VISVESVARAYA TECHNOLOGICAL UNIVERSITY BELAGAVI

An internship report on

“JSW STEEL LIMITED”

Submitted in partial fulfilment of the requirement for the Award of Bachelor’s Degree of

Electrical & Electronics Engineering

During the year 2022-23

Submitted By
DHANUSH M D 3PG20EE407

Internship carried out at

JSW STEELS VIJAYANAGARA WORKS, TORANAGALLU

Internal guide Internship Coordinator HOD External guide

Mrs. SUMA Mrs. Firdosh P Mr. Prakasha S Sr. Manager (HR)
Asst. Professor Asst. Professor Asst. Professor JSW, Toranagallu

V.V.SANGHA’S

PROUDADEVARAYA INSTITUTE OF TECHNOLOGY

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
T.B. DAM, HOSAPETE-583225
 PROUDADEVARAY INSTITUTE OF TECHNOLOGY
ENGINEERING
DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING
T.B. DAM, HOSPETE-583225

CERTIFICATE

This is to certify that the Internship work on “JSW STEELS LIMITED” is a bonfire
work carried out by DHANUSH M D (3PG20EE407) in fulfilment for the award of
degree of Bachelor of Engineering in “ELECTRICAL & ELECTRONICS
ENGINEERING” of Visvesvaraya Technological University, Hospet, during the
academic year 2022-2023. It is certified that all corrections/suggestions indicated for
Internal Assessment have been incorporated in the report deposited in the department
library. The Internship report has been approved as it satisfies the academic requirements
in respect of Internship work prescribed for said Degree.

…………………………… …………………… …………………………

Signature of the Coordinator Signature of the Guide Signature of the HOD
Mrs. Firdosh P M.Tech Mrs. SUMA M.Tech Prof. Prakash. M.tech,.(PhD).

External Viva
Name of the Examiner Signature with date
1 ………………. ..…………………..
2 ………………. ……………………
 ACKNOWLEDGMENT

I am grateful to Shri Palleda Doddappa chairman, PDIT, Hosapete, for having provided
me excellent academic environment which has nurtured my practical skills and for kindly
obliging the requests and providing timely assistance.

I am grateful to Dr. Rohitha.U.M, Principal, PDIT, Hosapete, for having provided me

excellent academic environment which has nurtured my practical skills and for kindly
obliging the requests and providing timely assistance.

I express deep sense of gratitude to Prof. Prakash. S, HOD, Department of Electrical and
Electronics Engineering, PDIT, Hosapete, for their valuable guidance and suggestions in
carrying out this work successfully.

I express deep sense of gratitude to my technical guide Prof. Suma G.C Assistance
Professor, Department of Electrical and Electronics Engineering, PDIT, Hosapete, for their
valuable guidance and suggestion imparted at various stages in carrying out this work
successfully.

I am grateful to my interns coordinator Prof. Firdosh P assistance professor, (EEE) for

their valuable guidance and suggestion imparted at various stages in carrying out this work
successfully.

I express my sincere thanks to all the faculty and staff members of Department of Electrical
and Electronics, PDIT, Parents, Friends, for their kind and constant support throughout this
work.

DHANUSH M D
3PG20EE407
 DECLARATION

I am DHANUSH M D, student of VIII semester B.E studying in the Department of

Electrical and Electronics Engineering. Proudhadevaraya Institute of Technology,
Hosapete. Hereby declare that the Internship entitled “JSW STEEL LTD STEEL
MAKING” has been carried out under the supervision of MR. LAVKUSH ANNAND,
HR, JSW steel ltd, Toranagallu and submitted in partial fulfillment of the requirements
for the award of degree in Bachelor of Engineering in Electrical and Electronics
Engineering of Visvesvaraya Technological University, Belagavi during academic year
2022- 2023

PLACE: HOSAPETE DHANUSH M D

DATE: 3PG20EE407
 CONTENTS

SL. NO DESCRIPTION PAGE.NO

ACKNOWLEDGEMENT i
DECLARATION ii
CONTENTS iii
ABSTRACT iv
1 INTRODUCTION 1

1.1 JSW at a Glance 1

1.2 Historical Background 1

1.3 Challenges Faced By JSW 2

1.4 Production Process 2

1.5 Products Manufactured By JSW 3

2 PROCESS OF IRON ZONE DEPARTMENT 4

2.1 Explanation and Flow diagram of sintering process 4

2.2 Operation of sintering plant 5

2.3 Major equipment’s used in the sintering process 8

3 PROCESS OF STEEL ZONE DEPARTMENT 11

3.1 Process Flow Diagram 11

3.2 Power System 12

3.3 Hot Metal Desulphurization 13

3.4 .Electric Arc Furnace 13

3.5 Material Handling System 15

4 TASK PERFORMED 16

4.1 Fume Extraction System For Furnace 16

4.2 Ladle Heating Furnace 16

4.3 Water System 17

5 BILLET CASTER 18

5.1 Block Diagram of Billet Caster 18

5.2 Components of Billet Caster 18

5.3 Liftable Ladle Turret 20

5.4 Tundish Preheater 20

5.5 Tundish and Its Equipment’s 21

5.6 Liftable Tundish Car 21

6 MAIN EQUIPMENTS OF BILLET CASTER 23

6.1 Lance Temperature Measurement 23

6.2 FCC Mould 23

6.3 The Hydraulic Mould Oscillator 24

6.4 Electromagnetic stirrers (EMS) 25

6.5 Steam Exhauster 26

6.6 Withdrawal and Straightening Unit 26

6.7 Dummy bar 27

6.8 Intermediate roller table 28

6.9 Torch Cutting Machine (TCM) 29

6.10 In case of emergency the cutting is done by manual cutting 30

6.11 Discharge Roller Table 31

6.12 Lateral comb transfer 32

6.13 Walking beam cooling bed 33

6.14 Billet marking unit 33

6.15 Water Systems 33

6.16 Programmable Logic Controller (PLC) 35

7 SAFETY PRECAUTIONS IN INDUSTRY 36

8 REFELECTION NOTES 37

8.1 Internship Experience 37

8.2 Importance of Industrial Safety 38

8.3 Technical Outcomes 39

8.4 Non-Technical Outcomes 41

9 CONCLUSION 43

REFERENCES 44

Course Objective 45

Program Outcomes (POS) 46

Course Outcome Assessment Matrix 47

JSW Steel ltd. Vijayanagar Works

CHAPTER 1
INTRODUCTION
1.1 JSW at a Glance
The flagship company of JSW Group, JSW Steel is one of India’s leading integrated
steel manufacturers with a capacity of 18 MTPA. It is one of the fastest growing companies
in India with a footprint in over 100 countries. With state-of-the-art manufacturing facilities
located in Karnataka, Tamil Nadu and Maharashtra, it is recognized for its innovation and
quality. JSW offers a wide gamut of steel products that includes Hot Rolled, Cold Rolled,
Bare & Pre-painted Galvanized & Galvalume®, TMT Rebars, Wire Rods and Special
Steel.

JSW Steel continues to enhance its capabilities to meet the rapidly changing global
market needs. To stay on the leading edge of technical advancement, JSW has entered
technological collaboration with JFE Steel Corp, Japan to manufacture high strength and
advanced high strength steel for the automobile sector. JSW Steel has also entered into a
joint venture with Marubeni-Itochu Steel Inc. Tokyo, to set up a state–of-the-art steel
processing centres strengthen its global network, the Company has also acquired a Pipe
and Plate making steel mill in Baytown, Texas in USA. By end of next decade, JSW Steel
aims to produce 40 million tons of steel annually.

1.2 Historical Background

The foundation stone for “Vijayanagar Steel Plant” under Public Sector was laid by
then India’s PM, in 1971. More than 20 years later, in spite of Economic Liberalization in
1992, no one came forward to fulfil the dreams of the PM, because none considered it a
viable proposition. The invitation from the Govt. of Karnataka in 1994, & naturally was
accepted as a challenge.

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1.3 Challenges Faced By JSW

1. Barren land
2. Inadequate water source
3. No electricity
4. Poor road and rail connectivity
5. Poor infrastructure
6. Non availability of carbon fuel
7. People to build and operate
8. Low quality iron ore

1.4 Production Process

1. Beneficiation
2. Pelletizing
3. Sintering
4. Blast furnace
5. Corex process
6. HMDS
7. Converter process
1. Beneficiation: In the mining industry beneficiation or beneficiation in extractive
metallurgy, is any process that improves (benefits) the economic value of the ore
by removing the gangue minerals, which results in a higher grade product
(concentrate) and a waste stream (tailings).
2. Pelletizing: Pelletizing is the process of compressing or moulding a material into
the shape of a pellet. A wide range of different materials are pelletized including
chemicals, iron ore.
3. Sintering: Sintering is the process of compacting and forming a solid mass of
material by heat or pressure without melting it to the point of liquefaction. Sintering
happens naturally in mineral deposits or as a manufacturing process used with
metals, ceramics, plastics, and other materials.

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4. Blast furnace: The blast furnace is a huge, steel stack lined with refractory brick,
where iron ore, coke and limestone are dumped into the top, and preheated air is
blown into the bottom. The raw materials require 6 to 8 hours to descend to the
bottom of the furnace where they become the final product of liquid slag and liquid
iron. The hot blast temperature can be from 900 °C to 1300 °C (1600 °F to 2300
°F) depending on the stove design and condition.
5. HMDS: The reagent transfer in the injection line is under dense flow conditions.
The process allows the use of several desulphurization reagents, such as lime,
calcium carbide and magnesium, which remove the Sulphur in the hot metal by
chemical reaction and convert it to the slag.
6. Converter process: Basic oxygen steelmaking (BOS, BOP, BOF, and OSM), also
known as Linz–Danowitz-steelmaking or the oxygen converter process is a method
of primary steelmaking in which carbon-rich molten pig iron is made into steel.

1.5 Products Manufactured By JSW

1. Hot rolled coils (HR-coils)

2. Cold rolled coils (CR-coils)
3. TMT Bars
4. Wire rods
5. Galvanised
6. Galvalume
7. Colour coated products
8. Neo-steel TMT Bars.

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JSW Steel ltd. Vijayanagar Works

CHAPTER 2

PROCESS OF IRON ZONE DEPARTMENT

2.1 Explanation and Flow diagram of sintering process

The sintering process is a pre-treatment step in the production of iron, where fine
particles of iron ores and also secondary iron oxide wastes (collected dusts, mill scale etc.)
along with fluxes (lime, limestone and dolomite) are agglomerated by
combustion. Agglomeration of the fines is necessary to enable the passage of hot gases
during the blast furnace operation.

Although simple in principle, sintering plant requires that a number of important

factors in its design and operation be observed to attain optimum performance. A simplified
schematic flow diagram of sintering process.

Fig 2.1 Simplified flow diagram of a sintering process

Two important properties of sinter are basicity, which is controlled by the amount
of limestone/lime, and strength, which is controlled by coke content.

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JSW Steel ltd. Vijayanagar Works

2.2 Operation of sintering plant

a) The sintering process starts with the preparation of the raw mix. Materials
consisting of ore fines, fluxes, in-plant waste material, fuel and return fines are stored in
storage bins. They are mixed in the correct proportions using weigh hoppers/disc feeders,
one per storage bin. The weighed materials pass along a conveyor to the mixing drum
where water is added as a calculated percentage of the weight of material entering the
mixing drum.

b) Intimate mixing of the feed materials is one of the most important. A pre mix
(usually called base mix) of the sintering ores, steel plant waste oxides, fluxes, and solid
fuels is made in a revolving primary mixing drum is transferred to an open base mix
blending yard. This total feed mixture is the subject to a water addition within a mixing
device such as a balling drum. These mixers are operated to produce small size nodules or
pellets which significantly improve the permeability of the sinter bed.

c) The amount of primary water added is proportional to the weight of base mix
entering the balling drum. Water additions in the balling mixers are now automatically
controlled these days .The secondary water feed set point is frequently taken as a proportion
of the base mix belt weight.

d) The continuous sintering process is carried out on a travelling gate of sinter

machine that conveys a bed of prepared mix (sinter mix). In transferring the sinter mix
from the balling mixer to the gate of the sintering machine, it is essential to feed the material
carefully so as to provide a uniform, homogeneous bed and to prevent compacting of the
bed.

e) To avoid a direct drop of feed onto the gate, a hearth layer of about 25 mm to
50 mm of coarse (already sintered) material is fed first onto the travelling gate. Feeding
devices typically include a roll feeder in conjunction with chutes which act to avoid
compacting the sinter mix.

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JSW Steel ltd. Vijayanagar Works

f) The bed depth is set and kept constant by adjusting the cut-off plate which is
fitted with probes to sense the depth of material and automatically vary the roll feeder
speed. The quantity of material in the feed hopper itself is held constant by automatic
adjustment of the feed rates from the individual sinter mix bins.

g) Once the sinter mix is charged onto the travelling gate, metal bars or rods already
inserted longitudinally along the gate for a distance of about 2 m to 4 m help to loosen up
the mixture to enhance permeability. Thereafter the surface of the sinter mix is ignited near
the head or feed end of the travelling gate using a mixed gas (coke oven gas and blast
furnace gas).

h) As the sinter mix moves along on the travelling gate, air is sucked down by a
draught fan through the ignited sinter mix layer to burn the fuel by downdraft combustion.
As the gates move continuously over the wind boxes toward the discharge end of the strand,
the combustion front in the bed moves progressively downward. This creates sufficient
heat and temperature, about 1300 deg C to 1480 deg C.

i) An important part of the sintering process is burn-through. The location along

the travelling gate where the combustion front touches the bottom of the bed is called the
burn through point. Burn-through point should ideally occur near the end of the strand bed.
It is controlled by altering the strand speed. Burn through is normally detected by
temperature probes under the sinter bed.

j) The strand speed is either controlled manually, or by measuring the waste gas
temperatures as an indication of the burn-through point. If it occurs too early, the average
waste gas temperature rises. If it occurs too late, the waste gas temperature decreases and
the strand speed is slowed to compensate. Wind box temperatures can be used to improve
the monitoring.

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JSW Steel ltd. Vijayanagar Works

k) After the end of the travelling gate, the sinter passes through a spiked roll crusher
and the hot screens to the sinter cooler. A number of fans are usually used for cooling, and
the speed of the cooler is to match the demand of the travelling gate and is determined by
the travelling gate speed and the bed depth. The fines removed by the hot screens are
conveyed to the return fines bin.

l) Cooling of the sinter below 150 deg C, so that it can be handled on conveyor
belts, is an important part of the operation. Sinter coolers can be either rotary coolers or
straight line coolers. Rotary coolers are more commonly used. The exhaust air from these
coolers is used for recovery of heat in some of the sinter plants.

m) After cooling, the sinter is passed into the discharge bunker. At this stage, the
level is controlled by varying the outlet feed rate. The sinter then passes to the cold
screening area, where it is passed through crushers and screens for the separation of product
sinter, bedding and return fines. Return fines, not suitable for downstream processing, are
conveyed to a bin for recycling in the sintering process.

n) Use of sized sinter is desirable for the improvement of production rates in the
blast furnace. Further, crushing the sinter to 30 mm size at the sinter plant yields a more
stable sinter because the smaller size fractions are more resistant to degradation.

A supervisory station controls all steps of the sintering process. From the control room the
operator has full control of the entire plant through the PC terminals.

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JSW Steel ltd. Vijayanagar Works

2.3 Major equipment’s used in the sintering process

Induction motor :An induction motor or asynchronous motor is an AC electric motor in

which the electric current in the rotor needed to produce torque is obtained
by electromagnetic induction from the magnetic field of the stator winding. An induction
motor can therefore be made without electrical connections to the rotor. An induction
motor's rotor can be either wound type or squirrel-cage type.
Table 2.1 Specifications of 10MW induction motor

Power 10MW
Voltage 3100 V
Frequency 50 HZ
RPM 1000
Amps 2191 A
P.F. 0.88
Efficiency 97%
Insulation Class F
Rated torque 95494 Nm
Load characteristics load% Efficiency % Power factor
100% 98.1% 0.87
75% 97.9% 0.85
50% 97.6% 0.79

b. Electrostatic precipitator: An Electro Static Precipitator (ESP) is a filtration device

that removes fine particles, like dust and smoke, from a flowing gas using the force of an
induced electrostatic charge minimally impeding the flow of gases through the unit.

c. Conveyor system: A conveyor system is a common piece of mechanical handling

equipment that moves materials from one location to another. Conveyors are especially
useful in applications involving the transportation of heavy or bulky materials. Conveyor
systems allow quick and efficient transportation for a wide variety of materials, which

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JSW Steel ltd. Vijayanagar Works

make them very popular in the material handling and packaging industries. They also have
popular consumer applications, as they are often found in supermarkets and airports,
constituting the final leg of item/ bag delivery to customers. Many kinds of conveying
systems are available and are used according to the various needs of different industries.
There are chain conveyors (floor and overhead) as well. Chain conveyors consist of
enclosed tracks, I-Beam, towline, power & free, and hand pushed trolleys.

d. Transformers: A transformer is a static electrical device that transfers electrical energy

between two or more circuits through electromagnetic induction. A varying current in one
coil of the transformer produces a varying magnetic field, which in turn induces a
varying electromotive force (emf) or "voltage” in a second coil. Power can be transferred
between the two coils, without a metallic connection between the two circuits. Faraday's
law of induction discovered in 1831 described this effect. Transformers are used to increase
or decrease the alternating voltages in electric power applications.

Table 2.2 Name plate details of 14MVA transformer:

KVA 14000
Primary voltage 33000
Secondary voltage 1725
Primary Amp 244.94
Secondary Amp 2342.87
% Impedance 9.64%
Vector Group Dd0yn1
Type Of Cooling ONAN
Temperature Rise In Oil/Wdg 40°
Tap Position 3

e. Induced Draft and Forced Draft fans:

Induced Draft: - An ID fan is used to extract the air from boiler post combustion
via (Electrostatic Precipitator if present) and to exhaust through the chimney.

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JSW Steel ltd. Vijayanagar Works

Forced draft: - A FD fan is used to force air into the boiler to provide more air for
combustion.

f. Variable Voltage Variable Frequency Drive (VVVFD): A variable voltage-

frequency drive (VVFD); also termed adjustable-frequency drive, variable speed
drive, AC drive, micro drive or inverter drive) is a type of adjustable-speed drive used
in electro mechanical drive systems to control AC motor speed and torque by varying
motor input frequency and voltage.

VFD= Variable Frequency Drive

VVVFD = Variable Voltage Variable Frequency Drive

The motto of both is same to control the speed of motor and in some cases current by
varying voltage. Both runs on v/f mode.

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JSW Steel ltd. Vijayanagar Works

CHAPTER 3

PROCESS OF STEEL ZONE DEPARTMENT

STEEL MELTING SHOP- 3

3.1 Process Flow Diagram

Fig 3.1: SMS 3 Process Flow Diagram

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JSW Steel ltd. Vijayanagar Works

3.2 Power System:

The power is provided into the units through LTSS-1 and LTSS-2. The main power
transformer provides a power of 33KV. Its rating is: 25/31.5 MVA; 33/6.6 KV. There are
two main supply transformers. The 33KV supply is converted in 6.6KV supply through oil
cooled transformers. Then the 6.6KV supply is converted into 415V supply which is then
supplied into various other feeders, transformers which control the process and
equipment’s of EAF, HMDS, LHF, WCS, CASTER and the cranes at each section.

Fig 3.2: 25/31 MVA, 33KV/6.6 KV Main Transformer

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JSW Steel ltd. Vijayanagar Works

3.3 Hot Metal Desulphurization

▪ The hot metal is transported from the pouring station to the injection position by
means of a ladle car.
▪ Treatment or de-sulphuration is done in the filled hot-metal ladle (process vessel)
by injecting reagents through lance with carrier gas as nitrogen.
▪ Treatment section has sub- systems for controlled functioning and operation of
individual equipment’s

Fig 3.3: Hot Metal Desulphurization

3.4 Electric Arc Furnace:

▪ Input:-
• HDRI(Hot Direct Reduced Iron),
• Scrap material,
• Hot Metal
- Three electrodes are used for arcing.
- There are four injectors for injection of oxygen and coke which is utilized to form
slag.

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JSW Steel ltd. Vijayanagar Works

▪ Operation:

Fig 3.4: Electric Arc Furnace

An electric arc furnace used for steelmaking consists of a refractory-lined vessel,

usually water-cooled in larger sizes, covered with a retractable roof, and through which
three graphite electrodes enter the furnace.

The furnace is primarily split into three sections:

• Upper shell, which consists of the water cooled panels and injectors
• Lower shell, which consists of the refractory that lines the lower shell;
• Roof, which is water-cooled. The roof also supports the refractory delta in its
centre, through which three graphite electrodes enter.

Refining operations in the electric arc furnace have traditionally involved the
removal of carbon, phosphorus, silicon, manganese from the steel. Traditionally, refining
operations were carried out following meltdown i.e. once a flat bath was achieved. These
refining reactions are all dependent on the availability of oxygen. Oxygen was lanced at
the end of meltdown to lower the bath carbon content to the desired level for tapping. Most
of the compounds which are to be removed during refining have a higher affinity for
oxygen that the carbon.

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JSW Steel ltd. Vijayanagar Works

Thus, the oxygen will preferentially react with these elements to form oxides which
float out of the steel and into the slag.

Liquid hot metal and DRI is converted into liquid steel by addition of fluxes & then
arcing and blowing gaseous Oxygen in EAF.

Thus liquid hot metal and DRI is converted into steel and tapped into refractory lined
steel ladles through tap hole. Which are transported further to the next process link in the
chain of steel making.

Fig 3.4[a]: Electric Arc Furnace

3.5 Material Handling System (MHS)

• MHS is used to charge the materials to the EAF and LHF which is weighed first.

• MHS provides fluxes such as lime (Cao), Calcined dolomite and dolomite
(Caco3.MgCo3), CDRI as coolant in furnace.

• MHS is having 5 storage bunkers.

o Two of which is capacity of 250 m3 for CDRI,

o One 250 m3 and 125 m3 is for Lime and one 125m3 is for Dolomite.

• MHS is filled with these Raw material from Bulk receiving Unit (BRU)

• And DRI Plant from main conveyor.

• There are 2 main conveyors for filling MHS.

• MHS is also having Flux and Ferro Alloy (FAFA) bunker each having capacity of
10m3 for flux and alloy addition in Ladle Heating Furnace (LHF).

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JSW Steel ltd. Vijayanagar Works

CHAPTER 4
TASK PERFORMED

Extractions for Furnace

4.1 Fume Extraction System for Furnace

A Fume Extraction system will be designed and installed for extraction of fumes
from EAF during processing, secondary fumes from EAF, LF, HMDS and RMHS.

The new EAF will be supplied with required water-cooled combustion chamber. A
set of water-cooled ducts will be required for cooling the primary fumes to a temperature
before entering the gas cooler. Requirement of water-cooled ducts will be up to a certain
length and this will be connected to uncooled ducts guiding the fumes to the gas cooler.
Uncooled ducts after gas cooler will be guiding the fumes to gas mixer and then to the bag
house. For extraction of EAF secondary fumes, the basic design of a new canopy at roof
top with ducts connecting to the spark arrester will be provided.

4.2 Ladle Heating Furnace

Secondary steelmaking is most commonly performed in ladles and often referred
to as ladle (metallurgy). Some of the operations performed in ladles include de-oxidation
(or "killing"), vacuum degassing, alloy addition, inclusion removal, inclusion chemistry
modification, de-sulphuration and homogenization.

It is now common to perform ladle metallurgical operations in gas stirred ladles

with electric arc heating in the lid of the furnace. Tight control of ladle metallurgy is
associated with producing high grades of steel in which the tolerances in chemistry and
consistency are narrow.

Fig 4.2 Ladle Heating Furnace

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JSW Steel ltd. Vijayanagar Works

4.3 WATER SYSTEM

Main Equipment’s of cooling water Quantity

Primary Secondary
Sl. No Description Emg. Water
Water Water

1 EAF 2507 M3/Hr 2435 M3/Hr 950 M3/Hr

2 LHF 512 M3/Hr 600 M3/Hr 175 M3/Hr

3 HMDS 100 M3/Hr 0

785 M3/Hr
4 Air Compressors 500 M3/Hr 0

5 FES 2800 M3/Hr 4410 M3/Hr 0

Caster Mould, Machines & EMS

6 1794 M3/Hr 1800 M3/Hr 492 M3/Hr
cooling

7 Spray cooling 700 M3/Hr 0

8 SVC system (Heat exchanger) 40 M3/Hr 0

9 Chillier unit Melt shop 250 M3/Hr 0

10 Chillier Unit Caster 350 M3/Hr 0

Table-1: Main Equipment’s of cooling water Quantity

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JSW Steel ltd. Vijayanagar Works

CHAPTER 5
BILLET CASTER
5.1 Block Diagram of Billet Caster

Fig 5.1 Block Diagram of Billet Caster

5.2 Components of Billet Caster

1. Ladle turret
2. Tundish car
3. Tundish preheater
4. Mould casing
5. Hydraulic unit

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JSW Steel ltd. Vijayanagar Works

6. Pumps
➢ Re-circulating pump
➢ Casting floor utility pump
➢ CCM utility pump
7. Slide gate
8. Mould Oscillator
9. Cooling
➢ Mould Cooling (primary Cooling)
➢ Spray cooling (secondary cooling)
➢ Tertiary cooling
➢ Emergency Water (it consists of three tanks )
10. Strands
➢ Total number of strand:6
➢ Dummy Bar
➢ Pinch roll control
11. Cutting torch
12. Cooling Bed
13. Run out area:
➢ Intermediate roller table1,2
➢ Torch cutting roller table
➢ Discharge roller table
➢ Withdraw straighten unit
➢ Cooling bed 1&2
➢ Pawl table

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JSW Steel ltd. Vijayanagar Works

5.3 Liftable Ladle Turret

Fig 5.3: Liftable Ladle Turret

➢ The casting machine is provided with a ladle turret consisting of two hydraulic
actuated lifting arms that are mounted on a single rotating frame.
➢ Support the ladle & rotate them from the charging position to the casting position.

5.4 TUNDISH PREHEATER

➢ Moisture removal in tundish.

➢ Maintain ideal super heat in tundish.
➢ Avoid thermal shock to pouring refractory.
➢ Ladle to tundish temperature drop minimized.
➢ Smooth start of casting.

Fig 5.4: Tundish Preheater

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JSW Steel ltd. Vijayanagar Works

5.5 Tundish And Its Equipment’s

Tundish:

Hold liquid steel and distribute it equally on the casting strands. Tundish Is lined
with refractory material and has a delta shape for optimal distribution of liquid flow on
the casting strands

Type: Delta

Nominal Capacity: 37 T

Max. Capacity: 39 T

Steel Level: 900mm

Overflow Level: 950mm

Steel Flow Control: FNC

5.6 Liftable Tundish Car

It is used to support the tundish & to transport it from the preheating position to the casting
position.

➢ Traverse movement

Two motors driven by a single variable speed drive set of limit switches.

➢ Lifting movement

-Four hydraulic cylinders

-Solenoid valves

-Position transducer

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➢ Centring movement

-Double solenoid valves

-Two hydraulic cylinders

➢ Weighting system

-Load cells

Fig 5.6: Liftable Tundish Car

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CHAPTER 6
MAIN EQUIPMENTS OF BILLET CASTER
6.1 Lance Temperature Measurement

A temperature measurement system is provided at cast floor. It has the purpose to

acquire the tundish temperature and notify it to the level 2.The temperature is acquired by
the means of immersion type probe.

Fig 6.1: Lance Temperature Measurement

6.2 FCC Mould

➢ FCC is an integrated and compact unit consisting in a fixed frame, an oscillating

table and Removable Mould Cartridge.
➢ It drives the mould, which is mounted to the oscillator table of mould oscillator.
The oscillator drive moves the mould up and down in a sinusoidal motion along the
casting radius.
➢ This kind of motion prevents the liquid steel and the Billet from sticking to copper
tube of mould.

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Fig 6.2 FCC Mould

6.3 The Hydraulic Mould Oscillator

The hydraulic mould oscillator allows the vertical movement of mould during the
casting. This movement prevents the sticking of the molten steel to the mould sleeve. The
oscillation is achieved by one hydraulic cylinder controlled by one servo-valve.

Fig 6.3 The Hydraulic Mould Oscillator

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-Servo-Valve for oscilador control

- Solenoid valves pressure and tank line cut-off
- Position transducer

- Pressure transducers
- Shock absorber low pressure
- Mould oscillator type : Hydraulic
- Number of Hyd Cylinders :2
- Working Pressure : 20 MPa
- Oscillation/min : 400 OPM
- Stroke : 16mm

6.4 Electromagnetic stirrers (EMS)

• The purpose of electromagnetic stirrers (EMS) is to stir the liquid steel.

• The stirring improves sub-surface/internal quality and increases the heat removal
factor (for high casting speed).

Fig 6.4: Electromagnetic stirrers (EMS)

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6.5 Steam Exhauster

• The cast strands passing through the cooling chamber are cooled by means of the
secondary open cooling water system. The large amount of steam generated, is
sucked out with 2 exhausters mounted at the lateral cooling chamber walls.
• An AC motor is used to drive the fan which is mounted outside the exhauster, by
means of pulleys and belts.
• Capacity : 60000 Nm3 / hr

6.6 Withdrawal and Straightening Unit

The withdrawal is used for the insertion or retraction of the rigid dummy bar and
retraction of the cast strand. The upper and lower withdrawal roll motors are provided with
an incorporated holding brake, for keeping the rigid dummy bar in position if re-stranded.

Fig 6.5: Withdrawal And Straightening Unit

Model: 5 roll

Driven Rolls: 3

Idle Rolls: 2

Number of unbending Points: 2

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Speed: 0.6 to 6m/min

Type of drive: Electrical

Pinch Action: By Hydraulic

• The lower withdrawal roll motor is provided with incorporated pulse generator
mainly used for tracking functions. The upper rolls of the withdrawal and
straightening unit can be raised and lowered with the rocker arms.
• The rocker arms are controlled hydraulically into their up/down positions. The
second pair of rolls (straightening rolls) has the function to bend the curved strand
to a straight one.

6.7 Dummy bar

• The purpose of dummy bar is to seal the mould when it is not yet filled with molten
steel.
• The dummy bar is then used to drive the billet until it exits from the withdrawal
rolls.

• The dummy bar is then separated from the billet by lowering the Straightner roll.
After disconnection the dummy bar is parked.

Bottom Feeding with radius: 9m

Length of Dummy Bar approx: 13m + 2m head

Recovering of DB: By Pneumatic

Parking Rotation: By Hydraulic

Length of parking Device: 14.44m

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Fig 6.6 Dummy bar

6.8 Intermediate roller table

-Support the strand during their travel from the straightening unit to the oxy-cutting
machine.

-Pinch roll is provided at the end of IRT & hydraulically operated to remove the
last bar length.

-No of rolls: 9 rolls approx.

-Rolls pitch: 1500mm
-Diameter of Rolls: 235mm.
-Type drive: AC Gear motor with inverter.

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6.9 Torch Cutting Machine (TCM)

Cutting the hot strand in billets variable lengths is made by a torch cutting machine
(TCM).The desired piece length is automatically detected by means of encoder at WSU.
Forward motion is achieved at casting speed when the pneumatic cylinder actuates the
clamping arms. A motor with frequency converter drives the torch in cross direction. After
cut completion a motor combined with an automatic actuated electromagnetic clutch drives
the torch cutter back to home position.

Fig 6.8: Torch Cutting Machine (TCM)

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6.10 In case of emergency the cutting is done by manual cutting

Fig 6.9: In case of emergency the cutting is done by manual cutting

-No of torches: 1 + 1
-Machine travelling distance: 4500 mm

-Billet Cut Length: 9-12 m

-Type of drive: Electric motor with inverter.

-Clamping: By pneumatic cylinder

Gas for cutting:

LPG (FR-12 nm3/ hr, Pr-2-3 bar) &

Oxygen (FR-55Nm3/hr, Pr-10-16 bar)

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6.11 Discharge Roller Table

The roller table is used to transport billet after the torch cutting machine

DRT:-

No of rolls: 8 rolls approx.

Rolls pitch: 1500mm

Diameter of Rolls: 235mm

Common roller table (CRT):

▪ No of rolls: 4 rolls approx.

▪ Rolls pitch:1500 mm
▪ Diameter of Rolls: 235mm.

Fig 6.10: Discharge Roller Table

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6.12 Lateral comb transfer

• Transfer of Billet from the strands to the walking beam cooling bed
• An AC motor driven by an inverter controls the transfer car traverse. It is equipped
by a electrical brake and cooling fan.
• An incremental encoder determines the position of the transfer car. The position
zero is done with the encoder reset limit switch. Two limit switches detect the right
and left side stop position.

Fig 6.11 Lateral comb transfer

Runway Length (approx): 10000mm

Pushing Speed: 24m/min

Type of drive: AC Motor.

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6.12 Walking beam cooling bed

It is used to cool down the billets while transporting them to the collecting table at cooling
bed exit

• The functions are:

• Translation forward/reverse
• Lifting/lowering
• The cooling bed horizontal movement is done two by hydraulic cylinders
• The cooling bed lifting is done by four hydraulic cylinders
• No of Notches: 53
• No of Fixed & Movable Blades: 9 each
• Length of bed: 20m
• Type of Drive: Hydraulic.

6.13 Billet marking unit

Mark the head of the billet with a combination of letters and numbers for identification.

Type of Drive: Electrical

Max no of characters:12

6.14 Water Systems

Mould Cooling System & Machine Cooling System

• The Purpose Of Mould Cooling System In Caster Is To Remove Enough Heat From
The Liquid Steel.
• Inside The Mould To Allow The Formation Of A Strand Shell, Which Has
Sufficient Strength Both To Prevent The Liquid Portion Of Steel Inside The Strand
From Breaking Out At The Mould.
• The Purpose Of Machine Cooling Is To Remove Enough Heat Which Is
Transferred From The Hot Strand To The Machine Parts By Thermal Conduction,
Convection And Radiation.

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Fig 6.13 : Water Systems

• SPRAY WATER SYSTEM

➢ Spray cooling system is for cooling the billet continuously during casting in caster
to form liquid steel to solid shell and to slab.
➢ It is having different flow at different loops i.e. areas as per the requirement
according to steel grade and casting speed.
➢ CCM Secondary Spray Cooling:540 m3/hr at 14bar

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6.15 Programmable Logic Controller (PLC)

Fig 6.14 Programmable Logic Controller (PLC)

• A Plc Is A Device That Was Invented To Replace Necessary Sequential Relay

Circuits For Machine Control.
• Plc Works By Looking At Its Inputs And Depending Upon Their State, Turns
On/Off Its Output.
• All The Equipments And Process Are Controlled By The Plc.
• Plc Is The Main Component Through Which People In The Control Room Can
Control The Equipment And Process & If Any Problem Occurs It Can Be Detected
Through The Plc.
• Plc Works By Continually Scanning A Program. This Scan Cycle Consists Of 3
Important Steps:
• 1. Checking Input Status.
• 2. Execute Program.
• 3. Update O/P Status.
• One Scan Time Is Defined As Time It Takes To Execute The 3 Steps.

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CHAPTER 7
SAFETY PRECAUTIONS IN INDUSTRY

The company has to strictly maintain the safety of workers and visitors and accidents
prevention measures.

Which are as follows-.

➢ The company has to make strict rules of wearing safety shoe, helmet, ear muffs,
leather gloves and safety goggles.

➢ Live electric wires are routed over head at site, so care should be taken while
shifting long conducting materials like steel rods.

➢ Workers should not start any work without obtaining any instructions from the
supervisor or safety officer.

➢ Ensuring that the machines you are using is properly checked and maintained.

➢ Smoking is not allowed at the work stations.

➢ In case of any emergency, the coded siren will be sounded for two minutes to alert
the work stations.

➢ Provision of adequate fire extinguishing equipment.

➢ Fire alarm systems and alert efficient and well-trained fire-fighting squads
promptly available at all times.

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CHAPTER- 8
REFELECTION NOTES

8.1 Internship Experience

Internship work carried out at JSW Steel Limited, Bar Rod Mill-1 was a good
experience. Most of the things which were studied as a part of academics could be
practically experienced. At the initial stage of internship understood briefly the steel
making process, all the departments involved and their contribution in steel making. During
the department allocation for internship I was allotted to Bar Rod Mill, were in billets are
rolled to get TMT bars which are mainly used in construction. Practically observed the
rolling mill stands, rolling process, water quenching involved for TMT process, reheating
of billet at furnace, use of hydraulic and pneumatic cylinders across all the mill line.
Opportunity to compare most of academics part with the practical situation like
operating of hydraulic cylinders, components of hydraulic system like pump, filter,
direction control valves, flow control valves, flow distributors. Exposure to material
handling systems at industry level.
Improvement in verbal and written communication, enhancing knowledge,
presentation skills, decision making and problem analysis skills, mail communication.
The most important outcome of Internship is the need for safety at industry, and
industry safety should be taken seriously. Any person entering the industry should have a
basic knowledge of safety. Different safety standards practiced at industry level.
Improvement in problem solving skills with the task performed at industry during the
Internship. Use of QC tools to determine the area contributing most for mechanical delays,
performing this task has helped in learning MS Excel, usage of Excel for plotting graphs,
usage of logic in Excel which makes calculations and tabulations easier and faster in MS
Excel.

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8.2 Importance of Industrial Safety

• The most important factor or the context to be understood is safety and should have
brief knowledge of industrial safety before entering any industry.
• Before starting the Internship at JSW Steel Ltd, mandatory training was provided
on Industrial Safety.
• It is mandatory to wear all the Personal Protective Equipments (PPE’s) which
include Safety helmet, Safety Shoes, Ear Plug, Goggles, Dust mask and Safety
jacket.
• Understood different hazards in the work location which include hot rolling
material, hot surface, rotating equipment, electrical shocks, slip and fall, noise.
• Different types of Fire extinguisher and how to operate them during Fire incident.
• Location of Assembly point, idea about unsafe act and unsafe condition.
• Important steps to be checked while working at height (above 1.8m from ground)
• Steps followed to avoid accidents are to follow the Standard Operating Procedure
(SOP) and Stand Maintenance Practices (SMP).
• Employees are given First Aid training, and availability of First Aid Kit at all the
work location
• Regular safety trainings carried out at JSW are Road Safety, Permit To Work, Lock
Out Tag Out, Work At Height, Confined Space Entry.

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8.3 TECHNICAL OUTCOMES

8.3.1 Exposure to Operational Aspects in Rolling Process
• During the course of Internship had a good exposure to Rolling Process.
• As Metal Forming Process (Rolling) being part of academics, could compare most
of the things studied, into a practical situation.
• Surface oxidation results in Scale formation and is removed off at De-scalar, if the
scale is not removed at the exit of furnace then it may lead in accumulation near
rolling stands and Guide rollers may jam and face difficulties during rolling.
• Defects due to defective billets or the input raw material. During rolling process
blow holes present in billet may lead to breaking of the rolling bar, and may stop in
between rolling stands which further leads to difficulties.
• Difficulties in handling equipment’s in hot rolling process. In mill stands the
temperature of billet will be around 950oC so it will be very difficult in inspection,
stoke checking and to work at mill stands immediately after mill stoppage.
• It is very important to maintain the Roll gap for smooth rolling or else it may lead
to splitting of material.
• Maintaining proper water flow and pressure for rolling speed is most important to
achieve the yield strength.
• Rolling results in wear of pass of Stand, hence it is very important to check for the
stock size at different locations for smooth rolling operation.
• Check for proper alignment between rolling stand and guides, as any misalignment
lead to improper movement of rolling material.

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8.3.2 Brief Understanding Of Industrial Procurement Process

• The end user gives the list of requirements to the planning cell.
• Planning cell consolidate the requirements, create the item code for the same.
• Purchase requisition will be raised based on the requirement and is processed for
approval as per the hierarchy.
• The approved purchase requisition will be sent to material management department
for procurement.
• Material management department will send the enquiries to different vendors for
the supply of material.
• Once the quotation from the vendors is received, the same will be forwarded to end
user for technical evaluation.
• After technical evaluation, the offers will be sent to material management
department for placing the order.
• Based on the technical evaluation the material management department will
negotiate with the vendors and the order will be placed with a delivery period.
• Vendor will supply the material within the delivery period to central stores and
goods receipt note will be raised.
• The end user will inspect the material as per the specification and the goods receipt
note will be cleared.
• The cleared invoice will be further forwarded to accounts department for
verification and clearance. Further it will be forwarded to treasury for payment as
per the purchase order terms.

8.3.3 Maintenance Practices

• Maintenance is the regular activity which is carried out to have good healthiness of
equipment’s and higher equipment availability.
• Monthly two or three shutdowns are planned to carry out the maintenance activities.
• Exposure to different type of maintenance practices like Preventive maintenance,
corrective maintenance, breakdown maintenance, opportunity based maintenance,
condition based maintenance.

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• Condition based maintenance practice include regular monitoring of Mill stand

Gearbox bearing vibration and speed. Oil analysis of all the lubrication and
Hydraulic system. The reports are analyzed and if any abnormalities an inspection
is carried out during planned shutdowns and opportunity downs and necessary
corrective action are planned.
• Regular points which are to be monitored are bearing temperatures, torque details,
vibration of bearing points, blade gap in case of shears, and condition for roller
surface for proper flow of material.

8.4 NON-TECHNICAL OUTCOMES

8.4.1 Decision Making and Problem Analysis
• Exposure to problem analysis, in case of any problem during rolling process how
actually the persons deal with the problem. The approach to the problem, finding
the root cause and taking corrective actions hence rectifying the same. Also regular
check for any deviation or abnormal such that the problem should not repeat.
• Use of Process Data Acquisition (PDA) in problem analysis.
• For every problem in the rolling line, we can analyses with the help of PDA. There
are signals for every parameter for example torque of mill stands, actual and
reference speed of equipment, operating feedback of cylinders, loop height in case
of loppers, presence of material at location by the feedback of Hot Metal Detector.
• Process data is saved regularly; we can have access to running mill and analyses
problem offline. Data for the past one month is easily available for the analysis.
• A good work experience enhances the decision-making capabilities of a person.
• At the time of problem how exactly industry persons take decision about the action
plan and also how do they communicate with higher official regarding the problem
have been learnt.

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8.4.2 Improvement In Verbal Communication

• During the course of Internship, discussing the daily tasks with the external guide,
also day progress reporting, and communication with line Engineers helped to
improve my verbal communication skills.
• Discussion with HR persons for Internship permission letter, final Internship
completion certificate, and Department allocation to carry out Internship.
• Monthly Internship Progress presentation at Industry and Colleges.
• Discussion with internal guide.

8.4.3 Improvement In Written Communication

• Preparation of Weekly and Monthly Reports of task assigned at industries.
• Mid- Internship Report preparation and submission at college.
• Final Internship Report

8.4.4 Improvement In Presentation Skills

• Presentation of weekly and monthly reports of internship at industry
• Mid Internship Presentation at college
• Attending some of the presentation given at industry level also enhanced my
presentation skills.

8.4.5 Improvement In Time Management Skills

• Clear understanding between important and urgent tasks and executing accordingly
• Opportunity based maintenance is perfect example for time management, as
utilizing breakdowns, section changes, pass change time for any maintenance
activities minimize the need for planned shutdown and also the duration.
• Understanding clearly the problems importance and its effect on production,
prioritizing the time and problem to solve the problem.

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CONCLUSION

In review, this internship has been excellent and rewarding experience. I have been
able to meet and mingle with so many officials by which I could get help for my internship.

One of the main things I have learnt through this internship is time management
skills as well as self-motivation. When I first started, I did not think I was going to be able
to work for 8 hours a day and six days a week. Once I realized what I had to do, I organized
my day and worked so that I was not overlapping or wasting my hours. I learnt that I need
to be organized so that I was not overlapping or wasting my hours. I learnt to get correct
feedback time to time.

From this internship, I learnt to inculcate the habit of being in the training room or
field using the time preciously. The main thing that I came across is about my working
capacity within the given time. That really gives a good meaning for the training. I came
up with various proposals and ideas that company is still looking into. I am also sure that
this internship training programme will help me out in future projects.

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REFERENCES

[1] Shoji Shiba and David Walden “Four Practical Revolutions in Management”
Productivity Press, New York, Centre For Quality Of Management, Cambridge,
Massachusetts
[2] George E. Dieter “Mechanical Metallurgy” SI Metric Edition, McGraw-Hill Book
Company
[3] JSW STEEL LIMITED, http://www.jsw.in/
[4] Jindal knowledge centres.

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Course Objective:
The objective of the seminar is to inculcate self-learning, face audience confidently,
enhance communication skill, involve in group discussion and present and exchange ideas.
Each student, under the guidance of a faculty, is required to
Choose, preferably, a recent topic of his/her interest relevant to the course of specialization.
Carryout literature survey, organize the course topics in a systematic order.
Prepare the report with own sentences.
Type the matter to acquaint with the use of Micro- soft equation and drawing tools or any
such facilities.
Present the seminar topic orally and/or through power point slides.
Answer the queries and involve in debate/discussion.
Submit types report with a list of references.
The participants shall take part in discussion to foster friendly and simulating environment
in which the students are motivated to reach high standards and become self- confident.

Course Outcomes:
At the end of the course the student will be able to:
CO1: Attain, use and develop knowledge in the field of electrical and electronics
engineering and other
Disciplines through independent learning and collaborative study.
CO2: Identify, understand and discuss current, real- time issues.
CO3: Improve oral and written communication skills.
CO4: Explore an appreciation of the self in relation to its larger diverse social and
academic contexts.
CO5: Apply principles of ethics and respect in interaction with others.

Graduate Attributes (As per NBA):

Engineering Knowledge, Problem Analysis, Design/development of solutions, Conduct
investigations of complex problems, Modern tool usage, Engineers and society,
Environment and sustainability, Ethics, Individual and Team work, Communication.

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Program Outcomes (POS):

A graduate of the Electrical and Electronics Engineering Program will demonstrate:

a. Engineering knowledge: Apply the knowledge of mathematics, science,

engineering fundamentals, and an engineering specialization to the solution of
complex engineering problems.
b. Problem analysis: Identify, formulate, review literature, and analyze complex
engineering problems reaching substantiated conclusions using first principles of
mathematics, natural sciences, and engineering sciences.
c. Design/development of solution: Design solutions for complex engineering
problems and design system components or processes that meet the specified needs
with appropriate consideration for the public health and safety, and the cultural,
societal and environmental considerations.
d. Conduct investigations of complex problems: Use research- based knowledge
and research methods including design of experiments, analysis and interpretation
of data, and synthesis of the information to provide valid conclusions.
e. Modern tool usage: Create, select, and apply appropriate techniques, resources
and modern engineering and IT tools including prediction and modelling to
complex engineering activities with an understanding of the limitations.
f. The engineer and society: Apply reasoning informed by the contextual knowledge
to assess societal, health, safety, legal and cultural issues and the consequent
responsibilities relevant to the professional engineering practice.
g. Environment and sustainability: Understand the impact of the professional
engineering solutions in societal and environmental contexts, and demonstrate the
knowledge of and need for sustainable development.
h. Ethics: Apply ethical principles and commit to professional ethics and
responsibilities and norms of the engineering practice.
i. Individual and team work: Function effectively as an individual and as a member
or leader in diverse teams, and in multidisciplinary settings.
j. Communication: Communicate effectively on complex engineering activities with
the engineering community and with society at large, such as being able to
comprehend and write effective reports and design documentation, make effective
presentations, and give and receive clear instructions.
k. Life -long learning: Recognize the need for, and have the preparation and ability
to engage in independent and life-long learning in the broadest context of
technological change.
l. Project management and finance: Demonstrate knowledge and understanding of
the engineering and management principles and apply these to one’s work as a
member and leader in a team, to manage projects and in multidisciplinary
environments.

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Course Outcome Assessment Matrix:

Course Program Outcomes

Outcomes a b c D E f g h i j k l
CO1 H L H H H H M M L
CO2 M L L L H M H M H L L
CO3 M L L M H H H H L
CO4 H L L M H M M M H M M
CO5 L M M H H H M H L

H: High M: Medium L: low

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