A REPORT ON

ONLINE INTERNSHIP AT JSPL RAIGARH

Submitted in partial fulfillment of the requirements for the award
of the degree of
Bachelor of Technology
in
Metallurgical & Materials Engineering
SUBMITTED BY

Aditya Raju Bhorde 01UG20050L02

SUPERVISED BY
Prof. md Izhar Hussain
(Lecturer In Opju)

Department of Metallurgical & Materials Engineering

OP JINDAL UNIVERSITY, RAIGARH,
CHHATTISGARH
Session -2021-22
 CERTIFICATE OF COMPLETION
This is to certify that the work which is being presented in
Internship Report entitled “Online Internship at JSPL,
Raigarh” is submitted by Aditya Raju Bhorde
(01UG20050L02), in partial fulfilment of the requirements for
the award of the Bachelor of Technology in Metallurgical &
Materials Engineering (MME), OP Jindal University, Raigarh,
is an authentic record of our own work carried out during a
period from August 14, 2021 to August 23, 2021 under the
supervision of Internship Incharge, Prof. Md Izhar Hussain,
Department of Metallurgical & Materials Engineering
(MME), OPJU.

The above statement made by the Students is correct to the best of my knowledge.

Date:

……............................................
(Signature of
supervisor)
Name
Md Izhar
Hussain
 Acknowledgement
First and foremost, we would like to thank our Internship
and Training In-charge, Prof Md Izhar Hussain for
providing the opportunity to attend the online internship
at JSPL, Raigarh and for his constant support and
guidance.
We express our sincere gratitude to our Dr. Ashok Kr.
Srivastava, Professor & Head, Department of
Metallurgical and Materials Engineering for
permitting us for this Internship.
We are thankful to all the respected faculties and Staff
for their valuable time, guidance and support provided to
us during the online internship.
.
 CONTENTS. PAGENO.
1. CHAPTER-1 (13August) …………………………. 3 - 15
1.1 RHMS PLANT.
1 .2 DRI PLANT
2.CHAPTER-2 (14 August) ………………………….. 16 - 26
2.1 LIME PLANT
2.2 BLAST FURNACE PLANT
3. CHAPTER-3 (16 August). … .………………......... 17 - 42
3.1 SINTER PLANT
3.2 COKE OVEN PLANT
4.CHAPTER-4 (17 August). ……………………….. 43 - 49
4.1 THERMAL POWER PLANT
4.2 COAL WASHARY PLANT
5. CHAPTER-5 (18 August). …………………………. 44 - 60
5.1 STEEL MELTING SHOP

6. CHAPTER-6 (19August). ……………………………. 61 - 68

6.1 FERROALLOYS PLANT
7. CHAPTER-7(20 August). …………………………. 69 - 78
7.2 RAIL MILL PLANT
7.2 REFRACTORIES

1
Page 3 of 95
 8. CHAPTER-8 (21 August) ……………………. 79 - 81
8.1 TECHNICAL SERVICE DEPARTMENT
9. CHAPTER-9 (23 August). ................................ 82 - 89
9.1 PRODUCER GAS PLANT
9.2 PLATE MILL PLANT
10.CONCLUSION REMARKS. ………………………. 90

2
Page 3 of 95
 CHAPTER -1 (13 AUGUST)
1.1 RAW MATERIAL HANDLING SYSTEM PLANT

• Functions of RHMS

1. Receive different raw materials from different sources byrailway

wagons and unloading through wagon tipplers.

2. Transport raw materials from wagon tipplers to different yards

3. through conveying system and store at different yards.

4. Raw materials supplied to internal costumers through Reclaimers

/conveyors/pay-loader/dumper up to input bins of the user plant..

5. Buffer stocks - keeping minimum for 40 days of all types of materials

at different yard / out of the yard.

• EQUIPMENT USED IN RHMS

1. Wagon trippler

Wagon tippler has a platform when the loaded wagons are placed for the unloading
and after emplied, the same is taken off from the platform
• Working of wagon trippler
1. Step 1. The loaded wagon is pillied by Side Arm Charger and placed on the tippler
plation. The weight of the loaded wagon is then registered.
2. Step 2. Thereafter rotation commences. The rail platforms its from its supports andas
results of the offiet pivot, the wagon tilts slowly until it rests against the longitudinal
side unders
3. Step 3. The rotation continues, and before the platform has rotated 90 degrees the
tippler top stape grips the top of the wagon, automatically locks to the and frame, thun
holding the wagon
4. Step 4. When the platform has rotated through approximately 155 degrees, the fully
tipped position is teached and the tippler halts
5. Step 5 After a short pause to allow the contents of the wagon to be discharged on the
hopper, the tippler rotates in the opposite direction and returns the now empty wagon.
3
Page 3 of 95
 Then the weight of empty wagon is registered which gives us the actual weight of the
material. One after the other, the same process continues till all the wagons of a rake
are emptied

Note -: The capacity of wagon tippler in RHS plant is 1500 metric tonnes/hour. There
are 50 wagons in which each have a capacity of 62-04 appros metric tone

2. SIDE ARM CHARGER

side arm charger is A marshalling device to position the loaded wagon centrally on
tippler platform one by one for unloading operation by wagon tippler. Side arm charger

4
Page 10 of 95
 is used to pull the loaded wagons along with the rake & push out the empty wagon from.
the tippler platform after tippling.

3. STACKER
The stacker is used to stack raw materials in the stacking yard in piles form

5
Page 10 of 95
 6
Page 10 of 95
 4. STACKER CUM RECLAIMER
Stacker cum Reclaimers is used to both stacking and recover the raw materials from a
stockpile to provide an uninterrupted supply with proper blending of raw materials to
the bin of the process plant.

5. RECLAIMER

Reclaimer is used to recover the raw materials from a stockpile to provide an

uninterrupted supply with proper blending of raw materials to the bin of the process pl.

7
Page 10 of 95
 6. YARD CONYEYOR
Reclaimer is used to recover the raw materials from a stockpile to provide an
uninterrupted supply with proper blending of raw materials to the bin of the process.

OTHER EQUIPMENT USED IN RHMS

8
Page 10 of 95
 ACHIEVEMENTS OF RHMS OF JSPL RAIGARH

9
Page 10 of 95
 1.2 DRI PLANT
Direct reduced iron (DRI) is the product which is produced by
the direct reduction of iron ore or other iron bearing materials in
the solid state by using non-coking coal or natural gas.
Processes which produce DRI by reduction of iron ore below the
melting point of the iron are normally known as the direct
reduction (DR) processes. The reducing agents are carbon
monoxide (CO) and hydrogen (H2), coming from reformed
natural gas, syngas or coal. Iron ore is used mostly in pellet
and/or lumpy form. Oxygen (O2) is removed from the iron ore by
chemical reactions based on H2 and CO for the production of
highly metalized DRI. In the direct reduction process, the solid
metallic iron (Fe) is obtained directly from solid iron ore without
subjecting the ore or the metal to fusion. Direct reduction can be
defined as reduction in the solid state at O2 potentials which
allow reduction of iron oxides, but not of other oxides (MnO, and
SiO2 etc.), to the corresponding elements. Since reduction is in
the solid state, there is very little chance of these elements
dissolving (at low thermodynamic activity) in the reduced iron, so
the oxides which are more stable than iron remain essentially
unreduced.

• DRI PRODUCTION PROCESSES

There two processes of DRI production
1. Gas based DRI
2. COAL BASED DRI

• GAS BASED DRI

10
Page 10 of 95
 The gas based process uses a shaft furnace for the reduction
In the gas based reduction processes, a vertical shaft kiln issued
in which iron ore is fed into the top of the kiln and finished
sponge iron is drawn off from the bottom after cooling it so as to
prevent its re-oxidation. The reducing gas is passed through the
ore bed, and spent gas is recirculated after heating and
reforming to a mixture of H2 and CO in a reformer, where it is
also heated to a temperature of 950 deg C, which is the
temperature needed to achieve adequate reduction reaction
rates. The shaft furnace works on the counter current principle
where the iron ore feed material moves downward in the furnace
by gravity and gets reduced by the up flowing reducing gases. In
the gas based DR process, gaseous fuels are used. These fuels
are to have the ability to reform or crack to produce a mixture of
H2 and CO gas. High methane containing natural gas is the
most commonly used gas. Natural gas is reformed to enrich with
H2 and CO mixture and this enriched and reformed gas mixture
is preheated and sent to the shaft DR furnace.Gas based
process is simple to operate and involves three major steps
namely (i) iron ore reduction, (ii) gas preheating, and (iii) natural
gas reforming.
Presently the gas based process is also available in which the
reforming of natural gas is not needed. . It is a cylindrical,
refractory-lined vessel and is a key component of the direct
reduction process. It is a flexible as well as a versatile reactor.
The reduction reactions take place both with H2 and CO in a
gas based DRI process.

• REACTION OF GAS BASED DRI PRODUCTION

11
Page 10 of 95
1. The reactions which take place with H2 are

(i) 3Fe2O3 + H2 =2Fe3O4 + H2O,

(ii) (ii) Fe3O4 + H2 = 3FeO + H2O, and (

(iii) iii) FeO + H2 = Fe + H2O.

2. reactions which take place with CO are

(iv) (i) 3Fe2O3 + CO = 2Fe3O4 + CO2

(v) , (ii) Fe3O4 + CO = 3FeO + CO2, and

(vi) (iii) FeO + CO = Fe + CO2

• There are three popular gas based processes.These are

(i) HYL process,

(ii) Midrex process, and

(iii) PERED process.

( latest version of HYL process is known as the Energiron)

12
Page 10 of 95
 13
Page 13 of 95
 2. COAL BASED DRI

In a coal based process, the reactor for the reduction reaction is

a rotary kiln which is slightly inclined to the horizontal position.
The process of direct reduction is carried out with the operating
temperatures maintained in a range from 1,000 deg C to 1,100
deg C. In the rotary kiln, both coal and the iron ore feed material
is charged from the same end of the kiln. During the movement
of feed material forward the oxidation reaction of carbon in coal
and reduction reaction of CO gas is carefully balanced. A
temperature profile ranging from 800 deg C to 1050 deg C is
maintained along the length of the kiln at different zones and as
the material flows down due to gravity the ore is reduced.

• BASIC REACTION IN COAL BASED DRI

(i) C + O2 = CO2,

(ii) CO2 + C = 2CO,

(iii) 3Fe2O3 + CO = 2Fe3O4 + CO2,

(iv) Fe3O4 + CO = 3FeO + CO2, and

(v) FeO + CO = Fe + CO2.

The product of the kiln (DRI and char mix) is then cooled in a
rotary cooler with external water cooling system to a
temperature of 100 deg C to 200 deg C. The product after it
is discharged from the kiln is screened and magnetically
separated. DRI being magnetic gets attracted and gets

14
Page 14 of 95
 separated from non- magnetic char.The separated DRI is
screened into two size fractions of +3 mm and -3 mm. -3 mm
fractions is sometimes briquetted by using hydrated lime and
molasses as binders

Advantages of DRI
1
Page 15 of 95
The various advantages of DRI are

(i) it allows dilution of metallic residuals in scrap during the

steelmaking,

(ii) since it is a manufactured product, it has a uniform

composition,

(iii) it has a uniform size,

(iv) it has low sulphur and phosphorus content as compared

to the scrap,

(v) if it is charged in blast furnace along with other burden

materials, it improves the productivity of the blast furnace.

16
Page 16 of 95
 CHAPTER-2(14 AUGUST)
2.1 LIME PLANT

• What Is Lime
?

Limestone is a type of carbonates stones used in the production

c Quicklime. 40-80 mm size fraction of Limestone is used in the
Kiln for I Lime (Cao) or Quicklime is produced by the calcinations
process of cart stones.

CACO3 > Pre-heating > Heating > Cooling > Cao + co2 ^

• The thermal decomposition of Limestone is given by

the following reaction:

CaCO3. +. Heat. =. Cao. +. Co2

(100). 56. (44)

( Limestone ) (Lime) (Carbon dioxide)

The above reaction is an endothermic reaction. It is carried out at

10000C temperature. In this process CO2 is being removed in
the form of gases and lime is obtained as the product. No
volumetric change occurs in this process but reduction in weight
takes place. This can be obtained from the above reaction for the
production of 1 ton of lime; 1.78 ton of limestone is required.

• Production process

17
Page 16 of 95
The production of lime begins with the quarrying and crushing of
limestone. Limestone is a general term that covers numerous
varieties of sedimentary rock. Limestone Can be composed of the
following four minerals, plus impurities: (CaCO3), aragonite (also
CaCO3 but with a different crystal structure from calcite), dolomite
(CaMg(CO3)2), and Magnesite (MgCO3)

2.1.1 Crushing

2.1.2

The first step in the manufacturing of lime is to crush the pieces of

limestone to make

Them smaller. There are two basic types of primary crushers:

compression and impact. Compression crushers use slow, steady
amounts of pressure to reduce the size of the rock, Whereas
impact crushers rely on intense, repeated blows. Compression
crushers are used Mainly for larger stones, impact crushers for
smaller sizes. In some plants, stones undergo Secondary
crushing as well. The crushed stone is screened to provide the
desired stone size And then conveyed to storage in conical
stockpiles (Gutschick, 1994).

• Calcination

Limestone is converted into lime through heating in a kiln, a

process known as Calcination. When limestone is subjected to

18
Page 16 of 95
 high temperatures, it undergoes a chemical Decomposition
resulting in the formation of lime (CaO) and the emission of
carbon dioxide Gas (CO2).To complete the thermal
decomposition of limestone into lime, the stone must be Heated
to the dissociation temperature of the carbonates, and this
temperature must be Maintained for a certain period of time. The
dissociation temperature varies depending onThe type of
limestone being burned. For example, calcite dissociates at
898°C (1,648°F) While magnesium carbonate dissociates at 402
to 480°C (756 to 896°F). Because this is a reversible chemical
reaction, the carbon dioxide emitted as a result Of calcination
must be removed to prevent recarbonation. Recarbonation
occurs when

• GENARAL PROCESS FLOW CHART OF LIME

PRODUCTION GIVEN IN FOLLOWING DIAGRAMME-:

19
Page 16 of 95
 20
Page 20 of 95
 Start Stone bunker Vibrofeeder & Weighing
Skip
hopper
transport

Product Product Conveyor Discharge Kiln Furnace Stone charging

Screen Vibrofeeder hopper

Product
Hopper SMS 2& SMS3

Product Fines Sinter Plant

21
Page 26 of 95
 • Uses of Lime-:

• It can be used as a building material.

• It is used in the production of cement by heating powdered
limestone with clay. Cement is an ingredient in mortar and
concrete. Mortar – used to join bricks together – is made by
mixing cement with sand and water. Concrete is made by
mixing cement with sand, water and aggregate (crushed rock).
• It is a major ingredient in toothpaste.
• It can be used as a food additive to provide calcium ions for
strong teeth and bones.

22
Page 26 of 95
 • It can be processed as a useful raw material in the chemical
industry.
• It can be used to neutralise acidic soil to allow plants to grow
more effectively. This is mainly used for large-scale agriculture.
Quicklime and slaked lime can also be used for this purpose,
as well as neutralising acidity in water sources such as lakes.
• Limestone is also used to remove impurities from the blast
furnace when making iron. The impurities are mostly silicon
dioxide (also known as sand). The calcium carbonate in the
limestone reacts with the silicon dioxide to form calcium silicate
(also known as slag

23
Page 26 of 95
 2.2 BLAST FURNACE PLANT
• BLAST FURNACE
In the Blast Furnaces (BF) liquid iron (popularly termed as
‘Hot Metal’) is Produced by the process of reduction at high
temperature from raw Materials like iron ore, base mix, sinter,
coke, fluxes (limestone / quartzite), Etc. &also air blast / O2. In
blast furnace the process is also known as “Counter current
process” as solid raw material is being charged from the Top
and hot air is being blown from bottom. During the process the
Impurities are removed in the form of slag and hot metal is
produced. Coal Is being injected to reduce consumption of
main fuel coke which is a cost Reduction measure. Liquid
metal and slag are being separated in the area known as cast
house. The liquid Hot Metal is transported in Hot Metal Ladles
/ Torpedoes to the Steel Melting Shops (SMS) for the
production of steel by the process of Oxidation of the Hot
Metal in specially designed Convertors. Sometimes the Hot
Metal is poured in the Pig Casting Machine (PCM) to
Produce Pig Iron.Slag produced is granulated by high
pressure water jets in the Cast House Itself or sent to Slag
Dumping in the Slag Pots.

Different Sections of Blast Furnace:

1. Furnace Proper: In the Furnace Hot Metal (along with slag)
is processed from the raw Materials.
2. Cast House:In the Cast House, Hot Metal & slag are tapped
from the Furnace tap hole And after flowing through a system of

24
Page 26 of 95
refractory lined troughs / runners flow Into Hot Metal Ladles /
Torpedoes & Slag Pots, placed on the iron & slag Side
respectively of the Furnace.
3. Stoves:Stoves heat the air blast provided by Turbo Blowers
to the Blast Furnaces Through the Tuyeres.
4. Raw material storage and Raw Material Charging Section:In
this there are designated bunkers for raw materials transported
from Mines / Sintering Plant (SP) / Raw Materials Handling Plant
(RMHP) / Coke Ovens (CO) by wagons / conveyors.
5. Gas Cleaning Plant (GCP):The blast furnace gas (BFG)
generated in the BF is cleaned through a series of steps before
transporting it to the BFG Holder.
6. Slag Granulation Plant (SGP) / Slag Dumping Yard:During
the process of iron making, the impurities are fluxed and
removed as slag. The hot liquid slag is made into slag granules
by means of high pressure water jets in the Slag Granulation
Plant in the Cast House itself (sometimes separate SGP is
located at a distance from the furnace proper).If the slag is not
granulated in SGP, it is poured in the Slag Dumping Yard.
7. Pig Casting Machine (PCM): Sometimes when there is poor
off take of Hot Metal by SMS or if the Hot Metal chemistry is
very adverse, Hot Metal is taken to this section for casting into Pig
Iron.
8. Pulvarised coal Injection:In this section coal is pulvarised to
fine dust in mills and injected in the furnace.

25
Page 26 of 95
 26
Page 26 of 95
 • TYPICAL MATERIAL BALANCES IN JSPL RAIGARH

27
Page 26 of 95
 CHAPTER-3 (16 AUGUST)
3.1 SINTER PLANT
• Sinterin
g
The term sintering denotes incipient fusion of iron ore
particles at temperatures near their melting point, resulting in
the formation of agglomerates.
• Objectives of Sintering:
1. the size of ore fines to a level acceptable to the Blast
Furnace.
2. form a strong and porous agglomerate.
3. remove volatiles from ores.
4. incorporate flux in the sinter.
5. To increase the BF output and decrease the coke rate.
• Raw materials for Sintering
• Iron ore fines 90 % (0-10 mm) -------- 67 % in mixture
• Fluxes 90 % (0-3 mm) ----------17 % in mixture
•Coke breeze 90 % ( 0-3 mm) ----------3-4 % in mixture and
rest is waste material.
• Sand/Quartzite 90% (0-3 mm)
• Waste Materials:

28
Page 26 of 95
 a). Flue dust ( From Blast Furnace but added in RMHP
) b). Mill scale ( From slabbing Mill, H.S.M.&CCS)
c). L.D.Slag (From S.M.S.)
d). Lime dust ( From R.M.P.)
e) Sinter return ( Own generation )
Dwight Lloyd sintering machine is used for preparation of
sinters.
• Parts of sintering machine:

• Storage bins, mixer, feeder etc.

29
Page 26 of 95
 • Ignition hood
• Band of pallets and rails for its movement
• Charge leveler
• Sinter breaker, screen, cooler
• Sintering process :
The sinter bed moves continuously like a chain at the
desired rate, from the feed end to the discharge end of the
strand.
• Once the mix is fed into a pallet, heating is begun
(referred to as ignition) using external burners (with blast
furnace/coke oven gas) located in the ignition hood at the
feed end of the machine.
• Sintering will commence by igniting the solid fuel in the top
layer. The combustion of solid fuel raises the temperature of
the top layer.
• Individual wind boxes located under the strand provide the
suction as each pallet moves from the feed to the discharge
end.
• Air is sucked under the strand so that the flame front after
ignition travels through the entire bed of the sinter mix.
• Due to suction , hot air flow through the sinter mix, heating
the charge material and settingOff the combustion reaction
(C+O2 CO2) at the top layer to generate large quantity of
Heat approx. 1400 oC.
30
Page 26 of 95
 • The air blast drawn thereafter through the bed not only
cools the top layer but preheats the Solid fuel in the next
lower layer and the combustion zone shifts downwards layer
by layer Till the grate bars.

31
Page 26 of 95
 • Heat transfer during sintering

• Sintering mechanism

32
Page 26 of 95
 • Advantages of the sintering
1. Any free or combined moisture in the ore is removed
and the carbonates are decomposed,
2.A part of the sulphur present in the charge is removed
during the sintering process,
3. The gangue constituents of the ore are pre-slagged
in fluxed sinter,
4. Some amount of heat in the blast furnace is saved as
dissociation of carbonates takes place During sintering.
5. Using super-fluxed sinter, the amount of limestone
charged in the BF is reduced, and thus,The solution
loss reaction (i.e. C(s) + {CO2} = 2{CO}) in BF is
decreased,
6. The evolution of CO2 gas in BF, due to dissociation
of carbonates, is much reduced,
• Product sintering quality demand by blast furnace
FeO – 9 to 10.5 %
CaO – 12 to 13 %
SiO2 – 5.5 to 6 %
MgO – 1.9 % Min
Al2O3 – 3.5 %
Max
Basicity – 2.2

33
Page 26 of 95
 3.2 COKE OVEN PLANT

34
Page 26 of 95
 • INTRODUCTION
Coke
Coke is a hard gray fuel, it bears the same relation to coal
as charcoal to wood. Coke is made in brick furnaces with
bituminous coal as the source. Coke is the most vital raw
material fed in a blast. Furmace operation and hot metal
quality. A high quality coke should be able to support a
smooth origin of the blast furnace burden with as little
degradation as possible while providing the lowest amount
of impurities, highest thermal energy, highest metal
reduction, and optimum absorptivity for the flow of
gaseous and molten products.

Metallurgical Coke
Coke is a solid carbonaceous material derived from
destructive distillation of low-ash bow-sulfur bituminous
coal The volatile constituents of the coal inchading water,
coal-gas and coal-tar are driven off by baking in an airless
oven at temperatures as high 1000 C. Metallurgical coke
is produced by carbonization of coal at high temperatures
to produce a macro-porous carbon material of high
strength and relatively large lump size. Metallurgical cokes
must have a high strength to support heavy bads in the
blast furnace without disintegration.
• Coal Carbonization
Carbonization of coal basically means enrichment of carbon
Coal. It is achieved by heating the coal up to a specified
temperature Range under prefixed oven conditions. The
resulting
34
Page 36 of 95
 solid residue Obtained after removing the VM is called coke.
The entire coke formation mechanism is guided by Sªfactors:
1. Soften
2.Swell
3.Stick (resolidify)

35
Page 36 of 95
 36
Page 36 of 95
 • Design parameters of oven in JSPL RAIGARH
According to JSPL- Raigarh
• 11 ovens = 1 battery
• Total 16 batteries are present = 176 ovens
• Dimensions of oven
: Length = 13 m,
Width = 3.5 m

• Coke is being made by following two processes

• Non-Recovery Coke Oven method &
• By-Product Coke Oven Method.
• Non-Recovery Coke Oven Process-:
• Utilization of the gas emanating from slot-type coke ovens
have become a major problem since the operations involved
are not always environment-friendly.
• Huge capital is required to make slot-type coke oven batteries
capable of fulfilling the stringent environmental norms that exist
today.
• For the above problem, nonrecovery type taller and wider
ovens are a partial solution.
• Principle: In the process of coke making, volatiles evolved
during coal carbonization are not recovered as byproducts but
are combusted in the oven itself in the presence of controlled
quantity of air and the heat of the volatiles of evolving gases is
utilized for coking the coal mass into coke and thus no
external heating is required.
• Because ‘non-recoveryovens operate under negative
pressure and the by-products of are burned within the ovens,
the door emissions are greatly reduced, and sometimes, totally

37
Page 36 of 95
 eliminated.
• In this process, coke is the main product, and the heat
recovered from waste gases generated during the process
generates steam in boilers and this steam is used for the of
electricity, which is the secondary product

• By-Product Coke Oven Process-:

• Each oven is relatively narrow, vertical, rectangular chamber.
Since the ovens are heated from outside, and the heat
38
Page 36 of 95
 required

39
Page 36 of 95
 for carbonisation is transmitted through the side walls, oven
widths are in order to achieve uniform heating within each
oven chamber.
• As a result, the only option left to increase the capacity of slot
ovens is to make them taller.
• Individual oven dimensions are typically 400-600 mm
wide, 1300-1400 mm long and vary in heightfrom 4 m to 7
m.
• Each oven has two adjacent heating chambers on either
side for gas firing to raise the oventemperature to 1350℃ at
the end of the carbonization period.
• All the ovens are charged with fine coal (-3 mm) through
ports ( normally 3 in number) provided onthe top using a
mechanically operated charging car.

40
Page 36 of 95
 • principle – In by product coke oven process coaking process
takes place with indirect heating through burners located
outside the furnace. It results in incomplete burning of the coal
which results in genaration vof by product.
• At the end of the carbonization cycle, the doors of the
oven are lifted mechanically on both Sides and the hot
coke is pushed out through a pusher car into the
quench car.
• The red hot coke is subjected to quenching with water
under quenching tower.

41
Page 36 of 95
 • Coke Quenching
• The hot coke discharged from the coke chamber is received
in a coke quench car for cooling.
• There are two methods of cooling the hot coke: (a) Wet
method and (b) Dry method

42
Page 36 of 95
 43
Page 36 of 95
 • Functions of coke -:
• Coke fulfils five major roles in blast furnace:
(i) It is a fuel providing heat for meeting the endothermic
requirements of chemical reactions and melting of slag and
metal.
(ii) It produces and regenerates reducing gases for
the reduction of iron oxides.
(iii) It provides an open permeable bed through which slag
and metal pass down into the hearth and hot reducing gases
pass upwards.
(iv) It supports the overlying burden, more so at the lower
regions.
(v) It carburizes iron, thereby lowering its melting point and
consequently the working temperature of the BF is reduced.
• The carbon content of coke should be maximum for it to be a
good fuel. In other words it should contain minimum of ash
and other impurities.

44
Page 36 of 95
 CHAPTER-4 (17 AUGUST)
4.1 THERMAL POWER PLANT
• INTRODUCTION
• A Thermal Power Plant converts the heat energy of coal into
electrical energy. Coal is burnt in a boiler which converts
water into steam. The expansion of steam in turbine produces
mechanical power which drives the alternator coupled to the
turbine.Thermal Power Plants contribute maximum to the
generation of Power for any country.
• Thermal Power Plants constitute 75.43% of the total installed
In and non-captive power generation in India.
• thermal generating stations coal, oil, natural gas etc.
are employed as primary sources of energy.
• Basic Machinery of Thermal Power Plant
• Coal handling system
• D M Plant
• Boiler
• Turbine
• Condenser
• Cooling tower
• Generators

45
Page 36 of 95
 • Excitation system
• Transformer
• Ash handling system
.•Ash Dyke
• Working Principle TPP-:
• the water is taken into the boiler from a water source. The
boiler is heated with the help of coal.
• The increase in temperature helps in the transformation of
water into steam. The steam generated in the boiler is sent
through a steam turbine.
• The turbine has blades that rotate when high velocity
steam flows across them. This rotation of turbine blades is
used to generate electricity.
• A generator is connected to the steam turbine. When the
turbine turns, electricity is generated and given as output by
the generator, which is then supplied to the consumers through
high-voltage power lines.

46
Page 36 of 95
 • Achievements of JSPL RAIGARH TPP
• variable cost of power reduced from 2.82 Rs/KWh (last year)
to 2.74 Rs/KWH resulted into cost saving of Rs 8.87 crore.
• -House installation of Lime Feeding arrangement into
Boilers to reduce SOX emission to comply with the latest
MoEF regulation.of solid waste utilization at AFBC and CFBC
boilers. 25% increase in CFBC boiler and 75% increase in
AFBC boiler which has resulted into fuel cost saving of Rs 8.8
crore.

47
Page 36 of 95
 • the drive of reduction of auxiliary power consumption saving,
we have reduced from 12.5 to 12% thereby cost saving of Rs
16.26 Crore annually.
• Capacity enhancement of Ashdyke(Lagoon-1) by raising
the bund by 5.0 meter completed within estimated budget
and time line. It was charged on 24th Jan'18. The entire
project was executed with compliance against all the
statutory regulations.
• Challenges in TPP
• Modernization and up gradations are required as the plant is
aged.
• Due to variations of coal quality and GCV, there is various
challenges arising such as blending of coal mix, maintaining of
plant parameters, etc.
• Stringent environment pollution norms which has
been recently revised have to be maintained.
• Ash disposal has been a challenge for the Power Plant. For
the wet disposal, Ashdyke being the limitation as it had raised
to >20m of height, similarly in order to maintain compliance of
Environmental Regulations (Flyash Notification, dry -ash
utilisation/disposal in the in the sites became a major
challenge.

48
Page 36 of 95
 4.2 COAL WASHERY PLANT
• Coal Washery Objective-:
• inferior grade coal (having 35-50 % Ash), from the
different colliery.
• Provide Low Ash (32 -33.50% ) coal to the DRI.
• By-products,Fines supplied to the power plant (After
drying) for power generation and Reject dumped for land
filling.
• Sizing / Crushing & Screening operations done for plants
ie –
DRI, Power plant & PGP .
• Process of coal Washery
• The process begins with a two stage closed circuit
Crushing & Screening system, to crush the lumpy coal (0-1000
mm) down to 30 mm size.
• The Coal Washery adopt the two stage dense medium
cyclone technology but at present only one circuit is in
operation.
• medium gravity separation methods uses magnetite to form
a dense medium than water to assist in separation

49
Page 36 of 95
 • Challenges in coal Washery
• Regular availability of Raw coal from Mines.
•Quality of Raw coal is not constant, Which impact Yield and
cost of Wash Coal.

50
Page 36 of 95
 • Capacity of JSPL RAIGARH coal Washery

▪ CHAPTER-5(18 August)
5.1 STEEL MELTING SHOP

51
Page 36 of 95
 • INTRODUCTION
• Steelmaking is the process for producing steel from iron
ore and scrap. In steelmaking, impurities such as nitrogen,
silicon, phosphorus, sulfur 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. Limiting dissolved gases such as
nitrogen and oxygen, and entrained impurities (termed
"inclusions") in the steel is also important to ensure the quality
of the products cast from the liquid steel.
• steelmaking has existed for millennia, but it was not
commercialized until the 19th century. The ancient craft
process of steelmaking was the crucible process. In the 1850s
and 1860s, the Bessemer process and the Siemens-Martin
process turned steelmaking into a heavy industry. Today there
are two major commercial processes for making steel, namely
basic oxygen steelmaking, which has liquid pig-iron from the
blast furnace and scrap steel as the main feed materials, and
electric arc furnace (EAF) steelmaking, which uses scrap steel
or direct reduced iron (DRI) as the main feed materials.
Oxygen steelmaking is fuelled predominantly by the
exothermic nature of the reactions inside the vessel where as
in EAF steelmaking, electrical energy is used to melt the solid
scrap and/or DRI materials. In recent times, EAF steel making
technology has evolved closer to oxygen steelmaking as more
chemical energy is introduced into the process.

52
Page 36 of 95
 • steelmaking processes can be broken into two categories:
primary and secondary steelmaking. Primary steelmaking
involves converting liquid iron from a blast furnace and steel
scrap into steel via basic oxygen steelmaking or melting scrap
steel and/or direct reduced iron (DRI) in an electric arc
furnace. Secondary steelmaking involves refining of the crude
steel before casting and the various operations are normally
carried out in ladles. In secondary metallurgy, alloying agents
are added, dissolved gases in the steel are lowered, and
inclusions are removed or altered chemically to ensure that
high-quality steel is produced after casting.

53
Page 36 of 95
 • Process And Process Flow Chart Of Sms Plant
Raw material of SMS Plant is Direct Reduced Iron, Molten
Metal and Scrap or may vary according to plant set up or
availability of Raw Material Modem steelmaking processes can
be broken into two categories: primary and secondary steel
making. Primary steelmaking involves converting liquid iron
from a blast furnace and steel scrap into steel via basic oxygen
steelmaking or melting scrap steel and/or direct reduced iron
(DRI) in an electric arc furnace. Secondary steelmaking
involves refining of the crude steel before casting and the
various operations are normally carried out in ladles. In
secondary metallurgy, alloying agents are added, dissolved
gases in the steel are lowered, and inclusions are removed or
altered chemically to ensure that high-quality steel is produced
after casting.

54
Page 36 of 95
 Basic oxygen steelmaking is a method of primary steelmaking
in which carbon-rich molten pig iron is made into steel.
Blowing oxygen through molten pig iron lowers the carbon
content of the alloy and changes it into steel. The process is
known as basic due to the chemical nature of the refractories-
calcium oxide and magnesium oxide-that line the vessel to
withstand the high temperature and corrosive nature of the
molten metal and slag in the vessel. The slag chemistry of the
process is also controlled to ensure that impurities such as
silicon and phosphorus are removed from the metal.
• Major Equipment Or Station-:
1. Electric Arc Furnace-:
An electric arc furnace (EAF) is a furnace that heats charged
material by means of an electric arc. Industrial arc furnaces
range in size from small units of approximately one ton capacity
(used in foundries for producing cast iron products) up to about
400 ton units used for secondary steelmaking. Arc fumaces used
in research laboratories and by dentists may have a capacity of
only a few dozen grams. Industrial electric arc furnace
temperatures can be up to 1,800 °C (3,272 “F), while laboratory
units can exceed 3,000 °C (5,432 “F). Arc furnaces differ from
induction furnaces in that the charge material is directly exposed
to an electric arc, and the current in the furnace terminals passes
through the charged material.

55
Page 36 of 95
 • Functions of EAF
• Melting of inputs and homogenization of steel bath,
Raising the temperature of the melt to 1620°C for tapping
• Decarburisatio
• Dephosphurisation.
• Slag free and compact stream tapping
2. Laddle Refining Furnace

56
Page 36 of 95
 Ladle refining of liquid metal is a proven technology to produce
high quality steel. A Ladle Refining Furnace is used to raise
the temperature and adjust the chemical composition of molten
metal. Without LRFs, higher tap temperatures are normally
required from steel making furnaces due to heat losses during
refining with conventional ladles.

57
Page 36 of 95
 • Functions Of LRF
1.Refining of steel
2 Achieving desired chemistry.
3.Thermal and Chemical Homogenization.
4.Raising desired temperature for casting

3. Vaccume Degassing
During the primary steelmaking process, gases like oxygen
(02), hydrogen (H2) and nitrogen (N2) dissolve in the liquid
steel. These gases have a harmful effect on the mechanical
and physical properties of steel. Dissolved 02 from liquid steel
cannot be removed as molecular 02 and its removal is termed
as deoxidation. The term degassing is used for the removal of
H2 and N2 gases from liquid steel. Since the degassing
process of liquid steel is carried out under vacuum, it is also
known as vacuum degassing of liquid steel. Vacuum
degassing processes are carried out in steel teeming ladies.

58
Page 36 of 95
 58
Page 58 of 95
 4. Continious Casting Machine-:
Continuous Casting is the process whereby molten steel is
solidified into a "semi finished" billet, bloom, or slab for
subsequent rolling in the finishing mills. Prior to the
introduction of Continuous Casting in the 1950s, steel was
poured into stationary moulds to form "ingots". Since then,
"continuous casting" has evolved to achieve improved
yield, quality, productivity and cost efficiency.

59

Page 59 of 95
 60
Page 60 of 95
 61
Page 61 of
 CHAPTER -6 (19August)
6.1 FERROALLOYS PLANT

• Introductio
n
• Ferroalloy is an alloy of iron with some element other than
carbon. Ferroalloy is used to Physically introduce or "carry"
that element into molten metal, usually during steel
manufacture.
• Ferroalloys are master alloys containing iron and one or
more non-ferrous metals as alloying elements.
• The ferroalloys are usually classified in two groups: bulk
ferroalloys (produced in large quantities in electric arc
furnaces), and special ferroalloys (produced in smaller
quantities, but with growing importance Bulk ferroalloys are
used in steel making and steel or iron foundries
exclusively, while the use of special ferroalloys is far more
varied.
• In total, 86.7 % of the ferroalloys produced are used in
the steel industry
• Depending on the raw material that is used (primary or
secondary raw material) the production of ferroalloys can be
carried out as a primary or secondary process.
• The primary process can be either carbo-thermic of metallo-
thermic reduction of oxide ores or concentrates.
• In the carbo-thermic reduction (the most important process),
carbon in the form of coke (metallurgical coke), coal or
Page 62 of 95
 charcoal is used as the reducing agent. When a blast furnace
62

Page 63 of 95
 is used, coke is also needed as an energy source. To
account for this, the process scheme also contains a fuel
input and combustion emissions output.
• Metallo-thermic reduction is mainly carried out with either
silicon or aluminum as the reducing agent.
• A highly competitive steel market requires the modern
steelmaker to be sensitive to customer demands in terms of
product properties, quality. Steels are being used for different
purposes like manufacturing of machine parts, motor cars,
aero planes, buildings.
• Special quality steels like Corrosion-resisting, stainless, acid-
resisting and capable of bearing load at high temperatures are
required for these purposes.
• Then steel manufacturers were decided to enhance the
quality of steel by alloying elements like Chrome, Nickel,
Manganese, Tungsten, Molybdenum, Niobium, Vanadium
etc as per requirement.

• Uses of Ferroalloy-:
• FeSi
• Deoxidizer in all kinds of steel the manufacture of
transformer and dynamo cores
6

Page 64 of 95
 • Reducing agent in the production of FeMo, Fev etc

• FeCr
• Increases hardness, strength, yield points and elasticity
in steels Used in structural, tool & special steels (acid &
heat resistance steels)
• Electric heating element
• Gas turbine & jet engine parts Ball & roller bearing steeels
• Advantages of Ferroalloys over pure metals
• Production of Ferro alloys is cheaper technically
& economically compared to pure metals
• Assimilation of alloying element is much faster in steel bath
due to lower melting point
• Quality steel with reasonable cost can be produced by using
Ferro alloy instead of individual alloying elements
• Faster rate of dissolution of Ferro alloys compared to pure
elements
• Recovery of alloying elements from Ferro alloy is higher than
that of individual alloying elements usage
• The types of ferroalloys

64
Page 66 of 95
 • Silico manganese (SiMn), with maximum 2 % carbon;
Low- carbon Silicomanganese (LC SiMn), with maximum
0.05% carbn;
• Ferro-nickel (FeNi);
• Ferrovanadium (FeV);
• Ferro molybdenum;
• Ferro-tungsten;
• Ferro-titanium;
• Ferro-boron;
• Ferro-niobium.
• The types of Ferroalloys production
• Aluminothermic reduction
• Silico thermic reduction
• Carbothermic reduction

65
Page 66 of 95
 • Routes of Ferro Alloy Production

• Blast Furnace

• Electric Arc Furnace

• Submerged Arc Furnace

• SAF, JSPL, Raigarh

• JSPL has started its journey in Raigarh in 1989 with

66
Page 66 of 95
 Submerged Arc Furnace (SAF) initially for the production of Pig
Iron and later on converted to the production of Ferro Alloys for
the captive consumption in the then Jindal Strips Ltd (JSL) –
Haryana for the production of Stainless Steel.

• Pig Iron, Silico Manganese (SiMn) & High Carbon Ferro

Chrome (HC FeCr) were produced in the 12 MVA SMS-
Demag designed SAF till June 2002 in Unit # 1and later on
scrapped that furnace as a new 24 MVA indigenously
designed SAF is started its operations from May 2012 in Unit
# 2 for the production of HCFeCr with a project cost of 30
crores.

• Presently HC SiMn is being produced and the

costliest product of JSPL.

67
Page 66 of 95
 6
Page 68 of 95
 69
Page 69 of 95
 CHAPTER-7( 20 AUGUST)
7.1 RAIL MILL PLANT

70
Page 69 of 95
 • Process Description:- In RUBM or Rolling Mill Plant the Raw
material like Bloom, Billet or Beam Blank of different size is
coming out from Steel Melting Shop according to requirement
or need of final Product of RUBM .Rolling Mill Process starts
from Reheating Furnace. Where the raw material coming from
Steel Melting Shop is heated inside a furnace up to 1260
degree centigrade. There after that heated raw material
extracted from furnace with the help of extractor kept roller
tablet further with the help of High pressure water descaling
process is done there After that Saw heated raw material
passes through Breakdown Mill where 30% size is reduced as
compared to Initial one. There after that material is passes
through BD it directly mentional Mil if it lighter section
otherwise it directly goes to Conventional Mill where it gets up
to 60% of final product shape. After that it transferred to the
Tandem Mill where with the help of three stands i.e. Universal
Roll, Edger Roll and Universal Finishing Roll which are in
series there after it forwarded to respectively, the final product
shape and finishing is done after that it passes through
Stamping Machine where heat no is mention on product there
after it Technogama where product profile is checked with the
help of High resolution Camera further that product is
transferred to the Universal Mill(KV-0 Mill) if the product is
channel, angle otherwise it passes to Hardening and Cooling
Module according to demand or requirement of customer.
Further with the help of Hot saws (Moving and Fix) a sample
ition in check the piece is cut from each product section to
check the profile of product manually to ensure that we are
exactly getting the shape which our customer demand after
that the product is
71
Page 69 of 95
 transferred to the Cooling Bed Where to the Cooling Bed
where temperature product is brought below 100 degree
centigrade there after that product passes through
straightening Machine where the product straightening of
product is done with the help of Roller arrangement after that it
Passes trough vertical straightening where lateral
straightening is done there after it passes through T2 Bed from
where product handling i started for final dispatch to the
customer if required then it cut in different length size
according to demand of customer or it forwarded for Non
Destructive Testing(N.D.T) after that final inspection it is
dispatch to the customer.

72
Page 69 of 95
 7.2 REFRACTORIES

• Refractory Material
• A material having the ability to retain its physical shape and
chemical identity when subjected to high temperatures.
• Refractories are inorganic, nonmetallic, porous and
heterogeneous materials composed of thermally stable
mineral aggregates, a binder phase and additives.
• Refractories are heat resistant materials used in all
processes involving high temperatures and/or corrosive
environment.

• A refractory material should be able to,

• Withstand high temperatures Withstand action of molten
metal, hot gasses and slag erosion etc;
• Withstand load at service conditions; Resist contamination of
the material with which It comes into contact;
• Maintain sufficient dimensional stability at high temperatures
and during repeated thermal cycling

• Important Properties of Refractories: •

73
Page 69 of 95
 1. Melting point
• Melting temperatures specify the ability of materials to
withstand high temperatures without chemical change and
physical destruction.
• For Alumina 3720 F; Graphite C Pure 6300 F
2. Size and Dimensional Stability:•
• Dimensional accuracy and size is extremely important to
enable proper fitting of the refractory shape and to minimize the
thickness and joints in construction.
3. Porosity:
• Low porosity materials are generally used in hotter zones,
while the highly porous materials (Highly insulating) are usually
used for thermal backup. Refractory materials with high porosity
are usually NOT chosen when they will be in contact with molten
slag because they cannot be penetrated as easily.
4. Bulk Density:
An increase in bulk density increases the volume stability,
the heat capacity, as well as the resistance to abrasion and
slag penetration.
5. • Refractoriness under load:
• The ability to withstand exposure to elevated temperatures
without undergoing appreciable deformation is measured in
terms of refractoriness. The refractoriness under load test (RUL

74
Page 69 of 95
 test) gives an indication of the temperature at which the bricks
Will collapse, in service conditions with similar load.

6. Creep at high temperature:

Refractory materials must maintain dimensional stability under
extreme temperatures (including repeated thermal cycling) and
constant corrosion from very hot liquids and gases.

7. Thermal Conductivity:
• High thermal conductivity refractories are required for some
applications where good heat transfer is essential such as coke
oven walls, regenerators, muffles and water cooled furnace
walls.
• However, refractories with lower thermal conductivity are
preferred in industrial applications, as they help in conserving
heat energy.
• Porosity is a significant factor in heat flow through refractories.
The thermal conductivity of a refractory decreases on increasing
its porosity.
Classification of Refractories
Refractories are typically classified on the basis of their
chemical behavior:
1. Acid Refractories:
7
Page 75 of 95
 • Acid refractories are those which are attacked by alkalis
(basic slags). These are used in areas where slag and
atmosphere are acidic. Examples: •1) Silica (SiO2), 2) Zirconia
(ZrO2),
2. Neutral Refractories:
• Neutral Refractories are chemically stable to both acids and
bases and are used in areas where slag and atmosphere are
either acidic or basic. Example: 1) Carbon graphite (most inert)
•
2) Chromites (Cr203); 3) Alumina
3. Basic Refractories:
• Basic refractories are those
which are attacked by acid slags but stable to alkaline slags,
dusts and fumes at elevated temperatures. Since they do not
react with alkaline slags, these refractories are of considerable
importance for furnace linings where the environment is
alkaline; Example: •Magnesia (MgO) – caustic, sintered and
fused Magnesia •Dolomite (CaO*MgO) – sintered and fused
dolomite • •Chromite -main part of chrome
ore.

76
Page 81 of 95
 • Stack lining:
• The lining here should have a very good abrasion resistance
and resistance to carbon
monoxide attack ( low permeability).
• The entire stack is lined with high duty firebricks.

77
Page 81 of 95
 • A 35-40 % Al2O3 firebricks with a close texture is
usually preferred for the stack.
• A 60 % Al2O3 bricks have been recommended for the lower
parts of stack.
• Bosh:
• In the bosh the brickwork has to withstand:
• High temperature conditions
• Erosion by the blast
• Lime and alkali slag attack
• Therefore the lining requires high refractoriness and
refractoriness under load.
• Bosh lining should be of aluminous fire bricks with Al2O3
content of 45-65 %.
• Note: As Al2O3 content in the refractory increases, its melting
point increases.
• Hearth:
• In the hearth, high temperature condition prevail, there is much
corrosion of the brick work By the molten iron.
• Breakouts, however, in this region, are a serious feature,
which cause considerable trouble And loss of output.

78
Page 81 of 95
 • In order to reduce metal penetration, the bricks used should
have a low permeability and Porosity.
• Since carbon is not wetted by metal or slag and is chemically
inert, (iron already saturated With carbon) it retains its original
contour in the furnace better than fireclay refractories.
• The raw material for the manufacturing of carbon blocks is a
mixture of tar and pitch (byproducts of coke).
• These are hardened in the moulds and fired to about 1000℃.

79
Page 81 of 95
 CHAPTER-8 (21 AUGUST)
8.1 TECHNICAL SERVICES DEPARTMENT

• Introduction
TIC functions as nodal agency for coordinating and monitoring
the various activities as envisaged in company procedure for
processing and implementing of AMR schemes.
• Following are various sections of TSD-:
1. TS-SMS

2. TS-MILLS

3. TS – TQM

80
Page 81 of 95
 81
Page 81 of 95
 82
Page 82 of 95
 CHAPTER-9 (23 August)
9.1 PRODUCER GAS PLANT

• Introductio
n
Producer gas is the cheapest fuel and can substitute
Furnace Oil, LDO, Kerosene, other fuel and other gases. It is
ideally adopted to industrial heating operation, because of its
uniformity, cleanliness and depend ability.
• Process Of Gas Generation
Producer gas is generated by injecting a blast of air and
steam through a layer of incandescent coal or coke.The
carbon of the coal or cock combines with oxygen of the air to
from carbon dioxide and the carbon dioxide as it goes up
meets hot unburnt coal or cock in reduction zone to form
carbon monoxide. The water vapors which passes through the
fuel reacts to form carbon monoxide and hydrogen.The chief
combustible elements in producer Gas are carbon monoxide
and some hydrocarbon.
• Fixed Coal gassfire
• For producing low carbon coal gas as fuel, generally a fixed
bed gasifier is recommended. In a fixed bed gasifier, the coal
passes downward in counter current direction to gas flow,
through various phases of drying, de-volatisation, gasification,
combustion zones and is ultimat

83
Page 82 of 95
 ely converted to ash which is extracted by rotation of a grate.
Mixture of air and steam is introduced in lower part of gasifier
through rotating grate.
• The basic reaction taking place in a typical fixed bed
gasifier
Coal +Air+Steam → CO2+CO+ H2+CH4 – (Coal Tar + Ash)
• The gas contains considerable amount of tar and in our
specific case, it must be cleaned (de-tarred by passing through
an Electrostatic Tar Precipitator (ETP). This produces a cold
clean gas.
• Raw materials For Production Of Producer Gas
1. RAW COAL
2. ATMOSPHERIC AIR
3. WATER
4. STEAM

Application
8
Page 84 of 95
 1. Producer gas is using as a fuel in various plant such as
Rail Mill, BSM, Plate Mill etc.
2. tar acquire as a by product which is using in various
chemical factories and laboratories for preparing other
product.

Advantages:-
1. Saving of furnace oil consumption.
2. Producer gas generating cost is low than furnace oil s direct
saving of cost.
3. running process is easy and low maintenance cost.
4. get coal tar as a by product. Selling rate of coal tar is
Rs.20000-25000/MT.
Disadvantages:-
1. Main component of this gas is carbon mono oxide, this is
most dangerous & poisonous.
2. There becomes environment pollution (air, land & water)
3. harmful gas for all alive being.
4. times very high safety precautions required and safety
apparatus are very costly.

85
Page 85 of 95
 86
Page 85 of 95
 9.2 PLATE MILL PLANT
• Introduction to plate mill plant
• JSPL is equipped with India’s first state-of-the-art plate
mill that started producing plates and coils of 5 meter and 3
meter width respectively, for the first time in the private sector.
• The plate-cum-coil mill (steckle mill) of 1 MTPA capacity
located at Raigarh, Chhattisgarh Produces plates ranging
from 8 mm to 120 mm in thickness in widths of 1500 mm to
3500 Mm and coils in thickness range of 8 mm to 25 mm
inwidths of 1500 mm to 2500 mm.
• The mill is equipped with walking beam type of reheating
furnace where slabs are re-heated at a temperature of 1250
degree celsius and rolled in a mill with a 2 hi-reversing type
roughing stand and a 4 hi-reversing type finishing stand. To
ensure excellent surface quality, high pressure de-scalers
are provided at the entry and exit points.
• An auto level 2 width and thickness controlling system
coupled with heavy leveler assures Close dimensional
tolerances and an increased level of flatness control. Right
from the slab Charging and plate production to the conclusive
stage, fully equipped inspection facilitiesAre in place.

• Process and Flow Chart

87
Page 85 of 95
 • Basically Plate Mill process starts from Continuous Slab
Caster where slabs are casted in different length and size
according to requirements of the final product. There after that
slab is transported to Charging table through different medial
there after that slab is charged in side the Reheating furnace
with the help of Charging Machine. Reheating furnace plays
an important role in Hot Rolling Mills. It’s necessary to bring
the hot metal above it’s recrystalisation temperature so that
hot rolling or we can say that plastic deformation can occurs.
• Reheating furnace consists of three zones ie preheating
Zone, heating zone and soaking zone in these zones slab are
guided to pass so that the slab gets the acquired temperature.
It takes approx 2-2 and half hours to heat up homogenously.
• After that slab is extracted with the help of slab extractor
Machine and the slab is kept on roller table which convey the
slab to the descaler where descaling is done after that the slab
is passes towards the roughing mills where in different no of
passes through roughing mills initial shape of the final shape
of final product is given there after that slab is transferred
towards the finishing mill where the final shape of the final
product is given which is either coil or plate. If the final
products are coils then where will be entry or exit coiler
fumace which purpose is to hold the entire length of the coil
and heat so that the recrystalization temperature after laminar
cooling is done after that it transferd towards upcoiler where it
gets the shape of the coil. And if it is plate then it is tranfered
to the heavy leveler where straighting is done or after that with

88
Page 85 of 95
 the help of divide shear that final plate cut in different size
there after it transfer to the transfer Bed
• PROCESS FLOW CHART

89
Page 85 of 95
 90
Page 90 of
 CONCLUSION REMARKS
The last Two weeks of training was very helpful and beneficial
for me. It gave me insight knowledge of at Jindal steel& power
plant. I would like to thank the entire faculty for helping me
browse throughout the Training. Through there skill of
expressing Of them, I have learned lot. In this report the
entire overview of the plant has been given and as a special
detailing Of each Section is Given

91

Page 91 of 95