Internship Program Report.

July - 2015

Report on
Internship Program at JSW Steel Ltd
Karnataka.
06th July 2015 to 18th July 2015

DKTE TEXTILE AND ENGG. INSTITUTE,ICHALKARANJI.

Prepared by, Submitted to,

Shivalinegesh Aiholli
Basaveshwar
Shreyas MunotEngineering College Officer (HR),
Pratik Patil
Bagalkot JSW Steel Ltd
Pratapsingh Sasane
Abhishek Patil

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

CONTENTS

 Introduction
 Safety Training
 Raw Material Handling Systems (RMHS)
 Beneficiation Plant
 Pellet
 Sinter Plant
 Coke Ovens and CDQ
 Blast Furnace
 DRI
 Steel Making Shop (SMS)
 Logistics
 Hot Strip Mill (HSM), Cold Rolling Mill (CRM), Bar-Rod
Mill & Wire Rod Mill

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

INTRODUCTION
A $11 billion conglomerate, the JSW Group is a part of the O.P. Jindal Group. JSW has set up
business facilities in various core sectors of India. With verticals that are exploring innovative and
sustainable avenues in steel, energy, infrastructure and cement, the Group is paving the way for
India’s development as a global superpower.
JSW Steel is India’s leading integrated steel producer with a capacity of 14 MTPA. The Group is
also leading from the front in every sector that it operates in. By maintaining exemplary
operational efficiencies, JSW Energy has grown ten-fold in just three years while JSW Cement
creates the building blocks of India with its environment friendly product. JSW Infrastructure is
contributing to the nation’s development by providing world class services to clients through
state-of-the-art ports, terminals, shipyards and other facilities.
The JSW Group is committed to creating more smiles at every step of the journey. JSW
Foundation, the Group’s CSR and sustainability arm, is in constant pursuit of making life better
for communities with its various initiatives in the fields of health, education, livelihood and
sports along with art and culture.
JSW’s zero effluent plants, green townships and happy employees are changing the course of the
nation with their spirited growth. JSW Group is proud to be charting a course to excellence that
creates opportunities for every Indian and leads to the creation of a sustainable, dynamic and
developed nation.

JSW Vijayanagar Works:

India’s first 10
12 MTPA steel plant at single location, “the fastest growing steel plant
in India”.
The JSW Steel Vijayanagar plant is the first integrated steel plant to reach 10 12 MTPA
capacity in a single location. It is the first in India to use the Corex technology for
hot metal production.
The first hot strip mill at Vijayanagar was commissioned in 1997. Since then it has
grown exponentially and now has an installed capacity to produce 10 MTPA of
steel. Located at a remote village Toranagallu part of under developed North
Karnataka in the Bellary-Hospet iron ore belt of Karnataka, the fully integrated steel
plant, is well-connected with both the Goa and Chennai ports.

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015
Unique features
Regarded as the world’s Corex showpiece; it was the first Greenfield project in
India and among the first in the world to have successfully used this technology to
produce “green steel”
Houses India’s largest blast furnace and the widest hot strip mill
The only plant in India with pair-cross technology and twin-stand reversible cold-
rolling mill
The highest productivity steel plant in India, producing 800-plus tonnes per person
per annum
Recognised for its ‘zero-effluent discharge’ status; it reuses more than 95 per cent
of process waste
Low carbon footprint as it recycles 96% of coke oven gas for power generation
Uses sophisticated ambient air control infrastructure beyond and has reduced gas
flaring to lower levels.

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

SAFETY TRAINING
The company aims to provide safe work conditions at
all JSW plant locations. The safety and health of the
employees has always been a prime concern of the
company. Safety is one aspect, which the company
has never been complacent. Umpteen numbers of
industrial safety drives and training programs
conducted in the company validates its high sense of
concern for the safety of its employees. The
management also makes sure that every employee
including outsourced employees undergo industrial
safety training before they actually take up their
assignments in the company.

Periodical health check-ups are conducted to all the employees every 6 months working in the
plant area.
JSW has tie up with DuPont for maintaining world class safety standards. DuPont standards and
corrective measures are being implanted across the organization.

An effective occupational safety and health program includes the following four elements:
 Management commitment and employee involvement
 Worksite analysis
 Hazard prevention and control

On the first day of our internship, we were given the safety training. They explained us about the
various accidents that might happen in an industry and possible methods to prevent them. Then
we were introduced to various Personal Protective Equipment(PPE) that one should use in the
steel plant.

PRSONAL PROTECTIVE EQUIPMENTS (PPE’s)

1. Helmet
2. Goggles
3. Ear Plug/Muff
4. Jacket
5. Hand gloves
6. Safety Shoes
7. Welding Shields
8. Safety Belts
9. Dust Mask

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

SAFETY HELMET SAFETY SHOES DUST MASK

SAFETY GOGGLE HAND GLOVE SAFETY BELTS

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

RAW MATERIAL HANDING SYSTEM (RMHS):

The RMHS is designed to handle iron ore, pellets, non-coking coal, coking coal,
coke, lime stone, dolomite, quartzite and manganese ore. Major equipments are wagon tipplers,
stacker cum re-claimer and barrel re-claimer. There are two units in RMHS, the first serving the
needs of 4MTPA and the second one for the 10MTPA facilities which includes base mix (preparing
feed to sinter plant).
The RMHS takes the raw materials from the wagons (goods train) using tipplers.
As the instructor explained, the tippler holds the rail car to a section of track and rotates the
track and car together to dump out the contents into an underground stacking area from where
the raw materials are sent to the required destination by means of conveyor belts. There are two
types of tipplers, Rotary type and Side tippler(in pic). The difference between the two tipplers is
the angle of rotation of the tippler. The Rotary tippler rotates by an angle of 175 0(max) while the
side tippler rotates by an angle of 1540(max).

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

A stacker is a large machine used in bulk material handling. Its function is to pile
bulk material such as limestone, ores and cereals on to a stockpile. A reclaimer can be used to
recover the material.

We visited the Tippler operation area where they explained us the various
electrical and electronic components involved and their operation. The whole mechanism of the
tippler is automated. The movement of the wagon is done by side arm charger whose position is
dictated by proximity sensors, while the temperature changes are detected by Resistance
Temperature Detectors(RTD) . Each sensor has got a supply of 24V. A PLC(Programmable Logic
Controller) system is used to set the parameters of the sensors and check continuously the
movement of the side arm charger, the forward movement of the wagon, the angle of rotation of
tippler and temperature. Whenever a condition fails, the input trips and hence the mechanism
stops.
Each tippler has a 3 transformer with a capacity of 2MVA, 6.6kV/415V. The various
motors that are used in the tippler mechanism get a supply of 415V and rated for a capacity of
5.5kW

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

BENEFICIATION PLANT:

The job of the Beneficiation Plant is to concentrate the low grade iron ore to high grade
ones. Various processes involved are milling, washing, filtration, sorting, sizing, gravity
concentration, magnetic separation, flotation.
In JSW plant we saw milling, magnetic separation and flotation in operation.

MILLING : This is a process of grinding and crushing of the ore to a required size for magnetic
separation. The major instrument used is Ball Mill.

The Ball Mill rotates at a speed of about 30-35 rpm which uses Induction Motor, whose speed is
controlled by Variable Voltage Variable Frequency drives (VVVF). The power output of the
Induction Motor during operation is 25kW. The output of the ball mill is sent to the magnetic
separator.

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

MAGNETIC SEPARATOR : Magnetic separation is most commonly used to separate

natural magnetic iron ore (magnetite) from a variety of less -magnetic or nonmagnetic material.

The Magnetic Separator consists of a conveyor belt and free magnet. The motor used in the
rolling of the conveyor belt is given a 415V supply. It rotates at a speed of 225 fpm. The whole
process is depicted in the pic given below:

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

PELLET PLANT:
Pellet plant: JSW has two pellet plants with a rated capacity of 4.2MTPA each and the
pellet size ranges from 8-16mm. The major units are dryers, ball mills, pelletizers of 7.5m dia,
indurating furnace, electro-static precipitator and water re-circulation system. We can see the
process flow in the fig below.

FLOW DIAGRAM OF PALLET PLANT

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

FLOW DIAGRAM OF PALLET PLANT

As seen in the above figs., we were given a brief explanation about the process. The
pellet plant takes its input from the RMHS site along with the wastes produced by various plants
like corex, blast furnace, coke oven. Hence it also acts as a scavenger. The balling disc is the main
device in a pellet plant. It gives a shape to the ore. The balling disc is shown below,

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

The balling disc runs on an induction motor of capacity 0f 5.5kW and rotates at a speed of 1470-
1480 rpm, but the required speed of the disc is 7-8 rpm. This is obtained by using a gear box.

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

We can see the IM above connected to disc through gear box.

The final product of the pellet plant is shown:

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

This is the major input for the corex plant and Blast furnace.

SINTER PLANTS

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

JSW steel plant has 4 sinter plants. SP 1 and 2 are each rated for a capacity of 2.3MTPA, SP 3 is of
5.75MTPA and SP 4 is of capacity 2.78 MTPA to produce suitable agglomerates for iron making .
Sinter plants agglomerate iron ore fines (dust) with other fine materials at high temperature, to
create a product that can be used in a blast furnace. The final product is 8mm to 25mm, and
<8mm sinter is used as return fines with raw materials for sinter making process. Sinter is
irregular nodule of iron mixed with small amounts of other minerals. The process, called
sintering, causes the constituent materials to fuse to make a single porous mass with little
change in the chemical properties of the ingredients. The process of the sinter plant is similar to
that of pellet plant but there is no balling disc. Hence the output has irregular shape.
Why Sinter is preferred for Blast Furnace
 It decreases coke rate.
 Increase productivity.
 Improves hot metal quality.
 Brings in smoothness in Operation.

Sintering Reactions:

 The sintering reaction starts with reduction of the hematite and formation of the low
melting liquid - mono calcium ferrite (CaO.Fe 2O3) - at around 1200ºC by reaction with
lime which absorbs silica and more of iron oxide.
 The melt so formed attacks the grain boundaries of hematite and the grains dislodge into
the melt forming CaO.2Fe2O3, 2FeO.SiO 2, CaO.FeO.SiO2, 2CaO.Fe2O3 , etc..
 With increase of temperature more and more hematite along with gangue go into
solution resulting in more of slag bonded complex sinter structure SFCA (silico-ferrite of
calcium and aluminum).
 At basicity levels of more than 2 calcium ferrite and di-calcium silicate forms and at lesser
than 1.6, glassy silicate and secondary hematite and magnetite forms .

Major Equipment at Sinter Plants & their Capacities:

Sinter Machine – 204 Sq Mtrs.

Sinter Cooler
Mixing Drum
Nodulizing Drum.
Double Roll Crusher.
Sinter Screens (HL & RF).
Waste Gas Fan
De-dusting & Other Process Fans.
Conveyors.
Lubrication Systems & Utilities.
Dust Handling Systems.
ESP (Electrostatic Precipitator)

Final product of Sinter

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

COKE OVENS:
A coke oven is a device used to produce coke, a product that is derived from coal.
The mixing and heating of bituminous coal at temperatures ranging from around 1832° to 3632°F
(1000° to 2,000°C) within the airless oven yields the coke by-product. This device is a crucial part
of the coke-making process.
JSW has both recovery and non-recovery type coke making facilities. The total installed
capacity of non-recovery type coke making facilities is 1.2MTPA. Coke oven 1 having 139 ovens,
and coke oven 2 has 140 ovens. The salient features of non-recovery coke making is the waste
heat recovery for power generation. Coke ovens 3&4 are recovery type coke oven with installed
capacity of 1.5MTPA and 1.95MTPA respectively. Coke oven 3 has four batteries each of 56 ovens
and coke oven 4 has 4 batteries each of 72 ovens. The salient features of recovery type coke
ovens is extractions of value added products like coal tar, ammonia and sulphur. After the coke is
obtained it is sent to the quenching plant where both wet and dry quenching techniques are
used.

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

BLAST FURNACE
Blast Furnace is a typical metallurgical furnace whose inputs are pellets and sinter.
There are 4 blast furnaces at JSW. The BF-1 is of 1250 cubic metre and a capacity of 0.9MTPA, BF-
2 is of 1680 cubic metre with a capacity of 1.3MTPA while BF-3 and BF-4 are of 4019 cubic metre
with a capacity of 3MTPA each. The blast furnaces 3 and 4 are the largest in India.

The process flow is depicted in the following picture

The output of both the corex and blast furnace is same i.e. pig iron, which is taken out as shown

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

STEEL MAKING SHOP (SMS):

Steelmaking is the process for producing steel from iron and ferrous
scrap. In steelmaking, impurities such as silicon, phosphorus, and excess carbon are removed
from the raw iron, and alloying elements such as manganese,
nickel, chromium and vanadium are added to produce different grades of steel. The process of
steel making used in JSW is Basic Oxygen Steelmaking.
The rated capacity of the Basic Oxygen Furnace shop is 10MTPA
liquid steel and this has seven converters in two separate shops SMS-1 & SMS-2. SMS-1 has a
heat size of 130 tonnes (3 converters) and SMS-2 has 175 tonnes (2 converters). The major units
are Hot metal de-sulphurising station, basic oxygen furnaces (converters), scrap yard, ladle
preparation, handling bay, ladle refining furnace, gas cooling and cleaning plant, and a water re-
circulation system. The salient technical features are pre-treatment of hot metal, bottom stirring
in BOF, adjustment of chemistry and temperature in ladle furnace, automated container
laboratory for quick analysis of bath samples, utilization of converter gas as fuel and slag
splashing system to enhance converter lining life.

Continuous Casting Plant: Continuous casting, also called strand casting, is the process
whereby molten metal is solidified into a "semi finished" billet, bloom, or slab for subsequent
rolling in the finishing mills. In JSW there are six slab casters and one billet caster which produces
caster of dimension 220mm*800 to 1300mm. Maximum casting speed of 1.8m/min. Major units
of CCP are casting machine, gega torch cutting unit, marking machine and a water re-circulation
system.

These are the end products of the SMS plant. 1. Slab, 2. Billet.

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

*Slab Handing at SMS.

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

MILLS:
The slabs and billets obtained by SMS are sent to the Mills where the total end
products are generated. The end products are steel strip, steel rods and steel wire.

HOT STRIP MILL (HSM):

The rated capacity of the HSM-1 is 3.2MTPA HSM-2 is 3.5MTPA of hot rolled coils. The major
units are walking beam re-heating furnaces, reversing roughing stand, coil box, high finishing
stands, down coilers, roll grinding shops and water re-circulation system. The salient technical
features are high pressure de-scaling (180 bar), AGC control in three finishing stands, work roll
bending, online thickness and width gauge, roll bite lubrication system and online marking
system. The end product is as shown

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

COLD ROLL MILL (CRM):

The CRM complex has a capacity of 1MTPA. The CRM complex is focussed on the value added
products geared towards automobile and white goods industry. The major units are continuous
pickling liners, six high twin strand cold compact mill, electrolytic cleaning line, batch annealing,
accumulator, stress reliving and four high skin pass mill, recoiling line and auto packing line. The
output of the CRM is similar to that of HSM but a difference in its thickness (.3mm)

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

BAR ROD MILL (BRM):

Rated capacity of 0.9MT capable of rolling rebar in the range 8mm to 32mm, angles, RCS etc. This
is the first three stranded mill to be installed in India. M/s Morgan is the technology supplier of
both the long product mill.

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot

Internship Program Report. July - 2015

WIRE ROD MILL (WRM):

Rated capacity of 0.6MT and is considered to be the fastest mill in India (110ms -1). It is capable of
rolling the wire end and rebar in the range of 5.5mm to 22mm dia. Equipped with the latest
equipments like reducing and sizing mill- 1st of its kind in India.
.

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot