VOCATIONAL TRAIING

AT
BHILAI STEEL PLANT

NAME-AVEERAJ SINGH MAAN

BRANCH-MECHANICAL
SEM-5TH
Bhilai Steel Plant: A
History of Progress
The Bhilai Steel Plant, located in India, is one of the largest and most productive steel
plants in the world. This presentation highlights the plant's history, facilities, and
achievements.
Facilities and Production Capacity

Production Capacity Facilities

The plant has a production capacity of 7.5 million tonnes The plant features state-of-the-art facilities including a
of steel per year, making it one of the largest steel plants blast furnace, coke oven batteries, and a steel melting
in the world. shop.
History of Bhilai Steel Plant
1988

A new steel melting shop was

1959
commissioned, significantly increasing
The construction of the plant began. production capacity.

1 2 3 4

1955 1961

The Government of India and the Soviet The first blast furnace was
Union signed an agreement to establish commissioned, and the production of
the Bhilai Steel Plant. steel began.
Bhilai Steel Plant: Achievements and Awards

1985 Prime Minister's Trophy for Best Integrated Steel

Plant

1992 Prime Minister's Trophy for Best Steel Plant in India

2005 Golden Peacock Environment Management Award

2011 Prime Minister's Trophy for Best Integrated Steel

Plant
Mines Associated With Bhilai Steel Plant
Dalli Rajhara is home of iron ore captive mines for
Bhilai Steel Plant, the largest integrated steel plant in
India. Dalli mines deposit was discovered by
Pramatha Nath Bose, the first Indian graded officer
of the Geological Survey of India around 1900.

Nandini limestone mines are the only source of

limestone for Bhilai Steel Plant. The mine is located
in Nandini village in Durg district of Chhattisgarh. The
mine has a proved reserve of 91.42 million tonnes of
limestone. The mine produces 1.08 million tonnes of
limestone per year. The limestone is used in blast
furnaces and sintering plants in Bhilai Steel Plant.

The coal for bhilai steel plant manly cones

from Kobra and Kargali Coal field.
The rest of the requirement of coal is fullfilled by
foreign import of coal from countries line austrilia
Mills and Departments
Blast Furnace Coke Oven Batteries

The blast furnace is the heart of the plant and The coke oven batteries provide coke needed to fuel
produces molten iron. the blast furnace.

Steel Melting Shops Rolling Mills

The Steel Melting Shop (SMS) is a critical part of a steel
The rolling mills convert the raw material into the
plant where pig iron is melted and refined to produce
final product, including hot and cold-rolled coils of
liquid steel. The liquid steel produced in the SMS is
sheets and plates.
then used to make various steel products.
Exploring the Bhilai Steel
Plant and its 8 Blast
Furnaces
Welcome to the Bhilai Steel Plant, one of the largest steel plants in Asia. In this
presentation, we will explore how 8 blast furnaces contribute to the plant's impressive
production capacity.
Building and Development of the Blast
Furnaces
Construction
The construction of each blast furnace
followed a similar process, with materials
such as steel, concrete, and refractory bricks
being used.
1 Development
The Bhilai Steel Plant was established in
1959, and the first blast furnace was
2 commissioned in 1961, with subsequent
furnaces being added over the years.
3 Completion
The completion of the 8th blast furnace in
2018 was a major milestone in the plant's
history, with a total annual production
capacity of over 4 million tonnes.
Blast Furnace Features and Technical
Specifications
Size and Dimensions
The 8 blast furnaces are all
uniquely designed and built to
withstand temperatures of up to
2400 degrees Celsius. The
largest furnace measures over
30 meters in height and has a
volume of nearly 4000 cubic
meters.
Materials and
Equipment
The furnaces are equipped with
a range of state-of-the-art
machinery such as tuyeres,
lining machines, and pressure
vessels. Materials such as coke,
limestone, and iron ore are used
as raw materials in the blast
furnaces.
Environmental Factors
The company prides itself on
its commitment to sustainable
development, and the blast
furnace operations have been
optimized to minimize
emissions and waste
production.
Operations and Production Processes
1 2 3 4

Raw Material Charging the Operations and Product

Preparation Furnace Maintenance Recovery

The raw materials The prepared The furnaces are The final product,
used in the blast materials are then operated molten pig iron, is
furnaces are first charged into the continuously, with recovered at the base
prepared and cleaned furnace, with regular maintenance of the furnace and
to ensure only the alternate layers of carried out to ensure transported to other
best quality materials coke, limestone, and the smooth areas of the plant for
are used. iron ore, along with functioning of the further processing
other materials like various machinery into finished steel
scrap metal. and equipment. products.
Overview of Steel Melting Shop (SMS)
Melting and Refining
The melting process takes place in
BOF(Basic oxygen furnace) which is then
refined to desired levels of carbon and other
impurities. The process is continuous and
takes about 2 hours.The liquid metal is
induced with high preassure oxygen gas and
some additional elements to get the required
steel property.
1 Raw Materials
The SMS uses mostly scrap iron, pig iron,
iron ore and other elements like nickel and
2 chromite to create steel.
3 Casting and Rolling
The molten steel is then cast into semi-
finished products using a continuous casting
machine. These products are then rolled into
finished sheets, plates and other shapes as
required by customers.
Equipment and Machinery used in SMS
Basic Oxygen Furnace (BOF) Vacuum Degassing Units

Highly efficient furnaces used for melting large They remove hydrogen and other gases from the
amounts of scrap and pig iron. They can hold up to molten steel to increase its strength, toughness and
150-300 tons of raw material and can melt it within ductility.
just a few hours.

Continuous Casting Machine Rolling Mill

Used to cast molten steel into billets, blooms or Used to convert semi-finished steel products into
slabs. final shapes like sheets, plates, strips etc.
Production Process of SMS

The Steel Melting Shop (SMS) at Bhilai Steel

Plant operates by melting raw materials like
iron scrap, pig iron, and additives in one of the
convertors of Basic Oxygen Furnace(BOF).

The intense heat from burning cone oven and

blast furnace gases which melts the materials,
and impurities are removed through chemical
reactions and fluxes.

Alloying elements are added for desired steel

grades. The liquid steel is cast into molds,
forming semi-finished shapes. This efficient
process ensures continuous casting, minimal
waste, and consistent, high-quality steel
production.
Continuous Casting

The molten steel is cast into semi-finished

products using a continuous casting machine.

Continuous casting is a modern method

used in steel production to efficiently
and continuously cast molten metal into
semi-finished shapes, such as billets,
blooms, or slabs. Unlike traditional
batch casting methods, continuous
casting enables a streamlined and
automated process that reduces waste
and increases productivity.
Introduction To Different
Rolling Mills
A rolling mill is a machine that uses two or more sets of rollers to reduce the
thickness and to make the thickness uniform of a metal. The concept is
similar to the rolling of dough. Rolling is classified according to the
temperature of the metal rolled. Rolling mill is the final stage of
manufacturing process ,Rolling mills produce final finished product.
Universal Rail Mill - Building the Backbone of
the Nation
Bigger and Better
The Universal Rail Mill
manufactures rails up to 130 meters
long and continues to push the
boundaries of technology to support
India's development.
Precision Matters
The rollers are engineered to mill
the perfect rail, whether it's for a
busy commuter line or heavy-haul
freight.
Keeping India Moving
Forward
The Universal Rail Mill has the
capacity to produce 1 million tonnes
of rails annually, ensuring that
India's transportation infrastructure
remains on track.
 Exploring the Versatile Wire Rod Mill
The Strongest Links Gearing Up
The Wire Rod Mill The Mill can also provide steel
manufactures wire rods with for auto parts, such as gears,
diameters ranging from 5.2 mm bearings, clutch plates and
to 22 mm. They are used in universal joints with the help of
building welding electrodes and automated systems and
other industrial applications. monitoring equipment.
Energy Saver
It has unique features like
walking-beam-type furnace,
pulse-jet type dust collector and
other facilities that reduce
energy consumption.
Bar and Rod Mill - A World-class
Manufacturer of Quality Products
Automatic System
The Mill is equipped with level 2 automation
through which it can automatic gauge
control, shears and cutting-edge
technologies, delivering quality products.
1 Dual Production
It manufactures reinforcing bars and wire
rods simultaneously.
2
3 Range of Sizes
The Bar and Rod Mill produces products that
cater to the needs of customers in diverse
sectors such as construction, fasteners, wire-
drawing, railways and more.
Advanced Plate Mill - Innovating Steel Sheets
for Our Future

State-of-Art Equipment Ingenuity at Work Effortless Rolling

The Plate Mill has the advanced
Schneider electrics for better and
efficient shearing.
The mill produces plates with
thickness ranging from 5 to 160mm
for use in energy, construction,
railways, defence, shipbuilding and
more.
It has underfloor cooling technology
that ensures better uniformity in
hardness, bending and stretching
qualities reducing risk of breakage
or other damage during
transportation and handling
Rail and Structural Mill - Forging the
Backbone of Infrastructure in India
The Strength to Carry On

The mill is fully equipped with advanced hydraulic

control systems, eddy current testers and other
facilities ensuring consistent quality control
processes.

1 2 3

Beyond Steel Rails Serving the Nation

The Rail and Structural Mill produces a wide range These products have been used in various
of structural sections like angles, flats, channels, and prestigious projects such as Delhi Metro, Mumbai
beams used for various constructional and industrial Airport and other vital infrastructure around the
requirements. country.
Bhilai Steel Plant: Conclusion
The Bhilai Steel Plant has come a long way since its establishment in 1955. Today, it
is a symbol of India's progress and boasts some of the most advanced steel-making
facilities in the world. Its achievements speak to the hard work and dedication of
everyone who has contributed to its success.
Thank you for your time and attention 🙂