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ORIENTATION TRAINING GUIDE

FOR

MANAGEMENT TRAINEES

TRAINING AND DEVELOPMENT CENTREVISAKHAPATNAM STEEL PLANT

VISAKHAPATNAM

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ORIENTATION TRAINING GUIDE

FOR

MANAGEMENT TRAINEES

TRAINING AND DEVELOPMENT CENTRE

VISAKHAPATNAM STEEL PLANTVISAKHAPATNAM

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AUGUST - 2006


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Rashtriya Ispat Nigam LimitedVisakhapatnam Steel PlantVisakhapatnam - 530 031

Y Siva Sagar RaoChairman-cum-Managing Director

Message

(Y Siva Sagar Rao)Chairman-cum-Managing

Director

Management Trainees form an important segment of RINL collective. They

infuse fresh talent to the management function and stand a good chance to be the

future leaders of the company. The present batch of Management Trainees have the

rare opportunity of getting associated with the production as well as construction of

the plant simultaneously. RINL has been giving utmost importance to training and

development and the Management Trainees are exposed to all facets of management

before shouldering any responsibility. Training and Development Centre has been

continuously putting its efforts in presenting an orientation guide and updating the

same as per need so as to provide the management trainees an integrated view of

the production facilities of the steel plant as well as nuances of corporate management.

The new revised and updated version will be of immense guidance and assistance to

the management trainees in their pursuit in understanding the organization and

developing them for higher mantles of management.

I compliment all concerned in bringing out this orientation guide which will

be of great use not only to the Management Trainees but will also serve as a ready

reckoner to the RINL collective.


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Rashtriya Ispat Nigam LimitedVisakhapatnam Steel PlantVisakhapatnam - 530 031

K. AYYAPPA NAIDUDirector (Personnel)

Message

I am happy to note that Training and Development Centre has

brought out this revised and updated Orientation Guide for Management

Trainees with the cooperation of concerned departments. This revised

version is enriched with up-to-date information covering the modifications

and improvements in various departments, besides adding some more

departments in Works and other than Works areas to make it as

comprehensive as possible.

I hope this Guide will be of immense help to Management Trainees

and also to others as a reference material. I compliment the efforts of

Training and Development Centre and all others involved in bringing out

this publication.

K. Ayyappa NaiduDirector (Personnel)


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VSPs VISION, MISSION, OBJECTIVES, CORE VALUES

VISION :

To be continuously growing world class company, We shall Harness our growth potential and sustain profitable growth

Deliver high quality and cost competitive products and be the first choice ofcustomers

Create an inspiring work environment to unleash the creative energy of People

Achieve excellence in enterprise management

Be a respected corporate citizen, ensure clean and green Environment and developvibrant communities around us

MISSION

To attain 10 million ton liquid steel capacity through technological up-gradationoperational efficiency and expansion to produce steel at international standards ofcost quality and to meet the aspirations of the stake holders.

OBJECTIVES

Expand plant capacity to 5 million ton by 2007-08 with the mission to attain 10million ton capacity in two subsequent phases

Wipe out accumulated loses by 2006-07

Be amongst top five lowest cost liquid steel producers in the world by 2006-07

Achieve customer satisfaction levels on par with world class organizations by2006-07

Make RINL the employer of choice by caring for employees. Develop people Asknowledge workers by 2005-06 and achieve an improvement of 5 percent Pointsin employee satisfaction levels every alternate year

Be ranked as an excellent business organization by 2006-07

Ensure zero effluent discharge by 2005-06 and contribute to improving Quality oflife (health, literacy and water) in at least one village every year

CORE VALUES

Commitment

Customer Satisfaction

Continuous Improvement

Concern for environment

Creativity and Innovation


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QUALITY, ENVIRONMENT AND

OCCUPATIONAL HEALTH & SAFETY POLICY

We, at Visakhapamam Steel are the committed to meet me needs and

expectations of customers and other interested parties, occupational health and

safety of our work for a and to preserve the environment. To accomplish this we

will -

Supply quality goods and services to customers delight

Document, implement, maintain & periodically review the management

systems including the policy, objective and targets.

Use resources efficiently and reduce wastage & prevent pollution.

Comply with all relevant legal, regulatory and other requirements applicable

to Products, activities and processes in respect of Quality, Environment,

Occupational Health & Safety and also ensure the same by contractor.

Continually improve quality, environment, occupational health and safety

performance with respect to products, activities, processes, premises andservices.

Encourage development and involvement of employees.

Maintain high level of quality, environment, occupational health and safety

consciousness amongst employees and contract workers by imparting

education and training.

This policy is communicated to all the employees and contract workers and

is made available to interested parties on request.

Dt. 24.01.2005 CHAIRMAN-CUM-MANAGING DIRECTOR


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ENERGENERGENERGENERGENERGY POLICYY POLICYY POLICYY POLICYY POLICY

We, at Visakhapatnam Steel Plant, are committed to optimally utilise the various forms

of energy in a cost-effective manner to effect conservation of energy resources. To

accomplish this we will :

Document, implement, maintain and continuously review the energy

management system

Comply with the energy conservation Act-2001 and any other statutory

requirements

Make Energy Conservation a way of life by involving all employees

Reduce energy cost by

- Recovery of waste energy and Recycling of waste

- Adoption of energy efficient operation, energy efficient maintenance,

- Energy oriented incentive policy procurement of energy efficient equipment

- Appropriate energy efficient technologies and use of cheaper forms of energy.

Reduce Specific Energy Consumption by 1% per year up to 2010

Date22-10-2004 (Y. Siva Sagar Rao)

Chairman-cum-Man aging Director


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INDEXChapter No. TOPIC Page No.

I. COMPANY INFORMATION AND PERSPECTIVES :

1. STEEL SCENARIO ................................................................................................................ 012. RINL/VSP HISTORICAL PERSPECTIVE - THE TURN AROUND .......................................05

3. MAJOR OPERATING STANDARDS AND NORMS .............................................................. 10

I I. MAJOR PRODUCTION UNITS :

4. RAW MATERIAL HANDLING PLANT (RMHP) ..................................................................... 27

5. COKE OVEN & COAL CHEMICAL DEPARTMENT (C & CCD) ......................................... 35

6. SINTER PLANT (SP) ............................................................................................................. 45

7. CALCINING & REFRACTORY MATERIAL PLANT (CRMP) ................................................558. BLAST FURNACE (BF) ......................................................................................................... 59

9. STEEL MELTING SHOP (SMS) ............................................................................................69

10. LIGHT AND MEDIUM MERCHANT MILL (LMMM) ...............................................................81

11. MEDIUM MERCHANT AND STRUCTURAL MILL (MMSM) ................................................. 91

12. WIRE ROD MILL (WRM) ...................................................................................................... 99

13. ROLL SHOP & REPAIR SHOP (RS & RS) ...................................................................... 107

III. SERVICE UNITS (WORKS) :

14. AIR CONDITIONING SYSTEMS (ACS) ............................................................................. 115

15. CENTRAL MAINTENANCE - ELECTRICAL (CME) ............................................................ 116

16. CENTRAL MAINTENANCE - MECHANICAL (CMM) .......................................................... 117

17. CIVIL ENGINEERING DEPARTMENT (CED)...................................................................... 119

18. ELECTRICAL REPAIR SHOP (ERS) .................................................................................. 123

19. ELECTRO TECHNICAL LABORATORY (ETL) .................................................................... 124

20. ENERGY MANAGEMENT DEPARTMENT (EMD).............................................................. 12621. ENGG. SHOPS & FOUNDRY (ES & F) ............................................................................130

22. ENVIRONMENT MANAGEMENT DEPARTMENT (EnMD) ................................................. 134

23. FIELD MACHINERY DEPARTMENT (FMD) ....................................................................... 143

24. INSTRUMENTATION DEPARTMENT (INSTN) ..................................................................... 146

25. INFORMATION TECHNOLOGY DEPARTMENT (ITD).........................................................152

26. MAINTENANCE MANAGEMENT SYSTEMS (MMS) ......................................................... 156

27. PLANT DESIGN (PD) .......................................................................................................... 157


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28. POWER ENGINEERING MAINTENANCE (PEM) .............................................................. 158

29. PRODUCTION PLANNING & MONITORING DEPARTMENT (PPM) ................................. 159

30. QUALITY ASSURANCE &TECHNOLOGY DEVELOPMENT (QATD) ............................... 162

31. RAW MATERIALS DEPARTMENT (RMD) .......................................................................... 166

32. REFRACTORY ENGINEERING DEPARTMENT (RED) ...................................................... 168

33. SAFETY ENGINEERING DEPARTMENT (SED) ................................................................173

34. SCRAP & SALVAGE DEPARTMENT (SSD) ...................................................................... 175

35. SPARE PARTS CELL (SPC) .............................................................................................. 176

36. TECHNICAL SERVICES DEPARTMENT (TSD) .................................................................. 180

37. TELECOMMUNICATIONS DEPARTMENT (TELE) .............................................................. 182

38. THERMAL POWER PLANT (TPP) ..................................................................................... 189

39. TRAFFIC DEPARTMENT ..................................................................................................... 198

40. UTILITIES DEPARTMENT .................................................................................................... 200

41. WATER MANAGEMENT DEPARTMENT (WMD) ............................................................... 210

IV. NON-WORKS DEPARTMENTS :

42. COMPANY AFFAIRS DEPARTMENT (CA) ......................................................................... 215

43. CORPORATE STRATEGIC MANAGEMENT (CSM) ........................................................... 221

44. FINANCE & ACCOUNTS DEPARTMENT (F & A) ............................................................. 223

45. MANAGEMENT SERVICES DEPARTMENT (MS) ............................................................. 227

46. MARKETING DEPARTMENT (MKTG)................................................................................. 235

47. MATERIALS MANAGEMENT DEPARTMENT (MM) ........................................................... 239

48. MEDICAL DEPARTMENT .................................................................................................... 247

49. PERSONNEL DEPARTMENT ..............................................................................................252

50. TOWN ADMINISTRATION DEPARTMENT (TA) ..................................................................259

51. TRAINING AND HRD ........................................................................................................... 264

V. OTHER DEPARTMENTS / TOPICS :

52. MINES DEPARTMENT ........................................................................................................ 271

53. PROJECTS DIVISION..........................................................................................................279

54. EXPANSION OF THE PLANT TO 6.3 MTPY..................................................................... 285


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1ORIENTATION TRAINING GUIDE FOR MANAGEMENT TRAINEES

Chapter - 1

STEEL SCENARIO

Iron was possibly used in Egypt, from the middle pre historic times (7000-6000 B.C.).Accordingly, to Sir Flinders Petrie' all such iron was of meteoric origin and that manufac-

tured iron did not come into general use until after the Assyrian invasion of Egypt in 666B.C.

The art of smelting iron was known in India in ancient times. Reference to iron has beenmade in the Rig Veda (2000 B.C.). It is probable that the Iron Age in India has startedabout 3,000 years before the industry started in European countries. In those daysHyderabad and Madras in South India were the centres of production of Wootz, theancient Indian Steel which was highly priced in world market.

"The famous Iron Pillar at Kutab near Delhi indicates an amount of skill in the manipulationof large mass of wrought iron.

The Iron Pillar according to this inscription is victory pillar created to commorate the victoryof King Chandra (either Chandragupta II or Vikramaditya of the Gupta Dynasty) who isdescribed as having conquered the Vangas, crossed the mouth of the Indus and subju-gated the Bahlikas".

The antiquity of the Indian process is no less astonishing than its ingenuity. We can hardlydoubt that the tools with which the Egyptians covered their obelisks and temples ofporphyry and syenite with hieoglyphics were made of Indian Steel.

Quintus Curtius has mentioned that a gift of steel was made to Alexander of Macedon byPorus, an Indian King whose country he had invaded. We can hardly believe that a matter

of 30 Ibs. Weight of steel would have been considered a gift worthy of acceptance by theconqueror of the world.

The iron pillar at Dhar, the ancient capital of Malwa, 33 miles west of Indore has a lengthof about 50 feet and weighs about 7 tons more than the Iron Pillar at Delhi.

There are a numerous beams and smaller pieces at the Sun Temple at Konark which ison the sea coast about 20 miles from Puri in Orissa. One of these beams which wasoriginally used in the temple, measures 25.5. feet 11 inches and weighs 9,000 Ibs. TheSun Temple was built in the earlier part of the 13th Centura A.D. The beams wereconstructed by welding short blooms together. There are not less then 20 beams in thetemple though none of them have become broken.

Sir George Birdwood wrote in the Note Book of the British Indian section of the famousParis Exhibition of 1878.

Record indicate

Cupola Furnaces were in use in 28 B.C. itself

China produced 1,25,000 tons of Iron a year by 11 00 AD.

French Scientist Merydiscovered that human blood contains iron.


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2 ORIENTATION TRAINING GUIDE FOR MANAGEMENT TRAINEES

A story says that a Russian studenttried to make an iron ring to present his lover by chemi-cally extracting iron from his blood, but had died of anemia as human body contains only 3grms of iron

In 1714 Iron Reboyer,a Worlcer working in a Copper Plant had suddenly became weak andwas unable to drag his feet even. He drank Water from Mariatian Waterfall, he recovered. It

was found that the water was containing iron.

In olden days Iron Water and Steel Wine were prepared with iron filings in Grape wineetc.,

Irons medicinal properties were also ascribed because of its Magnetic Property. Egyp-tians were treating some patients using this property.

Earths Crust Contains nearly 5% i.e 755 x 110 15 tons or 755 Million Billiontons of iron.

96 out of every 100 Kgs. of metal consumed by Industry Agricultureand every day life wasiron.

King Solomangave a feast and honouring the workmen on completion of temple in Jerusa-lem. He asked who contributed more : Black Smith, Carpenter and MasonFinally, the kingsaid it was Black Smith.

DEVELOPMENT OF STEEL INDUSTRY IN INDIA

Iron & Steel making as craft has been known to India for a long time. However itsproduction started only after 1900. In a short span of 3 decades or so that capacity was

increased from 11 folds to about 16 Million tonnes by nineties. Progress in next 15 years is

slow, just more than double i.e. 34.821 million tonnes.


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YEAR PRODUCTION

1945 113.1

1950 191.6

1955 270.0

1960 346.4

1965 454.0

1970 595.4

1971 582.6

1972 630.7

1973 697.1

1974 703.51975 643.4

1976 675.4

1977 675.4

1978 716.7

1979 746.8

1980 716.6

1981 707.9

1982 645.8

1983 664.1

1984 711.0

1985 719.0

1986 713.01987 735.9

1988 780.0

YEAR PRODUCTION

MAJOR STEEL PRODUCING COUNTRIES

(million metric tons crude steel production)

COUNTRY 2000 2001 2002 2003 2004 2005

CHINA 127.2 150.9 181.6 220.1 272.5 317.653

JAPAN 106.4 102.9 107.7 110.5 112.718 112.477UNITED STATES 101.8 90.1 92.2 90.4 99.681 93.899

RUSSIA 59.1 59.0 59.8 62.7 65.563 66.146

SOUTH KOREA 46.4 43.9 45.4 46.3 47.521 47.670

F R GERMANY 43.1 44.8 45.0 44.8 46.374 44.513

UKRAINE 31.8 33.1 33.4 36.9 38.738 38.641

INDIA 26.9 26.7 29.6 31.8 32.626 38.083

BRAZIL 27.9 27.3 28.8 31.1 32.910 31.631

ITALY 26.8 26.5 26.1 26.7 28.4 29.112

WORLD TOTAL 847.6 847.0 845.0 968.3 1046.326 1107.145

IN THE YEAR 2003-04 INDIA STOOD AS EIGHTH LARGEST PRODUCER OF STEELIN THE WORLD.

WORLD CRUDE STEEL PRODUCTION:


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Production of steel(million metric tones)

China alone constitutes 25% of world steel production and consumption. China has

doubled its steel output from 90mt in 2000 to 320mt in year 2005. In the first quarter of 2004

indian steel export rose by 40% compared to last year. Presently India consumes 85% of its

production in the domestic market and exports the rest.

YEAR CHINA INDIA

2001 153.4 27.1

2002 185.6 29

2003 232.4 31.0

2004 . 263.0 32.0

2005 293.0 34.0

YEAR CHINA INDIA

2001 150.9 26.7

2002 181.6 29.6

2003 220.1 31.8

2004 290.0 34.25

2005 300.0 34.8

Consumption of steel(million metric tones finished steel products)


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Rahtriya lspat Nigam limited is a corporate entity of Visakhapatnam Steel

Plant.

The Steel plant is located 26 KM south of Visakhapatnam city. The Company also has BlastFurnace grade Limestone captive mine at Jaggayyapeta, a captive mine for Dolomite at Madharam,a Manganese ore captive mine at Cheepurapalli. It also has a mining lease for river sand of riverChampavathi.

But the vistas of excellence in their sequence of unfolding through the kaleidoscope, that is VSPdoes not rest with inherent beauty of the location or the sophistication of technology. They march

ahead parading one aspect after another, covering the entire gamut of India`s proudest, boldestand most unique experiment in the Steel Industry. In its unyielding journey,Visakhapatnam SteelPlant has come a long way and has become the shining star on the industrial horizon and hasbecome a symbol of every changing and endless new possibilities.

Recapitulation of the efforts involved in making this gigantic plant possible

evokes a tremendous sense of awe.

Making the impossible possible lies in man`s determinationand Sri Tenneti Viswanatham garuwas one such personality. He was an outstanding poet, patriot, scholar and statesman. He tookpart in the freedom struggle under the leadership of Mahatma Gandhi and was imprisoned for eight

years. Sri Tenneti Viswanatham had the all party agitation in 1966 demanding 5th integrated Steelplant for Andhra Pradesh at Visakhapatnam. Struggle of thousands and lakhs of such selflesspeople has paved a way for establishing such a big plant. VSP salutes all those who made VSPpossible and pays tributes to these persons who were paragons of dedicated service to

society, its welfare and reformation.

Happiness alleviates all pain. This was the experience when the then prime minister of Inida, LateMrs. Indira Gandhi annouced in the parliament on 17th April 07 governmment`s decision to establisha Steel plant at Visakhapatnam. The activities kicked off by appointing site selection committee in

june ` 70 and subsequently the committee`s report was approved for site. On 20th Jan 71 the thenPrime minister of India has laid the foundation stone. Consultants were appointed in Feb 71 andfeasiblity reports were submitted in 1972. The first block of land was taken over on 7th April`74.

M/s M.N. Dastur & Co was appointed as the consultant for preparing the detailed Project report inApril 75 and in Oct 77 they have submitted the report for 3.4 mtpa of liquid steel. With theGovernment of erstwhile USSR`s offer for assistance, a revised project concept was evoled. DPRfor a plant capacity of 3.4 Mtpa was prepared by M/s M.N. Dastur & Co in Nov`80. In Feb81contract was signed with Soviet-Union for preparation of working drawings for Coke ovens, BlastFurnace and Sinter plant. The blast furnace foundation was laid with 1st mass concreting in theproject in Jan 82. The construction of township also started.

First they ignore you, then they laugh at you, then they fight you, then you win.

- Mahatma Gandhi

Chapter - 2

RINL/VSP HISTORICAL PERSPECTIVE - THE TURN AROUND


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A new company Rashtriya lspat Nigam Limited (RINL) was formed on 18th Feb. 1982. VSP wasseparated from SAIL and made a corporate entity of RINL in April`82.

One`s best success comes after their greatest disappointments. In the roller coaster rideduring the construction phase, due to continued fund constraints and delay resulting in high cost,

it became imperative to go for a rationalised concept during 1985, in which a plant capacity of 3

Mtpa of liquid steel has been envisaged. The rationalised concept envisages not only working atinternational levels of efficiency, but also operating the plant with 30 to 35% of the manning of the

Public sector plant of similar capacity operating in the country. The rationalised concept was

approved by the Government of India in June` 88.

Go on working, freely and furiously, and you will make progress. While on one side the

economics and approvals were being worked upon, on the other side the construction activities

were in full boom.

The fragrance always remains in the hand that gives the rose. The credibility of making this

plant goes to the work force who their dedication and commitment have given unending hours to

this plant. At the time where there were bear minimum facilities in all respects, the construction

team went about their business with blinders on and nothing distracted them from acheving their

aims. VSP owes a lot to the home makers of the work force who have given their unstinted support

and encouragement and never complained about the loss of personal life.

The auxiliary units including structural shop were the first units to be commissioned in 1987. The

year 1989 witnessed commissioning of many units. In Jan`89 Steam coal handling system of

RMHS was commissioned and in March `89 Turbo Generator No. 1 was commissioned.

Commissioning of metallurgical units started in Sep`89 with the commissioning of Coke oven

battery No. 1 Sinter plant (Machine-1) was commissioned in Nov `89 & in Dec`89 Ore & Fluxhandling system -1 of RMHS was commissioned.

The first hot metal flowed from Godavari, The first Blast furnace was blown on 28th Mar 90.

On 3rd May90 the then prime minister dedicates Godavari to the nation. The year 1990 is marked

in the history of VSP with commissioning of major units. A few of them include Converter No.1

CCM and No. 3 of SMS in Sep90, Billet production in LMMM, rolling of Wire Rods from 21 Nov90

and commissioning of Turbo Generator no.3 in Dec90. In the year 1991 CCM no. 1 & 4, Converter

No. 2 of SMS/ Lime Calcining plant and Dolomite Calcining plant. Bar mill of LMMM, Coke oven

battery No. 2 and Sinter machine No. 2 were commissioned.

The year 1992 is a spectacular year for VSP. On 20th March, 92 Medium merchant and structural

mill was commissioned and on 21st March, 92 the second blast furnace Krishna was commissioned.

Remaining units were also commissioned. Coke Oven battery No. 3 which was commissioned on

30th July92 marks the completion of commissioning of all units of the 3 Million tonne plant.

If what youre working for really matters, youll give it all youve got. After the commissioningof all units, the production has been increasing in a linear manner.


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VSP`s Product Mix comprises Wire Rods, Bars, Angles, Channels/Beams, Rounds and Billets.

The Plant also produces Pig Iron, Granulated Slag and Coal Chemicals. The rolled products findextensive usage in the Construction, Infrastructure, Railways, Power, Defence. Transport and ShipBuilding sectors. Coirs and Rods are used mainly for reinforced concrete work for housing,construction of dams, buildings factories, manufacture of agricultural implements, fabrication oflight engineering components. The Wire rods are used in Wire Drawing industry for electrodes

transmission lines etc.The structurals find application in engineering, house building, agriculturalimplements machinery, transmission towers, etc.

VSP - the state of the art technology. The steel plant has many technological features, whichare unique amongst the steel plants in the country. The company is a pioneer in introducing manynew technologies in the country. The production of TMT rebars by tempcore process is a shiningexample in this respect. The IT applications at RINL have been developed and implementedkeeping the overall organisational business objectives in view. IT infrastructure has been upgradedrecently with IBM-RS 6000 servers and ORACLE-91 as the data base server and data communicationwith back bone fibre-optic network. In the area of marketing VPN based wide area network hasbeen implemented to provide vital information to regional marketing offices as well as customers.

One has to learn to treat people as a resource. They have to ask not what do they cost, butwhat is the what can they produce? This was the approach toward human resource in VSP andhuman resource initiatives are closely linked to the corporate strategy of e organization. VSP hasexemplary industrial relations here the entire work force works as a well knit team for the progressof the company. Participative management, by involving cross section of the employees, indevelopment of the policies and strategy actively implemented in the company. The total workforceis 17000 plus. If you go to work on your goals, your goals will go to work on you. If you goto work your plan, your plan will go to work on you. Employees are motivated by recognisingtheir commitment and dedication by various awards and rewards.

Whatever good things we build end up building us.With this motive a large township is builtfor the employees with all the facilities and a unique township with greenery everywhere. Around10000 dwelling units are constructed. Shopping complexes for every sector, Banks and ATMs,community welfare centres, places of worship, parks, clubs, sport complexes, gymnasiums, library.Cultural centres and spiritual groups, schools & junior colleges and Creche are a part of this grandtownship. A man should be proud of the place he lives. He should live so that his place willbe proud of him.VSP township is a model India with residents from varied cultural backgroundsare living with unity. Horticulture and land scaping increase the beauty of the township. Environmentalprotection is given prime concern and one plant per tonne or liquid steel are planted in VSP. Asof now there are more than 3.5 million trees resulting in lowering of ambient temperature by 30Cwhen compared to city. Afforestation at RINL has been multi-faceted and multi-dimensional, aimedat restoring and conserving the ecological balance, beautifying the surroundings, fighting heat, dust

and noise pollution. 41 % out of the total acquired area of 8,827 hectares i.e 3600 hectares is ear-marked for extensive afforestation. The afforestation programme has earned recognition fromvarious quarters and VSP was awarded the prestigious Indira Priyadarshini Vrikshamitra award asearly as in 1994. The green plants every where mesmerizes visitors and a visit to the plant andtownship is cherished for a long time. The three official guest houses of Visakhapatnam Steel Plantare unique. A view from Hill top guest house captures all hearts. Be it hospitality or its location ina peaceful environment adjacent to the captive Gangavaram beach, stay at Gangavaram guesthouse is cherished for ever.


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Health of VSP family is wealth of VSPand the company runs a 160 bed general hospital with4 health centres, providing free medical aid to the employees. The general hospital is a modemmulti-speciality hospital with more than 90 doctors and around 300 supporting staff.

VSP is surrounded by four rehabilitation (RH) colonies and 18 villages. The need of the people livingin surrounding areas are ascertained through regular interactions with them. Literacy drive, healthcare, vocational training, self-employment and provision of basic amenities to the surrounding

villages are some of the activities related to peripheral development. Two villages i.e Dibbapalemand Devada have been developed as model villages.

We must embrace pain and balm it as fuel for our journey. RINL/s commissioning of 2nd phasein 1992 coincided with the introduction of new economic policy initiatives in the country. Theliberalisation of the Indian economy brought visible changes in the Indian steel industry. Buoyantgrowth in the initial years was witnessed. Many private sector steel plants came up and productionand domestic consumption improved considerably. However, from the middle of 1997, developmentson the international front, like economic crisis in the South East Asian countries and Japan, hadan adverse impact on the steel industry worId-wide. This situation snowballed into a prolongedrecession, one of the worst of its kind. India was affected with this recession and suffered a setback

in steel exports. The slowdown in Indian economy resulted in less investment in infrastructure andthereby reduction of steel consumption. Coupled with above factors were the increase in projectcost and the stabilisation problems of Coke oven battery which resulted in financial set backs. VSPwas in a grip of fear to be reported to BIFR. When the entire globe witnessed the rolling of a newmillennium with jubilation, VSP welcomed with uncertainty and hope. On one side the productionfigures were reaching rated capacities and on the other side there was the threat of getting reportedto BIFR.

There is no better teacher than adversity. Every defeat, every heartbreak, every loss, contains itsown seed, its own lesson on how to improve your performance the next time. Patience andperseverance have a magical effect before which difficulties disappear and obstacles vanish. This

was what exactly how VSP successfully met the challenges of teething problems of stabilization,liberalisation of Indian economy and upheavals in the steel Industry. Through perseverance VSPcould register a steady growth even when the steel Industry was reeling under recession.

The future belongs to those who believe in the beauty of their dreams. The dream of VSP wasrealized in the year 2002-03, the most significant achievement of the company has been attainingfinancial turnaround. This year saw VSP surpassing well above the rated capacities in almost allthe areas and become fourth consecutive year to register more than 100% fulfillment with respectto MOU targets. This year the MOU ratings are excellent. Labour productivity in the year 2002-03has been as high as 256 tonne of crude steel per man year. During 2002-03 the steel market isbuoyant and this trend is continuing this year also. Boost in the construction and infrastructure

sector propelled domestic steel consumption.

Net profit of Rs. 521 Crores were achieved during the year 2002-03

If you can imagine it you can create it. If you can dream it, you can become it. The end of Sep03saw a debt free VSP.

Success depends above all, upon people. Build relationships, teams, partnerships and

motivate people to contribute. Cultivate leadership, creativity & excellence. Listen, seek new

ideas and advice.


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This was the approach of the efficient top management of VSP which has helped in turnaround ofthe company. At one time the pay revision looked remote but in the year 2003 Pay arrears for aperiod of one year were also paid to its employees.

VSP won many accolades and won the prestigious silver trophy for turnaround category fromSCOPE for the year 2000-01, National Energy conservation Award-2002, Green Tech Environment

Excellence award-Silver award in steel sector are a few to name among many.The Visakhapatnam Steel plant strikes everyone with a tremendous sense of awe, wonder andamazement as it presents a wide array of excellence in all its facets in scenic beauty, in technology,in manpower, in management and above all, in product quality. Quality holds the key to pride,productivity and profitability.The economics of recent times has spawned the need to have theright resources to improve quality and reduce costs and at VSP, quality is the responsibility of oneand all. It is a matter of pride that VSP is the only integrated steel plant in the country to becertified for ISO 9001-2000, ISO-14001: 2004 and OSHAS 18001:1999.

The purpose of a business is to create and retain customers. Profit in business comes from repeat

customers, customers that boast about your product or service, and that bring friends with them.VSP builds relationship with external partners on the basis of trust and information sharing. RINLhas developed key partners and strategic relationship with vendors, customers and the agenciesassociated with our operations. Unmatched quality and superlative performance have made VSPthe first choice of customers who demand only the best.

Whenever an individual or a business decides that success has been attained, progress stops. Alearning organisation is an organisation that has an enhanced capacity to learn, adapt, and change.VSP is a learning organisation in which learning processes are analyzed, monitored, developed,managed, and aligned with improvement and innovation goals. Its vision, strategy, leaders, values,structures, systems, processes, and practices all work to foster peoples learning and development

and to accelerate the performance of the company. Having established itself as a major player,Visakhapatanm Steel Plant has drawn out strategic plans for the future with a view to sustain andto improve its market share and expand the customer base.

Dont measure yourself by what you have accomplished, but by what you should have accomplishedwith your ability. Having surpassed its rated capacities at all stages of production, VSPs corporateplan include phase-wise expansion of the plant to 10 million tonnes. The Government of Indiasanctioned the Coke oven battery No.4 and VSP is geared up for the construction of Battery No.4.The salient features of the corporate expansion plan include installation of compact strip caster andsetting up of cold rolling mills for producing high value products. In the long term a blend of longand flat products has been envisaged to gain competitive edge in the market. With all its inherent

and proven strengths in terms of modern facilities and latest technology, passion for quality, leanmanpower and the spirit to excel VSP shall forge ahead to conquer new horizons.

Success is not a destination that you ever reach. Success is the quality of your journey and thejourney of VSP continues.


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CHAPTER - 3

MAJOR OPERATING STANDARDS AND NORMSCOKE OVENS & BY PRODUCTS PLANT :

RECEIPT QUALITY OF COAL :Moisture Ash VM Fixed Carbon

% % % %Indigenous medium coking 1.2 19 24.3 56.7Imported coking General 7.0 10 26.0 64.0Imported Coking semi soft (Prime) 1.0 19 26.0 55.0

BLEND PROPORTION :

Indigenous medium coking 45Imported coking general 20Imported coking semi soft (Prime) 35

BLEND COAL QUALITY :

Ash 17.2

VM 25.7Thickness of plastic layer 6-8Thickness of plastic layer 13 mmSize analysis %0-3 mm size 80-82%0-0.5 mm 38-40%Bulk weight 0.76 tm3

BATTRIES :

i) Oven charge weight (T) dry 32.7

ii) Coking time (Hrs) 16

iii) Heat consumption ( x 103 Kcal/T) 6.86 per ton of dry coal charged

iv) C.V.of mixed gas for heating (Kcal/NH3) 1000

v) Yields from dry coal carbonised (%)

a) Run of oven coke 77.00 b) 25 to 70 mm coke 62.83 c) 0 to 25mm coke 14.17

vi) Coke Quality :

Moisture < 0.4% Ash 22.4 Sulphur 0.55 V.M 1.00

Medium strength + 40 mm 75.0 (min) - 10 mm 9.0 (max)

COKE DRY COOLING PLANTS :

i) Temperature of coke charged in the chamber (0C) 950-1050ii) Temperature of cooled coke (0C) 200-250iii) Steam raising form one chamber (T/hr) 20-25iv) Steam pressure (atmos) 39-40v) Temperature of super heated steam (0C) 430-450


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BY-PRODUCTS PLANT :

1) Yield from one tonne of dry coal carboniseda) Coke oven gas 290 NM3

b) Ammonia 0.3%c) Crude benzol 0.9%d) Crude tar 3.2%e) H2S 0.181%

f) Phenols 0.0538%g) Pyridines 0.0137%

2) Characteristics of coke oven gas :Calorfic value (Kcal/NM3) 4425Calorific value (Kcal/NM3) 0.469Density (kg/m3) 6.1H2S (g/m

3) 2.3%CmHn 2.8%H2S + CO2 0.5O2 6.4%Co 6.4%

H2 56.7%CH4 27.8%N2 3.5%

SINTER PLANT :

1. Machine availability (% calendar hours) 90.42. Machine utilisation (% Available hours) 100.03. Specific Productivity (T/M2/Hr) 1.24. Quality of Materials to be sintered:

Orefines Metallurg Mangane Lime Dolomite Sand Clek Ash

% Blue ical se Stone (%) (%) (%)dust% Wastes% (%)Fe Total 64.50 65.11 22.00 ... ... ... 7.42Fe2O3 92.0 74.31 31.42 0.61 1.20 0 10.60FeO ... 16.83 Total ... ... ... ...MnO ... 0.38 Mn ... ... ... ...Mn2O3 ... ... 32 .... ... ... ...Sio2 2.00 Max 4.72 6.70 8.24 3.81 85 min 54.40

Al2O3 3.50 max 1.73 7.21 1.59 1.10 6 max 26.20CaO ... 1.59 ... 49.44 30.3 0.20 3.00MgO ... 0.32 .... 1.65 19.81 1.70 0.80ZnO ... ... ... ... ... .. ..

TiO2 ..... 0.01 ... .... ... ... 1.70SO3 ... 0.01 ... 0.13 ... ... 1.10P205 0.09 0.10 0.68 0.09 .... ... 1.10Na2O+K2O ... ... ... ... ... ... 1.10lgnition 1.8.2% ... 4.12 38.0 44.8 ... ...LossSize mm 0-10 min 0-10 0-10 6-40 6-80 0-3 ...Desired Bulk 2.8 2.3 1.8 1.6 1.6 1.4 ...Wt.T/M3 Moisture% 8-12 8-12 .. .... ... ... ...


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5. Yield (on dry charge %)

Gross sinter 62.68Circulating Load 25.04

6. Crushing Fineness (% . 3mm)

Flux 97 (Min)Coke Breeze 95 (Min)

7. Moisture in Sinter raw mix (%) 7.0

8. Raw material consumption (kg), dry basis Per Tonne of Charge Sinter

Ore fines & blue dust 744Lime Stone (including screenings) 73Dolomite (Including screenings) 122Managanese Ore Fines 36Crushed Coke 82

Sand 16Metallurgical Waste 69

9. Quality of Sinter (%)

Fe 53.07FeO 9.75MnO 0.59SiO 6.20

Al2O3 4.06Ca0 10-11

MgO 2.97SiO2

6.20

Basicity :

Cao/SiO2 1.6 - 1.65

10. Ignition : Calorific Value of Gas mixture (Kcal/NM3) 2000Ignition Temperature ((C) : Primary 1250 - 1300

Extended hood 800-1000

11. Bed Height (mm) : Hearth 40 mm

Raw Mix 300

12. Size of sinter for Hearth Layer 10-25 mm

13. Vacuum under grates (MM,WG) 100014. Services consumption (Per tonne of sinter)

Hear (103 Kcal) 122Power (KWH)Compressed air (M3) 7.94


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BLAST FURNACE

1. Furnace availability (% on Cal hrs) 95.902. BF Productivity Ton/cum/day 1.523. Quality of sized Iron-ore(%)

Fe 66.90 + 0.5

SiO2 0.90 + 0.25Loss on ignition 1.56Size (mm) 10 to 25

4. Raw material comsumption kg (per Tonne of Hot metal)

Fulxed Sinter 1390Sized Iron ore 316Coke 627

5. Percent sinter in burden 80-82

6. Average Blast Temperature (0C) 1,100

7. Average Top Pressure (atm) 2.0

8 Rate of consumption of moistened blast (NM3/T) 1,470

9 Moisture content of blast (gms/NM3) 36

10. Yield of other products (per tonne of Hot Metal)

Slag (Kg) 412

Top Gas (NM3

) 1,805

11. Yield of granulated slag from molten slag (%) 98.0

12. Slag Quality :

Al203 22 (max)Mgo (%) 9.47Basicity (CaO/SiO2) 0.96

13. Characteristics of BF gasMoisture content (gm/NM3)

Density (kg/Mz)Calorifi0c vafue (Kcal/NM3)Dust content (gm/NM3)CO CO2ratioCO (%)N2(%)H2(%)CH4(%)

11.5840

6.3

1.35

25 (max)

54 to 54.5

1.8 to 1.9

0.4


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14. Iron Analysis (%)Si 1.00Mn 1.00P 0.16S 0.03C 4.20

15. Hot metal ladle life (No. of heats) 500

16. Hot Blast Stoves - Dome Temperature 14500CWaste flue temperature 4000 CCalorific value of mixed gas 1,100 kcl/NM3

Heat consumption (x103 Kcal/T) 660

17. Pig Casting machines:Machine availability (%) 75.0Weight of pigs (kg) 45

Yield of cold pig from metal poured (%) 95

18. Gas Expansion Turbine station:Operating hours 8000Power rating 15.6MWConsumption of BF gas (19.4x103 NM3hr)Gas pressure, KSCG: Before GET 1.75

After GET 0.15

STEEL MELTING SHOP

I. QUALITY OF RAW MATERIALS:

(a) Hot metal C(%) 4.2Si(%) 1.00Mn(%) 1.00P(%) 0.16 maxS(%) 0.025 max

(b) Iron Ore Fe(%) 66.9SiO2(%) 0.9

Al2O

3(%) 1.6

MnO2(%) 0.05

Size(mm) 15-60

(c) Calcined flux CaO(%)MgO(%) 90-92SiO

2(%) 2-2.5

R2O

3(%) 2.71

LOI(%) 5.0-7.0Size(mm) 10 to 30


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d) Oxygen Purity(%) 99.5Nitrogen(%) 0.1 (max)Relative moisture(%) 20.0

e) Dry Nitrogen Purity(%) 97-98

f) Argon Purity(%) 99.99Moisture(g/NM3) 0.03 (max)

g) C.V.of fuel (Kcal/NM3) 4425

II. CONVERTER SHOP

a) Yield of liquid steel from metallic charge (%) 88.5

b) Availability UtilisationConv. CCMS

Availability (% Cal.Hrs) 66.67 82.2Utiiisation (% Av.Hrs) 100 100

c) Tap to Tap time (min) 50

Break up:Slag draining & preparation 2Charging 7Blowing 18Sampling, Temp Measurement etc. 5Tapping 6Unforseen delays 6Preparation of converter 3Intermediate slag off 3

d) Liquid Steel make per heat (T) 150

e) Converter lining life (No.of heats) 300

f) Relining time (days) 5

g) Raw material consumption (Kg)

Per T of liquid steelHot metal(including mixer loss) 900-1000Pig Iron 12-15Steel Scrap 100-110

Iron ore 12Calcined flux 60-65Ferro Manganese (H.C.) 0.22Ferro Silicon Slicon manganese 9.0

Aluminium 1.35

h) Oxygen consumption (NM3) 60-65

I) Hot metal to scrap ratio 1000:110


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j) Arising of by products Per T of liquid steelSlag(Kg) 188Converter gas (NM3) 71

k) CV.of converter gas (Kcal/NM3) 2000I) Steel ladle life (nos. of heats) 30

III. CONTINUOUS CASTING MACHINES :

a) Yield of C.C. blooms from liquid steel (%) 94.0b) Machine availability (% Cai.hrs) 82.2c) Time required for argon rinsing (Min) about 10 mm

d) Machine parameters:

i) Casting speed 250x250 bloom 250x320 bloom0.774 0.605

ii) Casting duration (min) 100iii) Preparation for casting subsequent heat(min) 100.00

e) Machine utilisation (% av hrs) 100.00

f) Size-wise production of blooms (% total)250x250mm 32.1250x320 mm 67.9

g) Tundish life (no.of Heats in sequence) 5-6

IV. CONSUMPTION OF REFRACTORIES & OTHER MATERIALS

(PER TONNE OF CAST BLOOM)

Consumption of Refractories per ton of liquid steel - 18.57kg

V. CALCINING PLANT:

a) Raw material analysis:

Lime stone Raw dolomite LS DPOCaO(%) 52-55 29-31 51.00 30.50MgO(%) 0.7-1.3 19-22 1050 21.20SiO

2(%) 0.8-1.2 0.8-1.2 2.40 0.90

LOI(%) 43-45 43-45

b) Ratio of flux feed to kilns (Lime stone : Dolomite) 5:1

c) Consumption par ton of calcined flux (kg)

Limestone 1878Raw Dolomite 376

d) Screening losses of calcined flux (%) 20%e) Availability of Kilns (% Cal hours) 90.4

f) Utilisation of Kilns (% AV hrs) 80.6

g) Kiln productivity (T/hr) 13.54

h) Availability of Dolomite Kiln (% Cal hrs) 84.9

I) Productivity of Dolomite Kiln (T/hr) 4.167

j) Heat consumption in calcining plants (106 Kcal/T) 1.367


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VI. DOLOMITE BRICK PLANT

a) Raw material consumption (kg)/Pitch bonded bricks

Dead burnt dolomite (2-25 mm) 1030

Dehydrated tar 9

Sea water magnasite 5.81

Pitch 52.0

Pitch:

Softening point 62.5!C

Coking residue 47.9%

Arthracene oil 10.4%

Toliere insoluble 25-31%

Characteristics of Tar:

Softening point 75!C

Density 1.2 gm/cc

Viscosity at 80!C 25-50 sec.

Water content 0.5%Ash content 0.2 to 0.3%

c) Availability(% Cal Hrs) 82.2

d) Productivity T/day 79

VII. REFRACTORY MASSES COMPOUNDS & POWDER SHOP:

a) Shop availability (% Cal.Hrs) 82.2Composition of masses:

BF tap role mass:

Grog 15%

Plastic clay 35%

Coke breeze 50%

Dehydrated coa! tar 25% over and above 100%

BF tap-hole mass:

Coke breeze 38%

Plastic clay 42%

Pitch 20%

water 8% over and above 100%

BF runner mass:

Plastic clay 19%

Coke breeze 60%

Pitch 21%

Water 10% over and above 100%


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LIGHT AND MEDIUM MERCHANT MILL

1. MILL AVAILABILITY (%) (Calender Hours):a) Net availability 81.91

2. MILL UTILISATION (% available rolling time)Billet Mill 89.7Bar Mill 92.5

3. MILL PRODUCTIVITY (T/Utilised hrs)Bar Mill 157.2a) Sections rollings:

(in terms of finished product)

I) Rounds 12-16 mm 13418 mm and above 192

ii) Reinforcing bars 10 mm 74.512 to 16 mm 13418 to 25 mm 192

iii) Squares 170iv) Flats 173 & 192v) Equal angles 192

vi) Unequal angles :45x30x5-6 mm 19275x50x6-10 mm 192

ii) Tbars 192viii) Channels 192ix) Average for all sections 157.2

4. YIELD FROM BLOOMS (%)

i) Saleable billets 96ii) Billets for wire rod mill 97iii) Billets for Sections rolling 97

5. Yield of LMMM products from Billets 97

6. Average productivity of billet mill 331

7. Arisings (% to input)a) Mill scale 1.5b) Scrap 1.5

8. Services consumption:Bar Mill Per T of Billet Mill per T ofbillet rolled bloom rolled

a) Heat(103Kcal) 490 384,8b) Power(KWH) 15 52.58c) Water (M3) 5d) Compressed air(NM3) 4e) Steam(kg) 10f) Rolls (kg) 0.4


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g) Refractories (Kg) 0.6h) Oil & Grease (Kg) 0.12I) Oxygen (NM3) 0.4 0.33

9. Rolling speed (m/sec)Break down group 1.3 to 1.6 m/sec

WIRE ROD MILL1. Net availability (% Calender hours) 81.912. Mill utilisation (% on available rolling time) 86.50

3. Mill productivity (per utilised hour)In terms of finished product (T)i) 5.5 169.4ii) 6.0-12.0 mm rebars 192

8.0-12.0 190.1

4. Yield(%)From Billets 96.0

5. Arisings (% to input)a) Mill Scale 1.00b) Scrap 3.00

6. Service consumption (per T of finished product)a) Heat (103Kcal) 322.8b) Power(103KWH) 121.18c) Oxygen (NM3) 0.63

7. Max. rolling speed (Metres/second) 80

MEDIUM MERCHANT AND STRUCTURAL MILL

1. Mill availability (% calender hours)a) Net availability 81.92

2. Mill utilisation (% net available hours) 82.00

3. Mill productivity (per utilised hours)in terms of finished product (Tonnes)

i) Rounds : 42-45 mm 16850-75 mm 213

ii) Squares : 40-65 mm 213

iii) Equal angles : 75x75x6-10 mm 20880x80x6-10 mm 21090x90x6-12 mm 221100x100x6-12 mm 234110x110x6-12 mm 235

iv) Unequal angles : 208

v) Flats : 100x10-20 mm 155150x10-20 mm 211


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vi) IPE beams : 100 mm x 55 mm 219120 mm x64 232140 mm x 73 235160 mm x 82 231180 mm x 91 235

vii) HE beams 235viii) T Bars 190

ix) Channels : 100 x 50 mm 229125 x 65 mm 229150 x 75 mm, 175x75mmand 180x90 mm 235

x) Average for all sections 222.2

4. Steam generation from evaporative cooling system(T/hr) 12-15

Service consumption (per T of finished product)a) Heat (103Kcal) 362b) Power(KWH) 100c) Oxygen (NM3) 0,96

5. Max. Rolling speed (metres/second) 9.0

SERVICES AND UTILITIES :

WORKS TRANSPORTATION :

1 No.of wagons required per day;Receipt 662Despatch 284

2. No.of trains received per day: Load/empty 16/8Share of modes of transportation of inplant traffic:Conveyors 72Rail 22Road 6

POWER PLANT & BLOWER HOUSE:

1. Quality of coal : moisture 5-8%Fixed carbon 32-40%

Ash 30-38%VM 25-38%Calorific value 3680-4500 Kcal/kg

2. Boiler operation ParametersSteam output 330 T/hrPressure 101 KSCATemperature 540!C

3. Steam balance: (Average) T/hr %Generation 990 100.0Consumption: Turbo generators 745 74.8Turbo Blowers 176 17.7


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Auxiliary Load 55 5.5Losses 20 2.0

4. Heat-Consumption

(X 103 Kcal/T of steam) 700-730

5. Power generation (MW)

6. Quality of water: Raw Treated(DM water)PH 9.5 6.8 to 7.2Suspended solid (mg/lit) 2.0 0.2 (max)

Alkalinity (mg/lit) 123 (1 PPM)Total dissolved solids (Mg/lit)


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4, Pressure of gaseous fuels:Coke Oven gas: before boosting 600 mm Weafter boosting 1200 mmWc,Blast furnace gas 1200 mm WqConvenor gas: Before boosting 180-250 mm'Woafter boosting 1,500 mm We

Mixed gas 700-800 mm Wc 50

5. Availability of coke oven gas boosting station (%)

COMPRESSED AIR PLANT:

1. Equipment availability:(%)

a) Turbo Compressors 66.7

b) Reciprocating air compressors 100

c) Air blowers 66.7

d) Dry stations 100.0

2. Equipment utilisation (% available time)a) Turbo compressorso 100

b) Drying stations 100

c) Reciprocating 100

AIR SEPARATION PLANT :

1. Purity of products:Oxygen 99.5%Nitrogen 98%

Argon 99.99%2. Plant availability (%) 66.67%3. Nominal rating(%) 874. Services consumption: Water 0.164 M3

(per NM3of gaseous oxygen)Electricity 4.23

a a a


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MAJOR

PRODUCTION

UNITS


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RMHP


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Chapter - 4

RAW MATERIAL HANDLING PLANT

The Raw Material Handling Plant (RMHP) receives the basic raw materials required for thesteel making process from various sources through railway wagons and by road. These are

stacked by stackers and reclaimed by reclaimers and distributed to various departments of VSPthrough conveyor system. The Iron Ore Fines, Iron Ore Lump, Sized Iron Ore, Limestone (BF&SMSgrades), Dolomite (BF & SMS grades), Sand, Quartzite and Manganese lumps are stacked at Ore& Flux Yard. The Imported Coking Coal (ICC), Medium Coking Coal (MCC) , Boiler Coal (BC) arestacked in Coal Yard. Coke is sent directly to Blast Furnace after tippling from ore and flux wagontipplers .

These raw materials are sent to various departments as indicated below:

Sinter Plant : Iron Ore Fines, Lime stone (BF), Dolomite, Sand and LD slag.

Blast Furnace : Sized Iron Ore, Limestone (BF)/ LD slag, Manganese Lump,Quartzite and Coke.

SMS : Dolomite (SMS), Sized Iron Ore, Dolo chips.

CRMP : Limestone (SMS), Dolomite (SMS), Dolo chips.

TPP : Crushed Boiler Coal.

COCCP : Imported coking coal (ICC), Medium coking coal (MCC).

The Raw Material Handling Plant is divided into two sections Coal Handling Plant (CHP) and OreHandling Plant (OHP).

The facilities available in two sections are as follows:

COAL HANDLING PLANT ORE HANDLING PLANT* 2 Wagon Tipplers * 3 Wagon Tipplers

* 5 Ground & 10 Track Hoppers * 10 Ground and 10 Track Hoppers

* Stock Yards ( 10 Beds) * Stock Yard (12 Beds)

* Boiler Coal Crushing Plant * Lump Ore Crushing Plant

* Stackers, Reclaimers * Lump Ore Screening Plantand Stacker cum Reclaimer

* Stackers and Reclaimers.

* Reclaiming Conveyors * Reclaiming Conveyors* Stacking Conveyors * Stacking Conveyors

SALIENT FEATURES OF RMHP

! Peripheral unloading system for railway wagons coming directly up to pushers.

! Blender Reclaimers for blending of ores and flux in which the bucker wheel has a lateralmotion across the bed.


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! Wheel on Boom Reclaimers for reclaiming different materials from same bed in Ore & Fluxyard and same type coals in CHP.

! 2 Ring Granulators for crushing of Boiler Coal.

! 3 Blender Reclaimers for blending of Iron ore fines and flux.

! PLC control of all systems.

! Drier for drying SMS Sized Ore.! Preparation of Sized iron Ore for use in BF to enable close size range of raw materials.

! Dust Extraction system is provided at various locations of RMHP to absorb the dust gener-ated during the process.

RAW MATERIAL SPECIFICATIONS :

The iron- bearing burden materials are Iron Ore fines supplied from Bailadilla mines and manganeseore from the deposite in Vizianagaram district.

The various raw materials handled in the OHP are as follows:

Sl.No. RAW MATERIALS

1.0 Iron Ore Fines.

2.0 Iron Ore Lump.

3.0 Sized Iron Ore.

4.0 Limestone (BF grade).

5.0 Limestone (SMS grade).

6.0 Dolomite (BF grade).

7.0 Dolomite (SMS grade).

8.0 Sand.9.0 Manganese Lump.

10.0 Quartzite Lump.

11.0 Sponge Iron.

12.0 Pellets.

13.0 LD Slag.

14.0 Coke.

The various raw materials handled in the CHP are as follows:

Sl.No. RAW MATERIALS1.0 Imported Coking Coal.

2.0 Imported Soft Coking Coal

3.0 Medium Coking Coal.

4.0 Prime Coking Coal.

5.0 Boiler Coal.


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These Raw Materials are sent in different proportion to various customer departments as indicatedbelow:

CUSTOMERS RAW MATERIALS

1. COKE OVENS Imported coking coal, Medium coking coal and Primary

coking coal.2. THERMAL POWER PLANT Boiler coal.

3. SINTER PLANT Iron ore fines, Limestone (BFgrade), Dolomite (Bfgrade),Sand and LD Slag.

4. BLAST FURNACE Sized iron ore, Limestone (BF grade), Manganeselump, Quartzite lump, Coke, Sponge iron, Pellets andLD Slag.

5. STEEL MELT SHOP Sized iron ore and Dolomite (SMS grade).

6. CRMP Limestone (SMS grade) and Dolomite (SMS grade).

RAW MATERIALS SPECIFICATIONS

The different raw materials are stored in the beds of stockyards and Ground hoppers (GH) & Trackhoppers (TH) and their identification, colour & sizes are as follows:

MATERIAL SIZE

1. SMS Limestone returns -25mm.

2. Limestone(BF grade) 6 to 40mm.

3. Dolomite (BF grade) 6 to 80mm.4. Manganese lump -40mm.

5. Sand/Quartzite fines 0 to 3mm

6. Sized iron ore 10 to 50mm

7. Iron Ore Lump -150mm

8. Iron Ore Fines -10mm

9. Limestone (SMS grade) -50mm

10. Dolomite (SMS grade) -50mm

11. Coke 10 to 60mm

12. Quartzite Lump 10 to 30mm

13. Sponge Iron 3 to 20

14. Pellets 20mm

15. LD Slag SP -10mm

- BF&SMS 10 to 30


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MATERIAL FLOW DIAGRAM OF COAL HANDLING PLANT (CHP)

ICC, ISC, PCC,MCC, BC

Wagon Tipplers - 2 NosApron Feeders - 4 Nos

Ground Hoppers Track Hoppeers

Junction House C-5Reversible Shuttle Conveyors

Conveyor Lines - 2 NosConveyor Lines - 3 Nos

Stock Yard(Coking Coal)

Stackers - 2 NosReclaimers - 2 Nos

Stacker cum Reclaimer - 1No.

COAL PREPARATION PLANT

Stock Yard(Coking Coal)

Stacker - 1 No.Reclaimer No - 1 No

Surge Bin - 1 Surge Bin - 2

Vib. Screen No. - 2Vib. Screen No. - 1

RG No. 1 RG No. 2

Single Conveyor Line to ISB (COAL)

Conveyor Lines to TPP


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MAXIMUM STORAGE CAPACITY AND NUMBER OF STOCK PILES IN RMHP

Material No. of Stock piles Storage capacity STOCK

& Approx size (days) Tonnes Cum

(M)

Lump Iron Ore 2-150X30X11.7 24 116,039 47,636Iron Ore Fines 3-325X30X11.72 32 343,543 163,592

Sized Iron Ore 2-170x30x11.70 44 133,907 54,656

LIME STONE

Sintering 2-90X30X10.9 40 39,613 24,758

Calcining 2-140X30X10.9 47 97,165 60,728

DOLOMITE

Sintering 1-90X30X10.9 40 65,773 41,108

Calcining 1-70X30X11.7 48 19,806 12,379(Flux grade)

Manganese Ore 1-70X30X11.7 44 22,489 9,778

Sand 1-50X30X11 35 7,574 5,410

Boiler Coal 2-290X30X5.52-290X60X5.5 30 135,850 1,69,812

Imported Coking 5-290X50X8 50 312,396 3,90,495Coal 2-290X25X8

Medium Coking 1X290X60X8 43 72,640 90,800Coal

Unloading facilities:

Facility Numbers Provided

Ore & Flux Coal

a) Rotary Wagon Tippler 3 nos 1200 tph 2 nos 850 tph

b) Wagon Pushers 6 nos 4 nos.

c) Track Hopper 10 nos 155 m3 each 1 set

d) Ground Hopper 10 nos 155 m3 each 1 set

e) Transfer car 1 no 1 no


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Stacking & Reclaiming facilites:

Facility Ore & Flux yard Coal Yard

a) Stackers 1400 tph ( 5 nos ) Twin Boom 850 tph ( 3 nos) Single Boom(Fixed Type ) (Swivelling Type )

b) Reclaimers 450 tph Wheel on boom 550 tph Wheel on BoomReclaimers ( 3 nos ) Reclaimers (3 nos)

1200 / 450 tph Blender Reclaimers ( 3 nos )

c) Stacker cum Reclaimer 850 / 550 tph ( 1no)

a a a

Crushing & Screening facilities:

CRUSHERS:

Material Type of Crusher Feed Rate Feed Size Nos Provided(TPH) (mm)

Iron Ore Cone Crusher 340 ( including -150 3

circulating load)

Boiler Coal Ring Granulator 550 -250 2Crusher


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COKE OVENCOKE OVENCOKE OVENCOKE OVENCOKE OVEN


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Chapter - 5

COKE OVEN AND COAL CHEMICAL DEPARTMENT

COAL PREPARATION :

From the storage yard, the coking coal is sent to foreign material removing section toremove foreign matter of above 150mm size. Iron traps for ferromagnetic articles andcylindrical screens are provided for this. For averaging and proportioning of coal, 16 nos.of bins each 800 tonnes of capacity are provided along with continuous action feeders ofup to 100 tonnes per hour capacity each. After blending the material is crushed to takecare of petrographic non-uniformity, high hardness and mineral content of coal. The crushingis carried out in reversible hammer crushers 2 operating and 1 standby. The crushed andblended coal (74-78% of 3mm size) is conveyed to two coal towers each of 4000 Tcapacity. Weigh bridges are provided under coal towers to weigh the coal charge. Systemof pneumatic blow down of blend is provided in the coal tower to take care of jamming

of coal.

BATTERY :

The prepared coal charge in the coal tower is drawn by a charging car on the top of thebatteries and charged into the ovens as per sequence. The charged coal is graduallyheated by the heating walls of the oven in the absence of air to attain a temperature of1000-1050oC at the central axis of the coke mass towards the end of coking period. Thecoking period is generally specified between 16 hrs and 19 hrs depending on ovencondition and production requirement. The volatile matter of coal liberated duringcarbonization is collected in gas collecting mains in the form of raw coke oven gas passingthrough stand pipes and direct contact cooling with ammonia liquor spray. The gas cooled

from 800o

C to 80o

C is drawn to coal chemical plant by Exhauster.The residual coke is pushed out of the oven by pusher car through a guide into cokebucket. The red-hot coke is taken to coke dry cooling plant for cooling.

There are 3 batteries, each having 67 ovens. Each oven can hold 32 tons of dry coalcharge. The volumetric capacity of each oven is 41.6 m3.

The heat for carbonization is supplied by under firing of coke oven gas having CV of 4200

Kcal/Nm3 or mixture of BF gas & CO gas having CV 900 Kcal/Nm 3.

The heating system of batteries is of under jet, compound type having twin-heating flues

with re-circulation of waste gases. The dimensions of oven are as follows.a) General Dimensions:

Length 16,000 mm

Height 7,000 mm

Width on coke side 435 mm

Width on pusher side 385 mm

Average width 410 mm


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b) Effective Dimensions:

Length 15,160 mm

Height 6,700 mm

Number of heating flues in one heating wall 32 Nos.

Distance between axes of ovens 1,400 mm

Number of charging holes 3

Number of gas-off take holes 2

Heating level (distance from the top of

the hairpin of the heating flue to the 1,100 mm

carbonizing chamber roof)

Temperature in heating flues is between 1330oC and 1390oC and final temperature of coke massat its central axis is between 1000 1050oC.

Following pressures are maintained:

a) Pressure of carbonizing chamber sole,

15 minutes prior to pushing coke +0.5 to +3 mm W.C.

b) Pressure in the gas collecting main +16 to +17 mm W.C.

c) Pressure in the heating system at hair

pin level for waste heat gases 0 +/- 0.3 mm W.C.

The refractory requirement per battery is 14000 T silica bricks, 5700 T fire clay bricks and 130 Tlightweight fire clay bricks.

Following oven machinery is provided.

Operating Total

Charging Cars 3 6

Coke pusher 3 5

Door Extractor 3 5

Electric Loco 3 5

Coke Car 3 7

COKE DRY COOLING PLANT:

There are three coke dry cooling plants, each having four chambers. Capacity of eachchamber is 50-52 TPH. Each coke dry cooling plant consists of cooling chambers withindividual lifter and lifting shaft, waste heat boiler, dust catching arrangements and smokefan.


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The cooling chamber has two technological zones. Red-hot coke is charged into theupper zone while cooling takes place in lower zone by circulating gases. Gas is forcedby smoke fan into distribution channels in the lower part of the chamber and fed into thecooling zone. The gas flows upwards and gets heated. Circulating gases enter boiler,cyclones and returned to bottom part of cooling chamber by smoke fan.

The coke is cooled from 1000 - 1050o

C to 180-200o

C while the circulating gases areheated from 160-180 oC to 600 800 oC. 20-25 Tonnes/hour of steam at 35-40 atmpressure and 430-440 oC is produced from one chamber. The cooled coke from thecooling chamber is discharged on to the conveyor continuously through a rotary dischargingsystem.

COKE SORTING PLANT:

From the dry cooling plant, coke is discharged into dedusting units by conveyor. Dedustingunits are provided with equalizing bunkers and belt feeders to compensate for irregularityof coke discharge from dry cooling plant.

From the dedusting unit, coke is conveyed to crushing section. It is first separated into+70mm and 70mm fractions. The +70mm fraction is fed to two roller-toothed crusher (2nos. each of 120 TPH capacity).

The crushed product along with 70mm fraction is conveyed to screening plant where 25to 70mm and 0 to 25 mm fractions are separated using roller screens. 25 to 70mm cokeis conveyed to blast furnace. Bunkers of 600 tonnes capacity are also provided forloading into wagons/trucks and dumpers for sending to yard.

0 to 25mm fraction is fed to vibrating screens provided to separate into nut coke (10 to25 mm size) and breeze coke (0 to 10mm). Nut coke is sent to blast furnace and breeze

coke is sent by conveyor to Sinter Plant.

CONVEYORS

The following types of conveyors are used in coke ovens & coal chemical plant.

Width (mm) 1600 1400 1200 1000 800 650 500

Quantity (nos.) 7 49 6 11 4 2

Length(m) 1645 4329 239 597 107 10

Total no. of conveyors .. 73

Total length (m) .. 6,926 (approximately)

COAL CHEMICAL PLANT :

The main by product in the process of coke making is crude coke oven gas and this haslot of valuable chemicals. Coal Chemical Plant recovers Ammonia (NH3), Tar and Benzol

from Co-Gas as per the process described below:


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The primary By-products from Crude CO Gas are Ammonium Sulphate (NH4) 2 SO4,Crude Tar Crude Benzol and cleaned coke oven gas.

QUALITY AND COMPOSITION OF COKE-OVEN GAS

Calorific value Kcal/N.cum 4300-4350

H2S g/Nm3 0.6Density kg/Nm3 0.43

CmHn % 2.0 - 2.5

O2 % 0.5 (max)

CO % 6.5 - 7.0

H2 % 59 - 60

CH4 % 25 - 26

N2 % 3.0-3.5

Yields of main Carbonization by-products based on coal are follows (percent on dry blend basis).

Crude Tar 3.2 %

Ammonia (NH3) 0.3% or 7-10 gm/Nm3of coke oven gas

Crude Benzol 0.7% or 20 gm/Nm3 of coke oven gas

Production of coke oven gas per ton of dry coal is 350 Nm 3 at calorific value of 4300 Kcal/Nm3

GAS CONDDENSATION SECTION :

The Coke Oven Gas (CO Gas) leaves the ovens at a temperature 800oC and is cooledin goosenecks and in gas collecting mains in the batteries by means of spraying Ammonialiquor (Flushing liquor) from 8000 C - 800 C. 60-70% of Tar present in CO-Gas is condensedhere. After gas collecting mains, the gas flows in three different independent streams tillprimary gas coolers. The CO-Gas along with Tar and liquor comes to a separator toremove liquor and condensed Tar. The cooled CO-Gas is then taken to primary gascoolers (10 no. of each having a heat transfer area of 2425m2) where it is cooled indirectlyby water to about 25 to 30oC. Along with the Tar, some amount of Naphthalene in cokeoven gas is also condensed.

The gas is then sent to Electro Static Precipitators (6nos. each of 27000 Nm 3/hr capacity)to remove the foggy Tar (about 5%) from CO gas. In ESP, foggy Tar particles areelectrically charged and collected on the surface of the electrodes and separated. Thegas purified from Tar is compressed in Exhauster to a pressure of max.2800 mm watercolumn. There are five electrically driven exhausters provided and each having capacityof 76000 Nm3/hr.


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Tar and Ammonia Liquor (Flushing liquor) from the separator are delivered to mechanizeddecanters (six nos.) each of having capacity of 370 m3. Here the crude Tar, Flushing liquorand sludge (coal and coke dust particles in Tar) are separated based on their densitydifference. The separated flushing liquor from decanter is collected in Tanks of capacityof 200 m3from where it is pumped continuously by flushing liquor-pump to gooseneck andgas collecting mains of coke ovens. There are six Nos. of Flushing liquor pumps of having

capacity of 1100 m3/hr.

Tar separated from the decanters is collected in an intermediate Tar tank of having capacityof 50 m3from where it is once again pumped to Tar decanters (2 nos. of capacity of 370m3), which are exclusively provided to remove further water from Tar. The gas condensatewhich is collected after the primary gas coolers, Electrostatic precipitators and exhausteris taken to a underground 50 m3 tank from where it is pumped to Tar Decanters forseparation. The flushing liquor separated from Tar decanters is collected in Flushing liquortanks. The clear Tar taken in another 50 m3 tank from where it is pumped to final gas

cooler.

AMMONIUM SULPHATE SECTION:

The CO-Gas from the Exhausters under pressure is sent to saturators in AmmoniumSulphate section through pre-heaters.

Acidity of the saturator bath is maintained at 4 to 5% and Sulphuric Acid is used for thispurpose. Ammonia present in CO Gas reacts with sulphuric acid and forms Ammoniumsulphate crystals. Nitrogen about 600 to 750 Nm3/hr for each saturator is being used foragitation purpose and this keeps the crystals in motion. Once the crystals grow biggerin size it settles at the bottom of the saturator.

There are five saturators of 6400 mm diameter (Three working and two standby) havingcylindrical body and conical bottom.

The Ammonium sulphate, (NH4)2SO4, crystals settled at the bottom of saturators is sentto the centrifuges by pumps where the crystals are separated continuously from the liquor(mother liquor).

There are 5 Nos centrifuges each having capacity of 1.7 to 3.2 tons per hour are provided.The crystals from centrifuges are dried in a fluidized bed drier and stored. The dried

Ammonium Sulphate crystals are bagged in 50 kg bags and shipped. This is used as a

fertilizer for agricultural purpose and having Nitrogen content 21%.

15 days production can be stocked in the godown. Sulphuric acid required for the productionof Ammonium sulphate, caustic soda & soda ash required for coal chemical plant are

stored in Reagent storage. A month requirement of Sulphuric Acid can be stored here.


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FINAL GAS COOLING AND NAPHTHALENE WASHING :

From the saturator the CO-Gas enters the Acid trap where the acid droplets that might becarried along with the CO-Gas are separated and sent to saturator. The acid free of CO-Gas enter the final gas cooler. There are two final gas coolers of diameter 5000 mm andheight 45.5 meters. Each cooler has got two sections. In the top section CO-Gas is sentfrom the bottom and cooled service water is sprayed from the top. There are perforatedplates in this section, which provides the necessary contact for the water and CO-Gas.

The CO-Gas enters the final gas cooler minimum at 55oC. Cooling of the CO-Gas is doneby direct water spray through a closed cycle system. In this way Naphthalene that ispresent in CO-Gas is scrubbed by water & this enters the bottom of the bottom section.The bottom section, Naphthalene washer, having Tar will come in contact with warm waterfrom top section. Lighter than Tar the water comes to the top and leaves the cooler.During this process whatever Naphthalene is present in (or dissolved) in the water getsdissolved in tar because the solubility of Naphthalene in Tar is many times higher thanwater. Then this Tar is taken out and stored in tanks and then sent to Tar Distillation Plant(TDP) for processing.

BENZOL RECOVERY :

Cooled Coke Oven Gas from final gas cooler (FGC) will successively pass through twobenzol scrubbers in each of the two streams. All four Benzol scrubbers are of 5000mmdiameter and height 48.5m.

Recovery of benzol hydrocarbons is carried out by solar oil, a petroleum fraction, incounter current. The Benzol content in CO-Gas before scrubbers is 27gms/Nm3and afterscrubbers it is 6gm/Nm3. Aluminum packing is provided in all the scrubbers for efficientcontact.

DRY PURIFICATION UNIT :

700 1000 Nm3/hr of coke oven gas is sent to dry purification system when H2S contentof the gas is required to be removed from 0.6-0.7 gms/Nm3 to 0.02 gm/Nm3. The H2S-free CO Gas is sent to laboratories and other special consumers like GETS at BF, CO Gasis supplied to dry purification unit after the electrostatic precipitators. Synthetic bog oreis used as purification mass. Spent purification mass containing 24 to 25% sulphur istransferred to dump.

GAS BLEEDER :

There are automatic system of discharge of gas and burning in bleeder when consumptionreduces or pressure increases above normal operation limit. Gas pressure in gas pipelineis 800 mm water column. Gas bleeder capacity is 45,000 Nm3/hr.


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TAR DISTILLATION PLANT :

It is designed to process 115,200 Ton/year of Tar. The crude tar having maximum watercontent 5% is heated in the pipe still furnace to 115oC and sent to the 1ststage Evaporator,where the Tar is separated from water and stored as dehydrated Tar. Further, this Tar isheated in the pipe still up to 400oC and taken to the 2ndstage evaporator.

Here the vapours and the residues (called pitch with softening temperature 67 to 73oC) areseparated and this vapour is sent to the Rectification Column all the products are withdrawnat different levels based on their boiling points difference and cooled and stored.

Naphthalene fraction crystallized in the crystallizers and then pressed to form a cake ina Hydraulic press and bagged and shipped. Pitch or Residue at the bottom of the 2ndstage evaporator is soft in nature and it is made hard by sending compressed air in pitchreactors. Due to the polymerization and condensation, which takes place in the reactor,the pitch becomes harder and withdrawn from the reactor. Pitch creosote mixture isprepared by mixing soft pitch and Anthracene Oil.

Major facilities of the plant are :a) 2 drum crystallizers, 8 mechanical crystallizers and 2 centrifuges and 2 hydraulic

presses for naphthalene. There is 10 days storage capacity for crude naphthalene.

b) 9 mechanical crystallizers, 3 centrifuges and 16 days storage capacity for crudeAnthracene.

c) Washing section for making Sodium Phenolates.

d) 4 still reactors, head Tanks, pipe still for production of pitch with softening tempera-ture of 75 to 95oC.

e) Facility for preparing Pitch Creosote Mixture.

f) 23 days storage for Tar and Tar products.

MECHANICAL BIOLOGIAL AND CHEMICAL TREATMENT OF

PHENOLIC EFFLUENTS :

Before treatment After treatment

mg/ltr mg/ltr

Phenols 400 not more than 1

Rhodanides 400 not more than 10

Tar & Oil 500 not more than 25

Biological Oxygen demand 2500 not more than 300

AMMONIA (NH3) 500 not more than 100

In CO&CCP amount of phenolic effluents are 120 m3/hr and this water is treated in theunit and is transferred into the network of sanitary domestic sewerage plant.


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BENZOL DISTILLATION PLANT :

The plant consists of

i) Benzol recovery & distillation using Solar Oil as scrubbing medium.

ii) Benzol refining & Rectification plant using continuous hydro refining process forproduction of Caprolactum grade Benzene, Nitration grade Toluene, Light Solvent Oil.

The Recovery & Distillation unit has two streams each consisting of one final gas coolertwo scrubbers connected in series. In scrubber the Solar Oil and CO-Gas is subjectedto counter current flow and thus Solar Oil absorbs and Benzol from CO-Gas and becomesbenzolised oil. This benzolised oil is taken to a stripping column, where with the help ofdirect steam, the benzol is stripped, removed and cooled. The de-benzolised oil is thebottom product, which is reused for scrubbing the CO Gas.

BENZOL REFINING & RECTIFICATION :

The benzol refining & rectification section is designed to handle Crude Benzol recoveredfrom the benzol distillation unit. It can handle 110 tons of crude benzol per day andoperating period is 330 days/annum.

The Crude Benzol recovered in Benzol Distillation Plant is processed in Hydro-refining unitto produce BTXS raffinate. Crude Benzol is refined by using hydrogen, recovered fromCO gas by Pressure Swing Adsorption (PSA) process. The refining process is carried outof 25 kg/cm2 pressure. The refining process involves removal of sulphur compounds intwo catalytic bed reactors called pre-reactor and main reactor. The product, which issulphur free, is called BTXS raffinate and is further subjected to rectification processwhere different products like Benzene, Toluene, SOL-110 and Light Solvent Oil are made.

This rectification process involves a series of distillation processes like pressure distillation,extractive distillation where NFM solvent is used to remove non-aromatics from Benzene& Toluene.


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SINTER PLSINTER PLSINTER PLSINTER PLSINTER PLANTANTANTANTANT


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Chapter - 6

SINTER PLANT

Sintering :

Sintering is a process of Agglomerating iron ore fines into a porous mass by incipient fusioncaused by combustion with in the mass of the ore particles.

History of Sintering

Iron ore fines (0-10 mm) which were a result of mechanized mining could not be chargedin a Blast furnace because they reduce the permeability of burden in a blast furnace. These ironfines that were generated at mines could not ignored because of their

i) Huge quantity and

ii) High iron content.

To use these fines effectively in a Blast furnace many processes were developed. Sintering being

one of them and widely in integrated steel plants.Raw materials used in sintering:

Various raw materials use din sintering process are

i) Iron ore fines (0-10 mm)

ii) Coke - used as fuel

iii) Limestone & Dolomite - to maintain required sinter basicity

iv) Sand - to maintain required sinter basicity

v) Metallurgical wastes - to use wastes effectively and thus reduce the cost of sintering

vi) Lime - to enhance the process of sintering

Sintering process

1) Preparation of various raw materials.

2) Mixing & Blending.

3) Mixing with sinter returns in presence of water to form green balls.

4) Charging on to the machine.

5) Ignition and suction.

Factors effecting the sintering process:

As you have discussed before sinter process consists of mixing of various raw materials,

palletizing the mixture with water, charging the sinter mix on the machine, igniting the top layer andsucking atmosphere air through the ignited the bed till the entire sinter mix becomes sinter.

Broadly the productivity of a sinter machine depends on the following factors.

a) Quality of input raw materials

b) Permeability of sinter bed

c) Vacuum under grate

d) Quality of sinter


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a) Quality of input Raw materials

Both physical and chemical qualities of input raw materials affect productivity of sintermachines. The various raw materials used in sintering are Iron ore fines, Coke breeze, Limestone,Dolomite, Sand, Metallurgical waste and Lime.

i) Physical properties

Iron ore fines used for sintering should be of the size of 0-10 mm. More of 1 mmfraction will reduce bed permeability and will reduce the vertical speed of sinteringreducing machine productivity. More of +.0 mm fraction will not participate in theprocess of sintering leading to poor quality of sinter and low productivity.

All other raw materials should be within the size range of 0-3 mm to provide for uniformchemistry and for best ignition conditions.

At VSP about 85% of iron ore fines lie between the size range of 0-10mm and95% of other raw materials lie within the range of 0-3mm. As these size ranges are bestsuitable for sintering nothing more could be done in improving this factor.

ii) Chemical properties:

The chemical composition of the input raw materials also affects sintering productivity.Low amount Alumina in iron ore fines and low loss on ignition factor of various rawmaterials increases the productivity of the sinter.

At VSP Alumina in iron ore fines varies from 2 to 3% and total loss on ignition of basemix varies from 18 to 20 %. As these factors are naturally linked with the various rawmaterials, the affect is these factors on productivity are considered as constant and noimprovement activities were carried out.

b) Vacuum under grate:

The vertical speed of sintering depends on the suction that is created under the grate morethe suction higher will be the vertical speed of sintering and more the productivity. At VSP twoexhausters are provided for each machine to create a suction of 1500 mm water column under thegrate. Each exhauster is driven by a 5.6 MW motor capable of rotation the fan at 1000 rpm withan output of 15,000 m3/min. Continuous operation of sinter machines causes wear to the suctiontrack. Regular maintenance is carried out to reduce losses in the suction track. At sinter plant ofVSP steps are taken on regular basis to maintain a minimum vacuum of 1100 mm of water columnunder the grate. It is observed that whenever vacuum falls below 1000 mm water column productivitycomes down. So regular plugging of leakages is taken up and once in a year capital repairs arecarried out to take up large-scale repairs.

c) Quality of Sinter :

Sinter quality also plays an important role in the productivity of sinter machines. Higher FeOgives strength and productivity increases but sinter with more than 11 % of FeO in undesirable ina Blast furnace. Low amount of MgO increases productivity but sinter with 2.4 % of MgO isrequired by Blast furnace to form a Non-viscous slag. As Quality of Sinter is the requirementof its customer i.e. Blast Furnace. Sinter plant has to stick to the quality requirements of Blastfurnace irrespective of its own productivity.


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At VSP the Blast furnaces have stringent requirement of sinter quality. The sinterplantproduces quality sinter that is required by Blast furnace without taking productivity into consideration.

d) Permeability of Sinter bed :

Permeability refers to the amount of space that is provided by the sinter bed to allowatmospheric air to pass through it. A bed with higher permeability will increase the vertical speedof sintering and thus productivity will rise. A bed with low permeability will offer resistance to theflow of air and the vertical speed of sintering will reduce resulting in low productivity.

All efforts should be taken up to increase the bed permeability. If we recall the otherfactors, which affect sinter machine productivity, we find that

a) In case of quality of raw material

MT(T) Material

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