STEEL AUTHORITY OF

INDIA LIMITED (SAIL)

PRESENTATION ON INDUSTRIAL
VOCATIONAL TRAINING AT
DURGAPUR STEEL PLANT (DSP)

DURATION: 27th MAY TO 07th JUNE, 2019

BY,
RAJEEV RANJAN
ROLL NO: 16ME8117
REG. NO: 16U10599
DEPARTMENT OF MECHANICAL
ENGINEERING
NATIONAL INSTITUTE OF
TECHNOLOGY, DURGAPUR
INDUSTRY PROFILE: A BRIEF OVERVIEW
 SAIL formed in 1973, as a holding company for Hindustan Steel Limited (Comprising of BSP, DSP,
RSP, ASP)
 Durgapur Steel Plant is one of the five integrated steel plants of Steel Authority of India Limited
(SAIL). It was set up with British collaboration in 1959 with 1 Million Ton per Annum (MTPA) crude steel
production capacity.
 The first ingot was cast from erstwhile Steel Melting Shop on 24.04.1960. The capacity subsequently
expanded to 1.6 MTPA crude steel during 1967-1969. In mid-nineties, modernization and expansion of
the plant were carried out.
     The present capacity of the plant : Hot Metal : 2.4 MTPA, Crude Steel : 2.2 MTPA, Saleable Steel :
2.12 MTPA
 DSP is accredited to various management systems like ISO 9001: 2015 for Quality Management
System (QMS), ISO 14001: 2015 for Environment Management System (EMS), OHSAS 18001:
2007 for Occupational Health & Safety, ISO 27001:2013 Information Security Management
System (ISMS), ENMS 50001 : 2011 for Energy Management System. The plant is also SAP-ERP
system enabled.

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 Merchant Products : 2,80,000 TPA
Structural : 2,07,000 TPA
Skelp : 1,80,000 TPA
 PRODUCTS:
Wheels & Axles : 58,000 TPA
Semis : 8,61,000 TPA
Total Sealable Steel : 15,86,000 TPA

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  Indian Railways
 RITES Ltd.
 Bangladesh Railways
 L&T MMH
 Boeing Business Jets
 West Bengal State Electricity Distribution Company (WBSEDCL)
 CUSTOMERS:  Lahmeyer India
 Simplex Infra Structures
 Wadia Techno Eng. Services
 Lloyds Insulations
 Tata Growth Shop
 M.N Dastur & Co.
 Kolkata Municipal Corporation (KMC)

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INTEGRATED STEEL PLANT:
 An integrated steel plant is a factory plant which includes the facilities for the processing of the raw
materials as well as the output of manufacturing. Thus, The plant has furnaces for blast burning of the
raw materials as well as the facilities of rolling, casting & shaping of the ore for different purposes.

 An integrated steel mill has all the functions for primary steel production: 

1. Iron making (conversion of ore to liquid iron), 

2. Steel making (conversion of pig iron to liquid steel), 
3. Casting (solidification of the liquid steel), 
4. Roughing rolling/Billet rolling (reducing size of blocks).

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 THE BASICS OF AN
INTEGRATED
STEEL PLANT:
(FIGURE 1)

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q THE BASICS OF AN
INTEGRATED
STEEL PLANT:
(FIGURE 2)

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 FACILITIES:

 Raw Materials Handling Plant

 Coke Ovens & Coal Chemicals
 Sinter Plant
 Blast Furnaces
 Steel Melting Shop
 Rolling Mills
 Railway Products
 Engineering Shops
 Research & Control Laboratory 

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 RAW MATERIALS
HANDLING
PLANT:

 The Raw Materials Handling

Plant prepares blend mix for
Sinter Plant and also supplies
raw material lumps to Blast
Furnaces and Steel Melting
Shop. It has 3 nos. tipplers
and 3 nos. blender-cum-
reclaimers.

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 COKE OVENS & COAL CHEMICALS:
 The Coke Ovens convert coking coal into coke, which is an input for Blast Furnaces. The Coke Ovens
and Coal Chemicals zone is divided into four basic sections namely coal preparation plant, coal
carbonization plant, coke handling plant and coal chemicals. The Blast Furnace grade coke produced in
Coke Ovens is directly used in Blast Furnaces while the undersized coke is used for sinter making. The
volatile matters, which emanate during the process of coke making subsequently produce a variety of
by-products like naphthalene oil, heavy creosote oil, light oil, crude tar partially distilled, ‘Raja’ brand
fertilizer, nitration grade benzene, nitration grade toluene, industrial grade toluene, light solvent naphtha
etc. The Coke Oven gas is generally used in combination with the Blast Furnace gas and BOF gas as
fuel and is carried through pipelines to different areas of the plant. The adjoining Alloy Steels Plant under
SAIL also gets this fuel gas from DSP.

No of batteries 6
No. of ovens per battery 78
Height of battery 4.45 meter
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 VIEW OF COKE
OVEN (DSP):

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 SINTER PLANT:
 The Sinter Plant coverts blend
mix into sinter – an
agglomerated input for Blast
Furnaces. In order to enhance
the productivity of the blast
furnaces, a high percentage
of sinter charge is a
prerequisite. Sinter is an
agglomeration of iron ore
fines, coke and limestone in
the form of cakes. DSP has
three sinter machines: 2 nos.
with sintering area of 142.8
sq. meter each and 1 no. with
sintering area of 180 sq.
meter.

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 BLAST FURNACES:

 The Blast Furnaces produce liquid hot metal, which is an input for Steel Melting Shop. The details of
three nos. of Blast Furnaces are as follows:

 The BF Slag (granulated) is sold to the cement manufacturing companies.

  BF No. 2 BF No. 3 BF No. 4

Capacity (t/day) 1, 820 1, 820 2, 340
Useful volume (cum) 1, 400 1, 400 1, 800
Stoves 3 3 3

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 BLAST
FURNACES
OPERATION
:

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 STEEL MELTING
SHOP:
 The Steel Melting Shop
converts hot metal into liquid
steel, which is primarily
processed through
Continuous Casting Plant.
The Steel Melting Shop
(SMS) has 3 nos. 130 T
Basic Oxygen Furnaces
(Converters), 1 no. of 130T
Vacuum Arc Degassing
(VAD) unit, 3 nos. of 130T
Ladle Furnaces, 2 nos. Billet
Casters, 1 no. Bloom Caster
and 1 no. Bloom-Cum-
Round Caster.

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 MERCHANT
MILL:

 The Merchant Mill produces

Earthquake Resistant (EQR)
Thermo Mechanically Treated
(TMT) bars of different sizes,
which are used for
construction and infrastructure
development. Its annual
production capacity is
2,80,000 Tonnes.

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 SECTION MILL:

 The Section Mill rolls out light and medium structural like
joists, channels and angles, which is also used for
construction and infrastructure development. Its annual
production capacity is 2, 07,000 Tonnes.

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 WHEEL & AXLE
PLANT:

 The Wheel & Axle Plant

produces forged wheels
and axle for Indian
Railways. DSP is the only
producer of forged wheels
in the country. Its annual
capacity is 58,000 Tonnes.

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 MEDIUM
STRUCTURAL
MILL:

 A new Medium Structural

Mill (MSM) of 1.0 Million
Tonne capacity is being
commissioned in DSP. The
medium structural to be
produced in the mill will be
used in construction and
infrastructure development
sectors.

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 ENGINEERING SHOPS:

 Durgapur Steel Plant has a number of captive engineering shops for repairs
and supply of spare parts. The Central Engineering Maintenance has a
Machine Shop, Structural Shop, Fitting and Assembly Shops. The Foundry
produces Ingot moulds and bottom plates for the Steel Melting Shop. There
are also Auxiliary Repair Shops such as Electrical, Wagon and Loco Repair
Shops.

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 RESEARCH AND CONTROL LABORATORY:

 The Research & Control Laboratory is well equipped for carrying out
sophisticated chemical, metallurgical and other tests both for better process
control and improved quality of products.

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 SAFETY FIRST:

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 CONCLUSION:

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THANK YOU