Training Report PRASAD

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<p>NATIONAL INSTITUTE OF TECHNOLOGYSRINAGAR</p> <p>DEPARTMENT OF METALLURGICAL ENGINEERING VIZAG STEEL PLANT TRAINING REPORT</p> <p>Submitted By:Kalikota Prasad, 5th Metallurgy, En Roll: 202/07, NIT Srinagar.</p> <p>CONTENTS</p> <p>1. ACKNOWLEDGEMENT</p> <p>2. INTRODUCTION</p> <p>3. MAJOR DEPARTMENTS IN VSP</p> <p>4. METALLURICAL POINT OF VIEW</p> <p>A. R M H P (RAW MATERIAL HANDLING PLANT) B. CO &amp; C C P (COKE OVEN AND COAL CHEMICAL DEPT) C. SINTER PLANT D. BLAST FURNACE E. STEEL MELTING SHOP F. Q A &amp;TD (QUALITY ASSURANCE AND TECHNOLOGY DEVELOPMENT) 5. FLOW CHART</p> <p>ACKNOWLEDGEMENT</p> <p>With profound respect and gratitude, I take the opportunity to convey my sincere thanks to the management of VISAKHAPATNAM STEEL PLANT (VSP), VISAKHAPATNAM for giving me an opportunity to undergo industrial training in their plant.</p> <p>We are grateful to Mr. J.PRABHAKARA RAO (Jr.Manager, Training and Department - VSP) for his support during the training at VSP. And also the technical staff, Sr. Superintendants, foremen, at various shops, who helped me to gain valuable practical knowledge that will help me in becoming a successful engineer in near future.</p> <p>Also, I offer my sincere thanks to Prof. M. A. Baba, Head of Dept,(Training and Placement),and Prof R.Ambardar, Head of the Dept, (Metallurgy), National Institute of Technology, Srinagar, for providing me with a good reference, without which I could have never got this opportunity.</p> <p>Yours SincerelyKalikota Prasad,</p> <p>5th Metallurgy, En Roll: 202/07, NIT Srinagar.</p> <p>INTRODUCTIONRashtriya Ispat Nigam Limited (RINL) is the corporate entity of Visakhapatnam Steel Plant. Visakhapatnam Steel Plant (VSP), the first coastal based Steel Plant of India is located, 26 Km south west of city of destiny i.e Visakhapatnam. Bestowed with modern technologies, VSP has an installed capacity of 3Million Tonnes per annum of liquid steel and 2.656 Million Tonnes of saleable steel. At VSP there is emphases total automation, seamless integration and efficient up gradation, which result in wide range of long and structural products to meet stringent demands of discerning customers within India and abroad. VSP has become the first integrated Steel Plant in the country to be certified to all the three international standards for quality (ISO-9001), for Environment Management (ISO- 14001) &amp; for Occupational Health &amp; Safety (OHSAS-18001).The certificate covers quality, systems, of all, operational , maintenance, service units besides Purchase systems, Training and Marketing functions spreading over 4 regional marketing offices, 20 branch offices and 22 stock yards located all over the country. The product profile of the plant comprises of wire rods, Rounds, reinforcement angles, channels , beams, squares, billets and blooms. The product profile also includes basic grade pig iron, granulated slag, coal chemicals and other by-products. The plant also exports power to AP Transco from its captive Thermal power plant. The steel plant has many technological features, which are unique amongst the steel plants in the country. The company is a pioneer in introducing many new technologies in the country. The production of TMT rebars by temp core process is a shining example in this respect. Because of high level of technology existing throughout the plant, the company has a ve ry good manufacturing capability to meet the needs of various customers. VSP exports quality Pig iron &amp; steel products to Sri Lanka, Myanmar, Middle East, USA, Southeast Asia (Pig iron). RINL- VSP was awarded Star Trading House status during 1997- 2000Having a total manpower of about 16,613 VSP has envisaged a labour productivity of 265 Tonnes per man year of Liquid Steel which is the best in the country and comparable with the international levels.VSP has achieved hi ghest carpenter life of hearts per campaign during January 2008 and best specific energy consumption of 6.08 G cal / TLS during 2005- 06 and maximum labour productivity of 414 T/Man year during 2005 -06 in pursuit of excellence.</p> <p>MAJ R EPAR ME C Ovens &amp; C l C emi l Pl nt</p> <p>C ing coal after selective crushing and proper blending is subjected to destructive distillation (heating in the absence of air) in the Coke Ovens. After heating for 0 nearl a period of 16- 18 hours at a temperature of about 1100 C coke is obtained and is used as a fuel as well as reducing agent in the Blast Furnace. The Coke Ovens of VSP are engineering feats by themselves. They are the tallest ovens metre constructed in the country. The Plant has 3 batteries of 7mtr.Tall ovens with each battery consisting of 67 ovens. Another feature is the dry cooling of coke carried out by the inert gas nitrogen thus; reducing pollution considerably. Besides a Bio-chemical plant it separately undertakes the treatment of effluents. By-products like benzene, toluene, xylene, naphthalene, coal tar, creosote oil, pitch; ammonium sulphate and benzol products are also recovered fromthe coke ovens gas. VSP produces, among other by-products, pushkala a prime fertilizer based on ammonium sulphate.</p> <p> Sinter Plant Iron ore fines, coke breeze, limestone and dolomite along with recycled metallurgical wastes are converted into agglomerated mass at the Sinter Plant, which forms 80&amp;percnt; of iron bearing charge in the Blast Furnace. The Sinter Plant comprises of two sinter machines each having 312 square metres of grate area with a total production capacity of 5.256 million tonnes per annum.</p> <p>P</p> <p> Blast furnace3 VSP has two Blast Furnaces with an effective volume of 3200 m . each of which are the largest in the country. Blast Furnace is charged with coke, iron ore and sinter from the top and produces about 5000 tonnes of molten iron per day. Their novel circular cast house withfour tap hole ensures continuous tapping of hot metal. The annual produc tion capacity of these Blast Furnaces is 3.4 million tonnes of liquid iron.</p> <p> Steel Melt Shop &amp; Continuous Casting3 Three Top blown converters, each of 133m volume, produce a total of 2.7 million tonnes of liquid steel per annum. This liquid steel thus produced is casted in six -4 strand bloom casters. A special feature in energy conservation is the collection of Converter gas to be used as a fuel in the 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 percent; Continuous casting on such a large scale has been conceived for the first time in India.</p> <p> Rolling Mills The cast blooms from continuous casting department are heated and rolled in the three high speed and fully automated rolling mills namely Light &amp; Medium Merchant Mill, Wire Rod Mill and Medium Merchant &amp; Structural Mill, to produce various long products like Reinforcement bars, rounds, squares, flats, angles, channels, billets, wire rods etc. Technologies adopted at Rolling Mills include world -class Stelmor and Temp core processes.</p> <p> Major Sources of Raw Material Raw Material Boiler Coal Coking Coal Medium Coking Coal Iron Ore Lumps &amp; Fines SMS Lime Stone Manganese Ore SMS Dolomite Water Supply Operational water requirement of 36mgd is being met from the Yeluru Water supply scheme of Andhra Pradesh. This water is then treated in various water treatment plants in VSP, so as to be usable for industrial purposes. Source Talcher, Orissa Australia Gid/Swang/Rajarappa/ argali Bailadilla, MP UAE Chipurupalli, AP Madharam, AP</p> <p>A. RMHP (RAW MATER AL HANDLING PLANT)</p> <p>The Raw Material Handling Plant (RMHP) receives the basic raw materials required for the steel making process from various sources through railway wagons and by road. These are stacked by stackers and reclaimed by reclaimers and distributed to various departments of VSP through conveyor system. The Iron Ore Fines, Iron Ore Lump, Sized Iron Ore, Limestone (BF &amp; SMS grades), Dolomite (BF &amp; SMS grades), Sand, Quartzite and Manganese lumps are stacked at Ore&amp; Flux Yard. The Imported Coking Coal (ICC), Medium Coking Coal (MCC), Boiler Coal (BC) is stacked in Coal Yard. Coke is sent directly to Blast Furnace after tippling from ore and flux wagon tipplers. These raw materials are sent to various departments as indicated below: 1. Si ter Plant: Iron Ore Fines, Lime stone (BF), Dolomite, Sand and LD slag. 2. Blast Furnace: Sized Iron Ore, Limestone (BF)/ LD slag, Manganese Lump, Quartzite and Coke. 3. SMS: Dolomite (SMS), Sized Iron Ore, Dolo chips. 4. CRMP: Limestone (SMS), Dolomite (SMS), Dolo chips. 5. TPP: Crushed Boiler Coal. 6. COCCP: Imported coking coal (ICC), Medium coking coal (MCC). The Raw Material Handling Plant is divided into two sections Coal Handling Plant (CHP) and Ore Handling Plant (OHP).</p> <p>The facilities available in two sections are as follows: COAL HANDLING PLANT 2 Wagon Tipplers 5 Ground &amp; 10 Track Hoppers Stock Yards ( 10 Beds) Boiler Coal Crushing Plant Stackers, Reclaimers And Stacker cum Reclaimer j Reclaiming Conveyors j Stacking Conveyorsj j j j j</p> <p>ORE HANDLING PLANTj j j j j j j j</p> <p>3 Wagon Tipplers 10 Ground and 10 Track Hoppers Stock Yard (12 Beds) Lump Ore Crushing Plant Lump Ore Screening Plant Stackers and Reclaimers Reclaiming Conveyors Stacking Conveyors</p> <p>SALIENT FEATURES OF RMHP i. ii. iii. iv. v. vi. vii. viii. ix. Peripheral unloading system for railway wagons coming directly up to pushers. Blender Reclaimers for blending of ores and flux in which the bucker wheel has a lateral motion across the bed. Wheel on Boom Reclaimers for reclaiming different materials from same bed in Ore &amp; Flux yard and same type coals in CHP. 2 Ring Granulators for crushing of Boiler Coal. 3 Blender Reclaimers for blending of Iron ore fines and flux. PLC control of all systems. Drier for drying SMS Sized Ore. Preparation of Sized iron Ore for use in BF to enable close size range of raw materials. Dust Extraction system is provided at various locations of RMHP to absorb the dust generated during the process.</p> <p>RAW MATERIAL SPECIFICATIONS The iron- bearing burden materials are Iron Ore fines supplied from Bailadilla mines and manganese ore from the deposit in Vizianagaram district.</p> <p>The various raw materials handled in the OHP are as follows: Sl.No 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 Raw Materials Iron Ore Fines. Iron Ore Lump. Sized Iron Ore. Limestone (BF grade). Limestone (SMS grade). Dolomite (BF grade). Dolomite (SMS grade). Sand. Manganese Lump. Quartzite Lump. Sponge Iron. Pellets. LD Slag. Coke.</p> <p>The various raw materials handled in the CHP are as follows: Sl.No. 1.0 2.0 3.0 4.0 5.0 Raw Materials Imported Coking Coal. Imported Soft Coking Coal. Medium Coking Coal. Prime Coking Coal. Boiler Coal.</p> <p>These Raw Materials are sent in different proportion to various customer departments as indicated below: 1. Coke Ovens : Imported Coking Coal, Medium Coking Coal, And Primary Coking Coal. 2. Thermal Power Plant: Boiler coal. 3. Sinter Plant: Iron ore fines, Limestone (BF grade), Dolomite (BF grade), Sand and LD Slag. 4. Blast Furnace: Sized iron ore, Limestone (BF grade), Manganese lump, And Quartzite lump, Coke, Sponge iron, Pellets and LD Slag. 5. SMS: Sized iron ore and Dolomite (SMS grade). 6. CRMP: Limestone (SMS grade) and Dolomite (SMS grade).</p> <p>Stacking &amp; Reclaiming Facilities Facility a) Stackers Ore &amp; Flux yard Coal Yard 1400 tph (5 nos) Twin Boom (Fixed Type) Coal Yard 850 tph (3 nos) Single Boom (Swivelling Type)</p> <p>b) Reclaimers</p> <p>450 tph Wheel on Boom Reclaimers (3 nos) 1200 / 450 tph Blender Reclaimers (3 nos) _</p> <p>550 tph Wheel on Boom Reclaimers (3 nos) _ 850 / 550 tph (1no)</p> <p>c) Stacker cum Reclaimer</p> <p>CRUSHERS a) Iron Ore b) Boiler Coal Cone Crusher. Ring Granulator.</p> <p>B. COKE OVEN AND COAL CHEMICAL DEPARTMENT</p> <p>COAL PREPARATION From the storage yard, the coking coal is sent to foreign material removing section to remove foreign matter of above 150mm size. Iron traps for ferromagnetic articles and cylindrical screens are provided for this. For averaging and proportioning o coal, 16 nos f of bins each 800 tonnes of capacity are provided along with continuous action feeders of up to 100 tonnes per hour capacity each. After blending the material is crushed to take care of petro graphic non-uniformity, high hardness and mineral content of coal. The crushing is carried out in reversible hammer crushers 2 operating and 1 standby. The crushed and blended coal (74-78% of 3mm size) is conveyed to two coal towers each of 4000 T capacity. Weigh bridges are provided under coal towers to weigh the coal charge. System of pneumatic blow down of blend is provided in the coal tower to take care of jamming of coal. BATTERY The prepared coal charge in the coal tower is drawn by a charging car on the top of the batteries and charged into the ovens as per sequence. The charged coal is gradually heated by the heating walls of the oven in the absence of air to attain a temperature of1000 0 1050 C at the central axis of the coke mass towards the end of coking period. The coking period is generally specified between 16 hrs and 19 hrs depending on oven condition and production requirement. 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 8000 C to 800 C is drawn to coal chemical plant by Exhauster.</p> <p>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. There are 3 batteries, each having 67 ovens. Each oven can hold 32 tons of dry coal charge. The volumetric capacity of each oven is 41.6 m3. The heat for carbonization is supplied by under firing of coke oven gas having CV of 4200Kcal/Nm3 or mixture of BF gas &amp; CO gas having Calorific Value 900 K cal/Nm3. The heating system of batteries is of under jet, compound type having Twin-heating flues with re-circulation of waste gases. The dimensions of oven are as follows: a. General Dimensions: Length Height Width on coke side Width on pusher side Average width b. Effective Dimensions: Length Height Number of heating flues in one heating wall Distance between axes of ovens Number of charging holes Number of gas-off take holes Heating level (distance from the top of The hairpin of the heating flue to the Carbonizing chamber roof)</p> <p>16,000 mm 7,000 mm 435 mm 385 mm 410 mm</p> <p>15,160 mm 6,700 mm 32 Nos. 1,400 mm 3 2 1,100 mm</p> <p>Temperature in heating flues is between 13300C and 13900C and final temperature of coke mass at its central axis is between 10000C 1050 0C. Following oven machinery is provided. Operating Total Charging Cars 3 6 Coke pusher 3 5 Door Extractor 3 5 Electric Loco 3 5 Coke Car 3 7 COKE DRY COOLING PLANT There are three coke dry cooling plants, each having four chambers. Capacity of each chamber is 50-52 TPH. Each coke dry cooling plant consists of cooling chambers with individual l...</p>