Bokaro Steel Plant, SAIL

SUMMER TRAINING

PRESENTED BY:

CHANDAN SHARMAROLL NO.: 1337340023M.E 5TH SEM

PRESENTED TO:

Mr. RAVISH SRIVASTAVAAsst. prof.M.E. DEPARTMENTN.I.T. MEERUT

REG. NO- 5901208

CONTENT

1. Sail2. Bokaro Steel Plant3. Air Separation Unit4. Propane Gas Unit5. Protective Gas Plant6. By-product Plant7. Primary Cooler & Exhauster8. Tar Distillation Unit9. Ammonia Removal10. Benzol Recovery Unit

11. Energy Management Department.12. Gas Analysis13. GMBS14. Conclusion

Steel Authority of India Limited Maharatna ISO Certification Domestic Construction Engineering Railway defense etc.

Foreign markets.

INTRODUCTION

There are five integrated steel plants (ISP) under SAIL as follow:

Bhilai Steel Plant (BSP) in Chhattisgarh Bokaro Steel Plant (BSL) in Jharkhand Durgapur Steel Plant (DSL) in West Bengal IISCO Steel Plant (ISP) in West Bengal Rourkela Steel Plant (RSL) in Orissa

• Special steel plant: Alloy Steel Plant (ASP) in West Bengal Salem Steel Plant (SSP) in Tamil Nadu Visvesvaraya Iron and Steel Plant (VISL) in Karnataka Chandrapur Ferro Alloy Plant

• Subsidiary: SAIL Refractory Company Limited

• Joint ventures: NTPC SAIL Power Company Pvt. Limited (NSPCL) Bokaro Power Supply Company Pvt. Limited (BPSCL)

BOKARO STEEL PLANT

• Fourth integrated plant in the Public Sector, started taking shape in 1965 in collaboration with the Soviet Union.

• Incorporated as a limited company on 29th January 1964, and was later merged with SAIL, first as a subsidiary and then as a unit, through the Public Sector Iron & Steel Companies Act.

• First Swadeshi steel plant, built with maximum indigenous content in terms of equipment, material and know-how.

• In its earlier stage it was famous as ‘Employer of more than one lakh people’.• At present its production capacity is 6.5 MTPA liquid steel.

Flat products 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.

AIR SEPARATION UNIT1.Separates atmospheric air

• Nitrogen• oxygen• In some cases argon and other rare inert gases.

2.Fractional distillation (cryogenic method)• high purity gases • energy-intensive.

3.Refrigeration cycle (Joule–Thomson effect) , and then cooling may be done by using either of the following heat exchanger: Two pairs of regenerative heat exchanger (Linde Frankl process). A recuperative regenerative heat exchanger (Kellogg's process).

• PROCESS FLOW DIAGRAM:

GAS BOILING POINTOXYGEN -183.5oCARGON -185.6oCNITROGEN -195.6oC

• A comparison of boiling point of different air components:

PROPANE GAS UNITA. Liquid propane is brought and stored at propane gas unit in an underground

tank having capacity of 5 ton.

B. Then the liquid propane is converted to gaseous form in a vaporizer at about 75 C to 80 C. Then the propane gas is send to other units as per requirement.

C. Its main consumers are Slabbing Mill, Continuous Casting Shop, and Hot Strip Mill.

D. In the following table a comparison between propane and acetylene shows the use of propane instead of other industrial gases:

Properties Acetylene(C2H2) Propane(C3H8)State Gaseous Liquid and gasAppearance Colorless ColorlessOdor Garlic like OdorlessSpecific Gravity 0.906 1.573Flash Point -32oC -156oCAuto Ignition Temperature 305oC 470oCCalorific Value (Kcal/Kg) 11573 10985Calorific Value (Kcal/M3) 13508 22250Expansion Rate ---- 250Maximum Allowable Pressure 15 PSIG Cylinder rating

Burn Velocity (M/Sec) 6.9 3.7Back Fire Tendency High LowToxicity High LowExplosion Sensitivity To Impact High Stable

Explosion Sensitivity To Electricity High Explodes

Explosive Limit (%Air Volume) 2.4-52.3 2.4-9.5

Explosive Limit(% Oxygen) 3.0-93 2.4-57Effect On Environment Generates solid waste Environment friendlyOzone Depletion And Global Warming Yes Less as compared to acetylene

Cost Of Energy (Rs/Gcal) 18500 5500Tangible Save Annually ---- < 60 millionIntangible Benefits ---- Faster preheat, higher penetration, faster

& smoother metal works.

PROTECTIVE GAS PLANT1.Protective gas is a mixture containing 95% nitrogen gas and 25% hydrogen

gas.

2. It is used to provide an inert atmosphere by forming a layer over steel surface during the annealing of steel sheets.

3. So the only consumer of protective gas plant is Hot Rolling Mill. Protective gas is prepared by cracking of ammonia gas as follow:

2 NH3 → N2 + 3 H2

4.Liquid ammonia is sent to cracking unit where it is heated to 800oC. Coke oven gas mixed with air is used as fuel for heating.

PROCESS DIAGRAM:

AMMONIA REMOVAL UNIT

• Because of the corrosive nature of ammonia, its removal is a priority in coke oven by-product plants.

• The ammonium sulfate process can take various forms but all basically involve contacting the coke oven gas with a solution of sulfuric acid.

• The sulfuric acid reacts readily with the ammonia in the coke oven gas to form ammonium sulfate.

• The sulfuric acid used in the ammonia removal process is produced at sulfuric acid plant by Contact Process.

ENERGY MANAGEMENT DEPARTMENT

1. High levels of power requirement and rising energy costs represent a major challenge for the steel industry.

2. Blast Furnace Gas is a by-product of blast furnaces where iron ore is reduced with coke into metallic (pig) iron.

3. Coke Oven Gas is a by-product of industrial coke production from pit coal; coke gas is created by high-temperature dry distillation of coking coals in the absence of oxygen.

4.Most of the time the calorific value of the gas required as fuel in different units of plant falls is such that neither pure coke oven gas nor pure blast gas can be used.

GAS ANALYSIS1. The gas analysis provides information regarding gases percentage composition

and their respective calorific value. Following are the three types of gas analysis based on purpose or point of operation:

Surrounding air analysis- The first and must analysis is of atmospheric air in the area surrounding the working site..

Fuel gas analysis-This is the analysis of gas mixture to be used as fuel.. Flue gas analysis-This is the analysis of gases leaving after combustion. This

analysis help in regulating air supply to the combustion process and complete combustion of fuel gases.

2. It was patented before 1873 by Mr. H Orsat.

ORSAT GAS ANALYZER1.The different solutions used for gas analysis

in Orsat Apparatus are described sequentially as follow:

A. Colored Saline Water: B. Potash Solution.C. Pyrogallol Potash Solution.D. Bromine Water Solution.E. Ammoniacal Cuprous Chloride.

2.Sometime the Orsat apparatus also comes with a Steel U Tube having cupric oxide (CuO) wire pieces inside it and a heater arrangement.

GAS MIXING AND BOOSTING STATION• This is the unit where gases are stored, mixed and send to their respective

consumers as per requirement. • The mixing of coke oven gas and blast furnace gas takes place by providing

a pressure difference of about 250 mmwc between both lines.• The mixing process is shown by a simple and general diagram as follow:

CONCLUSION

• The opportunity of getting vocational training at such a famous and prestige organization is an opportunity of lifetime.

• It helped me in understanding that despite of technology advancement and modern machinery, proper co-ordination between employees and their experiences is the key to a proper functioning and growing plant.

• The expansion proposal of Bokaro Steel Plant consist of two phase.1.Increasing its production capacity(liquid steel) from 6.5 MMTPA to 10 MMTPA by 2015. 2. From 10 MMTPA to 15 MMTPA by 2017.

• The quality of corporate life is excellent in BSL but the management should take initiative to satisfy the:

“There is a little bit of SAIL in everybody’s life”…

THANK YOU