SUMMER TRAINING AT BHILAI STEEL PLANT

A SUMMER TRANING

REPORT ONBHILAI STEEL

PLANTBY: SHARANYA MENON

DEPARTMENT OF ELECTRICAL AND ELECTRONICS

RCET, BHILAI

◦INTRODUCTION◦ACHIEVEMENTS◦DEPARTMENTS WHICH WERE ALLOTED:SAFETY TRAINING

STEEL MELTING SHOP

PLATE MILL

CONTENT

INTRODUCTION:• The Bhilai Steel Plant, located in Bhilai, in the Indian state of

Chhattisgarh, is India's first and is one of the largest steel plants. It has an installed capacity of more than 4 million tons of crude steel per year and covers an area of about 36 sq. KMs. It was built by RUSSIAN COLABORATION.

• BHILAI STEEL PLANT is the main producer of steel rails, as well as a major producer of wide steel plates and other steel products. The plant also produces and markets various chemical by-products from its coke ovens and coal chemical plant.

• SAIL is India’s largest steel producing company with a turnover of 48,681 cores. The company is among the top 5 highest profit earning corporates of the country. SAIL steel is widely used by sectors such as defense, railways, construction, automotive etc.

• Nine times winner of Prime Minister’s Trophy for best integrated Steel Plant in the Country, Bhilai Steel Plant is India’s sole producer for the rails and heavy steel plates and major producer of structural. The Plant is sole suppliers of the country’s longest rail tracks of 260 meters. With an annual production capacity of 3.153 MT of saleable steel, the plant also specializes in other products such as wire rods and merchant products. Since BSP is accredited with ISO 9001:2000 Quality Management System Standards, all saleable steel products of Bhilai Steel Plant come under The ISO umbrella.

• At Bhilai ISO: 14001 have been awarded for Environment Management System in the Plant, Township and DALLI MINES. It is only Steel plant to get certificates in all these areas.

 • The captive mines of the plant located at Dalli-Rajahara supplies

iron ore and lime stone used to be available from Nandini captive mines. At present lime stone is procured from outside. The other major raw material, coal is purchased from outside either through import or from indigenous market.

ACHIEVEMENTS OF BSP:• SAIL was featured in the 2008 list of Forbes Global 2000 companies at

position 647.

• SAIL was adjudged best PSU and conferred with Business and Economy Leadership and Excellence Awards 2008 by Planman Media.

• BSP won CII Sustainability Award – 2008 in independent unit category.

• Greentech Safety Gold Award by Greentech Foundation for outstanding achievement in Safety Management to Bhilai Steel Plant.

• Golden Peacock Award for Combating Climate Change – 2008 for BSP.

• National Safety Award to Bhilai Steel Plant announced by the Ministry of Labour & Employment, Government of India – 2008.

• Ispat Bhasha Bharati. The Rajbhasha Journal of SAIL has been awarded with the first prize under the All India House Journal Award Scheme - 2008-09.

• Golden Peacock Award for Corporate Social Responsibility won by Bhilai Steel Plant (BSP) for the third year in a row – 2009.

Type State owned enterprise public

Industry

Type

Steel

Public Sector IndustryFounded 1954Headquarters

Bhilai, Chhattisgarh, India

Products Steel, flat steel products, long steel products, Wire Products, plates

PROCESS FLOW AT BSP:-

SAFETY TRAINING:-• A Safety Training Workshop was conducted for Trainees at

HRDC of Bhilai Steel Plant, to make us understand the safety measures to be taken inside the factory.

 • The prime objective behind holding the workshop was to

ensure the safety of trainees and ensuring all the safety measures at the places of work while introducing an ideal work culture in the process. At this point we were made to understand safety of people should be the top priority.

• It was also elaborated the various provisions of Factory Act while stressing on their significance in the industrial scenario.

• The plant officials said that although BSP is committed for improving production, productivity, profit, cost control and also the welfare of employees, but it is equally concerned for ensuring the safety of its regular employees and also that of the contract workers and trainees.

• Here, we were also made to know about the basic introduction about the plant, it’s working process, achievements, accidents that took place and the reforms were made according to it, also about the basic work culture and the vision of the plant.

• We were made aware about the scope of the core as well as other branches in this sector.

 • The basic work ethics were explained and made the session to be a

motivation for everyone.

STEEL SMELTING SHOP:-•ANNUAL PRODUCTION PLAN/ACTUAL PRODUCTION

Main Facilities of S M S-1 :-

• 4 Nos. Twin Hearth Furnaces• Bulk charge yard• Ferro Alloy yard• Mould yard• Slag yard• Stripper yard• Magnetic yard• 2 Nos. Mixers(1300 ton each)

Process of Steel Making:- • First of all 50 tons scrap is added in the bottom of Furnace• 10 tons limestone is added.• 200 tons of hot-metal is charged from charging side through chute.• Then O2 is blown through lance.• Blow is finished after 1hr-45 min of blowing, with 1650ºC and bath

carbon below 0.10• After taking sample and temperature, re-blowing is done for

chemistry and temperature.• Metal is tapped in the preheated ladle provided by pit side.• Ferro Alloys are added as per requirement with the help of crane• Final sample and temperature is taken.• Then ready metal is tapped in the pre-heated ladle provided by pit

side.• Steel is sent to pit side for teeming into moulds.

PLATE MILL :-

•The modern Plate Mill rolls out heavy and medium plates, as well as those for pipe

manufacturers. Plates of wide variety, in any required size, and strength, chemical and

physical properties, can be produced here.

•It has capacity to produce high pressure, boiler quality and high tensile steels.

•Shipbuilding plates, conforming to Lloyds specifications, and pressure vessel boiler

plates, conforming to various ASTM, ASME standards, have withstood the challenges

of nature and time. Some of the unique features of the mill are on-line finishing

facilities and off-line normalising facilities.

Capacity - 9,50,000 T

Plates thickness - 8-120 mm

Width - 1500-3270 mm

Length - 5-12.5 M

•Bhilai has the widest plate mill in the country, and it uses continuously cast slabs as

input. Liquid steel produced under controlled conditions in the LD Converters is

rinsed with argon gas to homogenise the composition as well as to remove non-

metallic inclusions before continuous casting so as to ensure the production of high

quality feedstock for the Plate Mill. As per customers' requirement or specifications,

plates are normalised in a roller hearth normalising furnace.

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