REPORT ON

“INDUSTRIAL VISIT”

JSW STEEL , SALAV

SUBMITTED BY

ADITYA PRATAP DALVI

DEPARTMENT OF CHEMICAL ENGINEERING

DR. BABASAHEB AMBEDKAR TECHNOLOGICAL UNIVERSITY,LONERE
402103
2022-2023
 1.INTRODUCTION

JSW Steel (salav) Limited is a Non-govt company, incorporated on 27 Jun, 2008. It's a public
unlisted company and is classified as'company limited by shares'.

Company's authorized capital stands at Rs 200000.0 lakhs and has 67.89958% paid-up capital
which is Rs 135799.17 lakhs. JSW Steel (salav) Limited last annual general meet (AGM)
happened on 23 Jul, 2018. The company last updated its financials on 31 Mar, 2018 as per
Ministry of Corporate Affairs (MCA).

JSW Steel (salav) Limited is majorly in Manufacturing (Metals & Chemicals, and products
thereof) business from last 15 years and currently, company operations are active. Current board
members & directors are PRADEEP BHARGAVA, BHUSHAN LAL DEWANGAN, JUGAL
KISHORE TANDON, SASWATI GOSWAMI and PANKAJ RAJ MALIK .

Company is registered in Ahmedabad (Gujarat) Registrar Office. JSW Steel (salav) Limited
registered address is Welspun City, Village Versamedi, Taluka Anjar, Kutch Anjar GJ 370110
IN.

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 2.RAW MATERIALS

1.Prominent Source Of Natural Gas

2.Water
3.Iron Ore (Lumps and pallets)
4.Utility/Power

1.Natural Gas:

Natural gas to plant is supplied from GAIL (Uran) to the metering state located at the south of
the plant.
It is at high pressure 30-35 kg/cm2 , Pry valves controls the pressure of NG a n it is stored in
high pressure K.O Drum and pass through filter for filtration and removal of moisture then NG
is passed through HDS preheater which rises the temperature of NG to 3650C before entering
desulfurizer.
The raw NG contains about 25 to 30 ppm of sulfur by wt which needs to be <0.5 ppm because
it may affect the Nikel catalyst present in reforming reactions

The sulfur impurities are in the form of

H2S (Hydrogen sulfide)
CO-S(carbonyl sulfide)
These impurities are removed in desulfuriser Plant uses Zinc bed (ZnO) as a catalyst

The following reactions occurs:

R-CH2-CH2-SH  R-CH=CH2+H2S
H2S + ZnO  ZnS + H2O
COS + ZnO  ZnS =CO2
Now sulfur free NG can be used for reforming reactions and also raw sulfurized NG is used
for Burners in PGH and reformer burner

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2.Water:

Raw water from kundalika river is brought to the plant from roha and stored in the storage
tanks. Water in the plant is required for the purposes like Reforming process, Cooling process
and for drinking .
Water is filtered out and turbidity is reduced then the drinking water is separated and remaining
is further supplied to various type of processes.

3.Iron Ore:

iron Lumps and pallets are main materials needed for plant they are used as feed. It is reduced
by the reaction,

Fe2O3 + 3CO  2Fe + 3CO2

Fe2O3 + 3H2  2Fe + 3H2O

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4.Utility/power:

Electric power is very importaint in the plant. the Turbogenerator alone produce 8.6 MW worth
of electricity. It turns on the steam of 63 kg/cm coming directly from the steam drum.
Stand by NG generator an disel generator are used in case of equipment failure or emergency
ensureing the plant doesn’t stop.

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 3.REFORMER

We need Reforming gas reduction in order to carry out reduction. Desufurized NG and 12.5
legf/cm² of steam is mixed and heated upto 5400C and reforming reaction occurs

CH4 + 3H₂O  CO + 3H2

CO + 3H2O  CO2 + H2

The mixture of gas contain

75% hydrogen, 12% Carbon Monoxide , 7% Carbon Dioxide and 5% resudual gas.

Still we need to remove CO2 contain from reformed gas. This reformed gas is then passed
through CO2 Absorber plant where Solution is passed and CO2 is separated from reformed gas.
This gas is now called as process gas.

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 4.REACTOR

Reactor is located in the center of the plant. It is 117m in height. The main reducing reaction
occurs in reactor.there are 3 loading bins at the top thatfill the feed in the reactor. The columns
in the reactor are installed with control valves and a main Rotatory valve which is used for
separation of product in storage bin.

Process gas is heated up to 8300C to 9000C temperature by PGH which has 144 tubes which are
heated by 78 burners in radiation zone.therefor the reaction occurs,

Fe3O3 + 3CO  2Fe + 3CO2

Fe3O3 + 3H2  2Fe + 3H2O

While loading excess material after pre reaction occurs, IG after of pressure at 4kgf/cm² is
maintained.so the Product DRI is separated and excess steam and CO2 are sent for regeneration.

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 5. HBI Plant Operation

JSW Steel (Salav) Limited produces sponge iron with about 92% conversion of iron from iron
oxide. It is in basic two forms DRI (Directly Reduced Iron) and HBI (Hot Briquetted Iron).
DRI is having form of balls and lumps. HBI is in form of pallets which are produced by pallet
mill, both having almost same chemical composition but different in physical nature.

This NG is first de-sulphurised where sulphur compounds are removed from it. From de-
sulphuriser, NG is sent to reformer where it is mixed with steam and subjected to high
temperature. Reactions occur between NG and steam producing CO and H2, which are main
the components of reducing gas. The output from the reformer is subjected to quenching and
then sent to CO: absorber. In CO absorber, the excess CO2 present in the process gas is
removed.

From the absorber, the gas is sent to process gas heater where it is heated to 930°C and then
sent to the reactor.

Reduction reactions occur in the reactor in a complex manner. Final product is removed from
bottom of the reactor. The gas leaving from the reactor is subjected to compression, cooling
and mixed with the process gas before entering CO₂ absorber. The following process diagram
will give a brief description of the process.

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The JSW Steel HBI plant is based on the HYL-III process; It has been designed and planned
in line with proven HYL industrial plant engineering and latest technology available.

The plant consists of two independent sections:

1. Reducing Gas Generation

2. Reduction of Iron oxides

The reducing gas generation section includes a conventional natural gas-steam reformer and
auxiliary equipment such as heat recovery units, steam generators and reformed gas quenching
system.
The reformer consists of radient box containing a set of high alloyed tubes packed with nickel
based catalyst in which the reforming reactions takes place.
The reduction section concists of the HYL-III reactor in which oxygen removal from the iron
ore and carbon deposition take place. Also included in the reduction section are: One process
gas heater, one reducing gas recycle compressor, one top gas heat recuperator, one exhaust
reducing gas quenching / scrubbing system for water and dust removal and a carbon dioxide
scrubbing system. Iron ore pellets, lump ore, or mixtures of both, can be used as
feedstock in the reactor.

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Reducing Gas Generation

Natural gas, at 16 kg/cm2A. approx., is passed through a K.O. for removal of entrained liquids
and is conditioned in the desulphurization station to lower the sulphur level to less than 1 ppm,
which is adequate for the reformer catalyst. Desulphurized natural gas is mixed with superheated
steam in a steam to carbon ratio of about 2.4 to 1 by volume. The mixture is preheated to 550°C
and passed through the catalyst tubes in the reformer radiant section where the reforming
reactions are carried out at 830°C.

Reformed gas from the reformer, at 830°C and 6.8 kg/cm2g, is passed through the reformer
waste heat boller and the boiler feed water preheater, where sensible heat is recovered from the
reformed gas stream for the production of saturated steam. The reformed gas is then passed
through the reformed gas quenching system for H2O removal and is sent to the mixing point of
recycled reducing gas and reformed gas upstream the process gas heater. The thermal energy
requirements for the reducing gas generation unit are supplied by the combustion of gaseous
fuel. Since the combustion gases leaving the reformer radiant section carry a considerable
amount of sensible heat, several heat recovery units are installed in the reformer convection
section. In this manner, flue gases are discharged to the atmosphere with a considerably
lower temperature.

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Reduction of iron oxides

The set of components included in the reduction circuit are: Reactor reduction zone, top gas heat
recuperator, quenching/scrubbing system, recycle compressor, CO2 scrubbing system and
processing gas heater.

The reducing gas is made-up from the mixture of the reducing gas recycle stream, reformed gas
make-up and small amount of process natural gas. The reducing gas is passed the top gas heat
recuperator and then through the gas heater which heats it up to 933°C. The hot reducing gas
enters the reactor reduction zone and flows upward countercurrently to the iron oxide moving
bed. The reduction reactions and carburization of DRI take place in this zone.

Top exhaust reducing gas leaves the reactor at 380°C and passes through the top has heat
recuperator (where energy is recovered to preheat reducing gas going to the process gas heater)
and then to the quenching/scrubbing system. There, water produced during the reduction process
is condensed and removed from the top gas stream and most of the dust.carried with the gas is
also eliminated.

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 6.CONCLUSION

IMPORTANCE OF INPLANT TRAINING:

Theoretical study teaches us major aspects and facilitates us to construct a skeleton of our
profession. But, it still remains as an unachieved goal. This could be done easily by going
through practical aspects of the theory learnt in classrooms. Particular time duration for learning
such practical aspects to give a smooth finishing to our professions at the right time and of
course at a right place would be a clever idea to achieve this goal. My in-plant training at JSW
Steel Limitedproved to be a boon for my efforts towards beneficially completing my attitude of
being an under graduate. I have learnt efficiently the analytical concepts during this training
period. A perfect example of this could be my own report. Not just modification for the required
necessity but seeing the idea taking shape is an exceptional experience, which was very well
felt in this in plant training. Thus this project has been a rare opportunity and has been the perfect
transition from the study phase into the work phase. The contribution of this in plant training in
my career has been vital and intangible nature.

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