800T/Hr)• Main Sectionsa) Ingot Storage Yard b) Soaking PitC) Mill Proper d) Slab Storage Yard

Reheating Furnace of HSM

Strip Coming out of Finishing stands

Hot Strip Mill• Hot Rolling involves plastic deformation

of a metal under squeezing force (a pair of Rolls) above its re-crystallization temperature.

• This mill is designed to roll thin & wide strips for use in various industries such as wagon building, tube & pipe industry, drum & furniture manufacturing and further rolling in Cold Rolling Mill

• 3 Walking Beam Reheating Furnaces & 1 Pusher type furnace

• Vertical Scale Breaker• 5 Roughing Stands, 7 Finishing Stands• Hydraulic AGC in last four Strands

• 4 Hydraulic Coilers with automatic strapping & Robot marking

• Capacity: 3.955 MT of HR Coils• Coil Dimensions

– Strip thickness 1.6 to 16.0 mm

– Strip Width 910 to 1,850 mm– Coil inside dia 650 mm– Max Coil outside dia 2,300 mm– Max coil weight 32 T

• Rolling Speed: 20 m/sec Max.

Hot Strip Mill

Material Flow Diagram of HSM

Slab yard

Furnaces

Furnaces

VSB R1 R2 R3 R4 R5F. Shear

F6

F7

F8

F9

F10

F11

F12CC CC

CoilersFinishing Stands

Roughing Stands

Hot Roll Coil Finishing (HRCF)

•Functions : To shear the coils into plates and sheets

•Facilities : •Shearing Line I : 5-10x1800 mm, 2.5-12 mtr. plates capacity 6,45,000 T/year

•Shearing Line II : 1.6-4x1500 mm, 1.5-4.5 mtr length sheets capacity 4,75,000 T/year

•Slitting Line : 1.5x8x1800 mm, 150mm Min. width capacity 4,00,000 T/year

•Maximum Pkt. Wt.: 15 T

5-Stand Tandem Mill

Zinc coating on Cold Rolled Coil - HDGL

Cold Rolling Mills• Cold rolling is done to produce thinner gauge strip of

smooth finish with better mechanical properties than those obtained by Hot Rolling

• Uses : Automobile Bodies, Steel Furniture, Drum & Barrels, bending and shaping applications.

• Capacity: 1.66 MT of CR saleable

• CRM I: H2So4 Pickling Line, 4-Stand Tandem Mill (2-4.5mm

thick into 0.63-2mm thick) Annealing Furnaces, SPM-I & SPM-II, Shearing Line I & II, Slitting Line and Shipping-I

• CRM II: HCl Pickling Line, 5-stand Tandem Mill (1.4-2mm thick into 0.63-1.6mm thick) , ECL, CAL, DCR Mill, HDGL and Shipping-II

• Besides Continuous Annealing furnace103 Annealing Furnaces and 230 Bases are available in three areas. Annealing is done at 680-7200C in inert atmosphere (95% N2+5%H2) with the help of mixed Gas of 1550-1600 CV

GC Sheets

Services Department

PPC & SC : Coordination of plant operation and prodcution plant as per market demand.

R&C Lab : Chemical, Metallurgical, Inspection, R&D, a Network Testing Lab

Engg. Shops : Machine Shop, Structural Shop, Forge Shop, SF, IMF, ICF

Energy Mgmt.

: CDI in BF, CCS, Walking Beam Reheating Furnace

Envt. Mgmt. : - Installation of ESps in SP, BoD Plant- Recycling of Flux, Dust. Mill Scale, Lime Dust, LD Slag- Plantation of 42 lakh trees- BSL certified under ISO 1400 : 2004 EMS

Safety and Fire Services

: BSL certified under OHSAS 18001

Quality Assurance

: Major Units, Shops, Non-Works Deptt. Certified for ISO 9001 :2000 QMS

SA 8000 : Social Accountability Certification

Services Department

HRD :

• Management and Technical Development • In-house and External Training• Training for Safety, Housekeeping, Maintenance Operation, Project, QC• Communication Exercises• Quality Circle• Suggestion Scheme etc.

CSR : • Peripheral Development (Bokaro Steel Gramin Vikas Yojana)• Free Health Check up (Bokaro Steel Sarva Swastha Yojana)• Free Education and Scholarship (Bokaro Steel Shiskha Protsahan Yojana)

Other HRD Activities

Ancillary Development• Bokaro Industrial Area Development

Authority (BIADA)– 253 SSI Units registered with BSL– 81 accepted as Ancillary Units

• Various Concessions/Exemptions in– Tender cost, earnest money, security

deposit etc. – Price matching and purchase preference – BSL Laboratories offers testing facilities,

help in developing new designs and products and awareness on ISO 9000 System

• Last Modernization– Con-cast facilities integrated with SMS-II

• Ladle Furnace & Ladle Rinsing Station for Secondary Refining• Two Double Strand Slab Caster

– Up-gradation of Hot Strip Mill including• Change of Pusher Type Reheating Furnaces to Walking Beam

Type• Quick Work Roll Change System• Addition of fourth Coiler

• Next Phase Modernization (by 2010-11)– New SMS-III with 3.8 MT Capacity

• 3 x 160T Converters with 3 x 160T Ladle Furnaces & Degassing facilities

• 2 Single Strand Thin Slab Casters (1.2 MT each) & 1 conventional Slab Caster (1.4 MT)

• 7- Stand Compact Strip Mill & new Coil Yard – New CRM-III with 1.2 MT Capacity

• Coupled Pickling and Tandem Mill • ECL, Bell Annealing Furnace (100% Hydrogen Annealing)

Galvanizing Line with Galvanneal facilities

• Up gradation of 3 BF to 4900T/day capacity by enhancing volume from 2000 to 2365 M3 and installing CDI & CHSGin all BFs (presently 4&5 only)

• Sintering Area 252 m2 to 312m2 and productivity 1.2T/m2/hr

• Rebuilding of 3 CO batteries, computerised combination control system etc.

• Conversion of H2S04 PL-I to HCL Pickling Line• Enhancing capacity of SMS – II from 2.16 to 3.12 MT by

schemes• Addition of O2 generating capacities

Result of Expansion

Sl. No. Description Capacity

1. Hot Metal (MT) 7.44

2. Crude Steel (MT) 7.00

3. Saleable Steel (MT) 6.53

4. Yield of Saleable Steel from Liquid Steel (%)

91.4

5. Specific Energy consumption (Gkcal) 5.5

6. Coke rate Kg/THM 395

Ingredients 2006-07(Rs/Ton)

2007-08(Rs/Ton)

% Change

2008-09(Rs/Ton)

% Change (from 07-08)

Imported Coal

6970 6346 -9 16700 163

Indigenous Coal

3844 4159 8 6500 56

Coke 11977 11584 -3 30000 158

Ferro Alloy 42000 49000 16 87600 79

Comparative Statement of Purchase/Production Cost

Thank You