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BHILAI INSTITUTE OF TECHNOLOGY

Bhilai House, G.E.Road, Durg-491001 (C.G.),
India

Submitted By:
Name- Preyash Pandey
Branch- Mechanical Engineering
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Semester- 4th

A REPORT
ON VOCATIONAL TRANING
TAKEN AT
BHILAI STEEL PLANT, BHILAI (C.G.)

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INDEX:
 SUMMARY
 INTRODUCTION OF SAIL
 INTRODUCTION OF BHILAI STEEL PLANT
 SAFETY
 PLATE MILL
 BLAST FURNACE
 FOUNDRY & PATTERN SHOP

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 CONCLUSION
 BIBLOGRAPHY
Summary
S.n Department Date Learn Skill
o
From To
1 HRD 26/06/19 27/06/19 Learn All
information about
safety in plant
2 Garage 28/06/19 30/06/19 Learn about vehicle
Repair used in plants &
Shop their engines
3 Plate mill 31/16/19 02/07/19 Learn about
manufacturing of
plates & sheets
4 Blast 03/07/19 04/07/19 Learn about molten
Furnace metal / pig iron
5 Foundry & 05/07/19 06/07/19 Learn about
Pattern manufacture of
Shop required parts

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Steel Authority of India Limited 
A Maharatna

Steel Authority of India Limited (SAIL) is the

leading steel-making company; among the top five
highest profit earning corporate and one of fastest
growing Public Sector Unit in India. It is a public sector
undertaking which trades publicly in the market is
largely owned by Government of India and acts like an
operating company. It is a fully integrated iron and
steel maker, producing both basic and special steels
for domestic construction, engineering, power, railway,
automotive and defense industries and for sale in
export markets. SAIL is also among the five
Maharatna’s of the country's Central Public Sector
Enterprises and is the 16th largest steel producer in
the world.
 
SAIL manufactures and
sells a broad range of steel
products, including hot and
cold rolled sheets and coils,
galvanized sheets, electrical
sheets, structural railway
products, plates, bars and
rods, stainless steel and
other alloy steels. SAIL
produces iron and steel at five integrated plants and
three special steel plants, located principally in the
eastern and central regions of India and situated close
to domestic sources of raw materials, including the
Company's iron ore, limestone and dolomite mines.
The company has the distinction of being India’s
second largest producer of iron ore and of having the
country’s second largest mines network. This gives

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SAIL a competitive edge in terms of captive availability
of iron ore, limestone, and dolomite which are inputs
for steel making.

SAIL's wide range of long and flat steel products

is much in demand in the domestic as well as the
international market.

This vital responsibility is carried out by SAIL's own

Central Marketing Organization (CMO) that transacts
business through its network of 37 Branch Sales Offices
spread across the four regions, 25
Departmental Warehouses, 42 Consignment
Agents and 27 Customer Contact Offices. CMO’s
domestic marketing effort is supplemented by its ever
widening network of rural dealers who meet the
demands of the smallest customers in the remotest
corners of the country.

SAIL's International Trade Division (ITD), in New

Delhi- an ISO 9001:2000 accredited unit of CMO,
undertakes exports of Mild Steel products and Pig Iron
from SAIL’s five integrated steel plants.

With technical and managerial expertise and

know-how in steel making gained over four decades,
SAIL's Consultancy Division (SAILCON) at New Delhi
offers services and consultancy to clients world-wide.

SAIL has a well-equipped Research and

Development Centre for Iron and Steel (RDCIS) at
Ranchi which helps to produce quality steel and
develop new technologies for the steel industry.
Besides, SAIL has its own in-house Centre for
Engineering and Technology (CET), Management
Training Institute (MTI) and Safety Organization at
Ranchi. Our captive mines are under the control of the
Raw Materials Division in Kolkata. The Environment
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Management Division and Growth Division of SAIL
operate from their headquarters in Kolkata.

Ownership and Management

The Government of India owns about 86% of SAIL's
equity and retains voting control of the Company.
However, SAIL, by virtue of its ‘Maharatna’ status,
enjoys significant operational and financial autonomy.

MAJOR UNITS

Integrated Steel Plants

 Bhilai Steel Plant (BSP) in Chhattisgarh
 Durgapur Steel Plant (DSP) in West Bengal
 Rourkela Steel Plant (RSP) in Orissa
 Bokaro Steel Plant (BSL) in Jharkhand
 IISCO Steel Plant (ISP) in West Bengal

Special Steel Plants

 Alloy Steels Plants (ASP) in West Bengal

 Salem Steel Plant (SSP) in Tamil Nadu
 Visvesvaraya Iron and Steel Plant (VISL) in Karnataka

Joint  Ventures

 NTPC SAIL Power Company Pvt. Limited (NSPCL)

 Bokaro Power Supply Company Pvt. Limited (BPSCL)
 Mjunction Services Limited
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  SAIL-Bansal Service Centre Limited
 Bhilai JP Cement Limited
 Bokaro JP Cement Limited
 SAIL & MOIL Ferro Alloys (Pvt.) Limited
 S & T Mining Company Pvt. Limited
 International Coal Ventures Private Limited
 SAIL SCI Shipping Pvt. Limited
 SAIL RITES Bengal Wagon Industry Pvt. Limited
 SAIL SCL Limited

bHILAI STEEL PLANT

The Bhilai Steel Plant (BSP) - a public sector
undertaking run by the Steel Authority of India - built
with Soviet co-operation and technology, and began
production in 1959. Located in Bhilai, Chhattisgarh
is India's only producer of steel rails, and is a major
producer of rails and heavy steel plates and structural
components. In the 2004-05 fiscal year, it is the Steel
Authority of India Limited's most profitable plant.

This steel plant was set up with the help of the

USSR. Nine - time winner of Prime Minister's Trophy for
best Integrated Steel Plant in the country. The plant is
the sole supplier of the country's longest rail tracks of
260 metres. With an annual production capacity of
3.153 MT of saleable steel, the plant also specializes in
other products such as wire rods and merchant
products. Since BSP is accredited with ISO 9001:2000
Quality Management System Standard, all saleable
products of Bhilai Steel Plant come under the ISO
umbrella.

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 At Bhilai IS0:14001 have been awarded for
Environment Management System in the Plant,
Township and Dalli Mines. It is the only steel plant to
get certification in all these areas. The Plant is
accredited with SA: 8000 certification for social
accountability and the OHSAS-18001 certification for
Occupational health and safety. These internationally
recognised certifications add value to Bhilai's products
the best organizations in the steel industry. Among the
long list of national awards it has won, Bhilai has
bagged the CII-ITC Sustainability award for three
consecutive years.

Bhilai Steel Plant manages a well planned

township (Bhilainagar) which as 13 sectors. It was
deliberately located in what was then regarded as a
remote and "backward" rural area, profits being
secondary to employment in the planning priorities of
the time. BSP currently has nearly 55,000 permanent
workers on its direct pay-roll, of whom approximately
three-fifths work inside the 17 square kilometer plant
and the remainder for its associated mines and
quarries, and for the purpose-built BSP township. This
compares with a regular workforce of 63,400 in 1987.
In addition, on any one day there are at present
something in the region of 8,000 contract workers
employed by the plant and the township, and a further
3,500 - 4,000 employed by the mines.

BSP has for some years shown a profit, and

is widely regarded as the most successful of those in
the Indian public sector. It runs at its four million ton
capacity; produces cheaper steel, and has a record of
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considerably more harmonious industrial relations than
any of the other state-run steel plants, and also than
the vast majority of private sector factories which now
surround it, and for which it served as a magnet.

Though local job creation was

one of its main objectives, and though the principle was
soon established that one member from every family
which had relinquished land should have an automatic
right to BSP employment, the local Chhattisgarhis were
initially reluctant recruits.

Location: Forty kms west of Raipur, the capital city of

Chhattisgarh, along the Howrah-Mumbai railway line
and the Great-Eastern highway stands Bhilai Steel Plant
(BSP).

Source of Raw Materials:

1.     Iron Ore                          ….     Dalli, Rajahara Mines  

2.     Lime Stone                      ….     Nandini Mines
3.     Manganese                      ….     Balaghat Mines
4.     Sinter                              ….     Sintering Plants (SP-2, SP-3)
5.     Coke                               ….     Coke Ovens (Coke sorting plants)
6.     Converter Slag                ….     SMS – l

Captive mines
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Iron-ore - Dalli-Rajhara Iron Ore Complex, 80 kms from Bhilai
Limestone - Nandini, 23 kms from Bhilai
Dolomite - Hirri, 150 kms from Bhilai

Coke Ovens

BATT NO. NO. OF OVEN COAL USEFUL SP.HEAT

OVENS HEIGHT(M HOLDING VOLUME CONSPN.
) CAPACITY PER OVEN KCAL/KG
PER OVEN CU.M.
(T)
1-8 65 4.3 16.8 21.6 625-675
9&10 67 7.0 32.0 41.6 625-675

Blast Furnaces

 3 of 1033 Cu m capacity each

 3 of 1719 Cu m capacity each
 1 of 2355 Cu m capacity
 1 of 4800 Cu m capacity

Hot Metal Capacity: 7.50 MT / year

PROCESS FLOW OF BSP

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PRODUCTS OF BSP
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A.FINISHED PRODUCTS

Rail & Structural Mill

Rails in 13m, 26m, 65/78 m length and welded

panels of 130m / 260m length Indian Railways,
Export Heavy Structurals Construction, Crane
Rails, Cranes, Crossing sleepers, Broad gauge
sleepers

Merchant Mill

Lt. Structurals, Engineering and Construction, Med.

Rounds (Plain &
TMT), Heavy rounds (Plain)

Wire Rod Mill

Wire Rods- Plain Construction, Wire Rods- TMT, EQ
Wire Rods Electrodes

Plate Mill
Plates Boilers, Defence, Railways, Ship building,
LPG cylinders, Export

B. SEMIS

Billets (from BBM), Re-rollers Blooms (from BBM),

Narrow width slabs, CC Blooms, Killed Slabs

C. Pig Iron Foundry

D. By Products
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 Coal Chemicals, Ammonium Sulphate (Fertiliser)
Tar and tar products, (Pitch, Naphthalene, Creosote
Oil Road Tar, Anthracene oil, Dephenolised oil, PCM
etc.), Benzol & its products (NG Benzene, Toluene,
Xylene, Solvent oil, By. Benzol etc.), Processed
Slag Granulated slag from CHSG Plants & SGP for
cement manufacture.

PRODUCT-MIX TONNES/ANNUM
Semis 5,33,000
Rail & Heavy Structural 7,50,000
Merchant Products
5,00,000
(Angles, Channels, Round & TMT
bars)
Wire Rods (TMT, Plain & Ribbed) 4,20,000
Plates (up to 3600 mm wide) 9,50,000
Total Saleable steel 31,53,000

Requirements for producing of one ton of Hot Metal

(Specific Consumption)
1. Iron Ore                        ….     459 Kg
2. Lime Stone                  ….    850 Kg (Depending on Sinter Usage)
3. Manganese                   ….    800 Kg (50% in burden)
4. Sinter                            ….     35 Kg
5. Coke                             ….     08 Kg

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SAFETY
ACCIDENT in industrial sector defines any incident
which has potential to cause injury to human, loss of
property and damage to environment.
Causes for occurrence of accident

 Unsafe Act
 Unsafe Conditions
Hazards

 Conditions prevailing in work place finally leading

to accidents.
Types

 Mechanical
 Electrical
 Chemical
 Environmental
Precautions

 Look overhead
 Watch steps
 Wear shoes and helmets
 Take care of the flow opening
 Avoid lose clothing
 Always carry your I-D card

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 Plate mill

With the commissioning of 3600 mm Plate Mill under 4

MT expansion programme, Bhilai has entered into the
area of flat products in a big way. This giant rolling mill
complex which extends to over a kilometer in length
has an overall covered area of about 15680 m². It
consists of six main bays; 1-3 bays of span 36 meters
each, 2 bays of span 30 meters each and one bay of 18
meters span, also, two open gantries for scrap removal.
The mill is intended for an annual production of 0.95
million tonnes of finished plates in 5600 operating
hours. The thickness of the plates range from 5120
mm. It is called 3600 mm Plate Mill because the barrel
length of the work roll is 3600 mm.

Continuously cast slabs in the length range of 5.6-10.2

M are delivered in hot condition to the slab yard. These
slabs are cut to smaller lengths in 3 non flame cutting
machines as per requirement. Inspection and
conditioning is carried out after cutting of the slabs to
the required sizes. Inspected slabs with proper
identification are supplied to Plate Mill.

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Operations in plate mill :
 Slab heating
 Descaling
 Rolling
 Punching
 Leveling
 Cooling
 Inspection
 Shearing to normal size
 Normalized
 Dispatch

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Heating of slabs is done in three continuous double
row pusher type furnaces with an estimated capacity
of 120 T/hr each. These furnaces have five heating
zones: Soaking Zone, top and bottom preheating
zone, top and bottom heating zone. The soaking zone
has a flat roof with sixteen small capacity vertical
burners through the roof. The other four zones have
six burners each. Mixed gas of calorific value 2500 K
cal/cum is used as a fuel. In time of gas shortage,
provision for oil firing is also there in the four zones,
heating and preheating zones. Air for combustion is
supplied by individual blowers. This is preheated in
multicellular cross parallel flow type of metallic
recuperators. The slabs move on skid pipes in the
heating and preheating zones and over a solid hearth
in the soaking zone. The skid pipes are cooled by
evaporative cooling system instead of the
conventional water cooling system. The solid hearth
in the soaking zone is made of electro cast corundum
blocks. Programmed slabs from the slab yard are
placed by the means of overhead crane of the lifting
and lowering table. The slabs are pushed one by one
on the charging side roller table. The slabs are
positioned with respect to the furnace skids with the
help of movable hydraulic stopper. They are pushed
in to the furnace in cold condition for heating up to
the required temperature. The first slab on the
delivery side is pushed to pre-determined position by
the pusher and then it is extracted by shock free slab
extractors.

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MAJOR MODIFICATION –
 • Thyristorisation of vertical stand.
• Conversion of mech. pusher before cross cut shear into
hydraulic pusher.
• Modification of lubrication system of reheating furnace
blower providing individual lubrication system.
• Conversion of crane no. 23 from hook type to magnet
type.
• Replacement of all USSR made hydraulic distributors by
German made distributors.
• Modification of pliers from mech. drive into hydraulic
drive for its lifting mechanism.
• In-house development and commissioning of hot
reserves for various roll tables of Plate Mill.
• Provision of width digital display in CP-8 for measuring
post to achieve better width control.
• Modification of Cold Punching Machine line No. 2 by
providing compressed nitrogen supply as an additional
source of energy.
• Development, fabrication and installation of rescue
ladder for roof

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 Blast furnace
 The Blast Furnace department consists of 8 Blast
Furnace.
 Three of them are of 1033 cu.m. useful volume
 Three of them are 1719 cu.m.
 BF 7 is of 2000 cu.m.
 BF 8 is of 4800 cu.m.

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There are 3 main sections of the
department:
1. Raw Material Section
2. Furnace Section
3. Auxiliary section 

OBJECTIVE:
Blast furnace produces Hot metal (Liquid Iron) using Iron ore, Coke,
Sinter, Pellets and fluxes such as Lime-stone, Pyroxenite, and Quartzite
reacting with oxygen from pre heated air. This entire process of
production of hot metal is associated with various safety hazards like hit /
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entanglement with mobile equipment, burns, fire, slip & fall, exposure to
dust, smoke, noise, heat & gas etc.

PROCESS:
In the Blast Furnaces (BF) liquid iron (popularly termed as ‘Hot Metal’) is
produced by the process of reduction at high temperature from raw
materials like iron ore, base mix, sinter, coke, fluxes (limestone /
quartzite), etc. & also air blast / O2. In blast furnace the process is also
known as “Counter current process” as solid raw material is being
charged from the top and hot air is being blown from bottom. During the
process the impurities are removed in the form of slag and hot metal is
produced. Coal is being injected to reduce consumption of main fuel
coke which is a cost reduction measure.

Liquid metal and slag are being separated in the area known as cast
house. The liquid Hot Metal is transported in Hot Metal Ladles /
Torpedoes to the Steel Melting Shops (SMS) for the production of steel
by the process of oxidation of the Hot Metal in specially designed
Convertors.

Sometimes the Hot Metal is poured in the Pig Casting Machine (PCM)
to produce Pig Iron.

Slag produced is granulated by high pressure water jets in the Cast

House itself or sent to Slag Dumping in the Slag Pots.

Different Sections of Blast Furnace:

 Furnace Proper: In the Furnace Hot Metal (along with slag)

is processed from the raw materials.
 Cast House: In the Cast House, Hot Metal & slag are tapped
from the Furnace tap hole and after flowing through a system of
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 refractory lined troughs / runners flow into Hot Metal Ladles /
Torpedoes & Slag Pots, placed on the iron & slag side respectively
of the Furnace.
 Stoves: Stoves heat the air blast provided by Turbo Blowers to
the Blast Furnaces through the Tuyeres.
 Raw material storage and Raw Material Charging
Section: In this there are designated bunkers for raw materials
transported from mines / Sintering Plant (SP) / Raw Materials
Handling Plant (RMHP) / Coke Ovens (CO) by wagons /
conveyors.
 Gas Cleaning Plant (GCP): The blast furnace gas (BFG)
generated in the BF is cleaned through a series of steps before
transporting it to the BFG Holder.
 Slag Granulation Plant (SGP) / Slag Dumping Yard:
During the process of iron making, the impurities are fluxed and
removed as slag. The hot liquid slag is made into slag granules by
means of high pressure water jets in the Slag Granulation Plant in
the Cast House itself (sometimes separate SGP is located at a
distance from the furnace proper). If the slag is not granulated in
SGP, it is poured in the Slag Dumping Yard.
 Pig Casting Machine (PCM): Sometimes when there is
poor off take of Hot Metal by SMS or if the Hot Metal chemistry is
very adverse, Hot Metal is taken to this section for casting into Pig
Iron.
 Pulvarised coal Injection: In this section coal is pulverized to
fine dust in mills and injected in the furnace.

Some of critical Equipments/ facilities in Blast Furnace Department are

as follows:

SL. No. AREA MAJOR EQUIPMENTS / FACILITIES

Blast Furnace proper, stoves, skip car, yard

equipments, conveyors, bunkers, Coal Dust
1.) Blast Furnace & auxiliary Injection / Coal Tar Injection units, drill
sections machine, mud gun, pusher cars, ladle/

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 torpedo, TRT, Gas Cleaning Plant, Tilting/
Rocking Runner, Pig Casting Machine,
Utility lines, EOT cranes etc.

Foundry & pattern shop

1. Generally Foundry Shop is divided into four divisions:
a. Mechanical ground Work

b. Crane Working

c. Metallurgical work

d. Sand Screening

2. Types of casting done in Foundry Shop:

A. Ferrous metal

i. Cast Iron

ii. Steel

B. Non-Ferrous metal 

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Process :-

 Firstly, molten pig iron is brought to the foundry shop

through an 80 ton capacity ladle through a locomotive from
blast furnace.

 Then, it is poured into 100 ton reservoir container resting on

a pedestal (made of brass) with a gear arrangement for .tilting
.(temp. maintain by coke oven gas).

 Then for further processing molten metal is poured from 100

ton to 34 ton ladle which is preheated by coke oven gas.

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 With the help of transfer trolley (capacity 50 ton) shifting of
34 ton ladle is done

 . Now then casting is being carried out.

 After casting it will be sent to the Drying Oven (used to

remove moisture content).

 Mechanism Used - SPOCKET CHAIN & TRACK LINE

 STEEL:
 FURNANCE:- DIRECT ELECTRIC ARC FURNANCE (5 TON)

 RAW MATERIAL: - RAIL SCRAP Molten steel is taken

into 5 ton ladle & poured into cope and drag mould.

 MECHANISM: - Trolley, Roof, Door, Tilting (Spur Gear),

Electrode (Rack & pinion).

 FINAL PRODUCT: - Small machines & spare parts for

the plant.

 NON-FERROUS:-
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 FURNANCE: - INDUCTION FURNANCE (1 TON),
INDIRECT ELECTRIC ARC FURNANCE (0.5 TON).
 RAW MATERIAL:- Aluminium , Brass Final
 PRODUCTS: - ALUMINIUM SHORTS & ALUMINIUM CUBES
for deoxidization, BRASS BUSH.

 OVERHEAD CRANE: - 1.) Bus Bar,

2.)Control Panels
 REDUSER:- Pinion , Intermediate Wheel
 HOIST: - Made up of Cast Iron & the Jute Thread are
between the ropes of metal.

 SAND SCREENING:-

1. Bunker ( 10 ton capacity )

2. Vibro Feeder
3. Conveyor Belt
4. Iron Scrub (magnet placed) disposed
5. Gamma Machine (0.5-10mm particle)
6. Base Filter
7. Bunker (height 50ft)

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CONCLUSION:
This Project report gives brief information about the
different shops like PLATE MILL, FOUNDRY SHOP, etc of
Bhilai Steel Plant. The training at B.S.P was very helpful. It has
improved my theoretical concept of material making &
Production . I got to observe many machining process like
Grinding , Turning , Plate making , Welding , Rail making as
well as working of hydraulic machine .
I also got the chance to see Rail Mill and SMS shop where the
main working of steel plant is being done and also I saw the
working of various shops of the plant , which was interesting .
So the training was more than hope to me & helped me to
understand about steel plant more.
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BIBLOGRAPHY:
 NOTES TAKEN DURING V.Training
 WIKIPEDIA
 WWW.INTRANET.COM

 SAIL OFFICAL SITES

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