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Internship Program Report. July - 2015

Report onInternship Program at JSW Steel Ltd

Karnataka.06th July 2015 to 18th July 2015

JSW Steel Ltd. Basaveshwar Engineering collage-Bagalkot


Prepared by, Submitted to,Shivalinegesh AiholliBasaveshwar Engineering College Officer (HR), Bagalkot JSW Steel Ltd

CONTENTS

Introduction Safety Training Raw Material Handling Systems (RMHS) Beneficiation Plant Pellet Sinter Plant Coke Ovens and CDQ Blast Furnace DRI



Steel Making Shop (SMS) Logistics Hot Strip Mill (HSM), Cold Rolling Mill (CRM), Bar-Rod

Mill & Wire Rod Mill

INTRODUCTION A $11 billion conglomerate, the JSW Group is a part of the O.P. Jindal Group. JSW has set up business facilities in various core sectors of India. With verticals that are exploring innovative and sustainable avenues in steel, energy, infrastructure and cement, the Group is paving the way for India’s development as a global superpower.JSW Steel is India’s leading integrated steel producer with a capacity of 14 MTPA. The Group is also leading from the front in every sector that it operates in. By maintaining exemplary operational efficiencies, JSW Energy has grown ten-fold in just three years while JSW Cement creates the building blocks of India with its environment friendly product. JSW Infrastructure is contributing to the nation’s development by providing world class services to clients through state-of-the-art ports, terminals, shipyards and other facilities.The JSW Group is committed to creating more smiles at every step of the journey. JSW Foundation, the Group’s CSR and sustainability arm, is in constant pursuit of making life better for communities with its various initiatives in the fields of health, education, livelihood and sports along with art and culture.JSW’s zero effluent plants, green townships and happy employees are changing the course of the nation with their spirited growth. JSW Group is proud to be charting a course to excellence that creates opportunities for every Indian and leads to the creation of a sustainable, dynamic and developed nation.



JSW Vijayanagar Works:

India’s first 10 MTPA steel plant at single location, “the fastest growing steel plant in India”.The JSW Steel Vijayanagar plant is the first integrated steel plant to reach 10 MTPA capacity in a single location. It is the first in India to use the Corex technology for hot metal production.The first hot strip mill at Vijayanagar was commissioned in 1997. Since then it has grown exponentially and now has an installed capacity to produce 10 MTPA of steel. Located at a remote village Toranagallu part of under developed North Karnataka in the Bellary-Hospet iron ore belt of Karnataka, the fully integrated steel plant, is well-connected with both the Goa and Chennai ports.Unique featuresRegarded as the world’s Corex showpiece; it was the first Greenfield project in India and among the first in the world to have successfully used this technology to produce “green steel”Houses India’s largest blast furnace and the widest hot strip millThe only plant in India with pair-cross technology and twin-stand reversible cold-rolling mill The highest productivity steel plant in India, producing 800-plus tonnes per person per annumRecognised for its ‘zero-effluent discharge’ status; it reuses more than 95 per cent of process wasteLow carbon footprint as it recycles 96% of coke oven gas for power generationUses sophisticated ambient air control infrastructure beyond and has reduced gas flaring to lower levels.



SAFETY TRAINING

The company aims to provide safe work conditions at all JSW plant locations. The safety and health of the employees has always been a prime concern of the company. Safety is one aspect, which the company has never been complacent. Umpteen numbers of industrial safety drives and training programs conducted in the company validates its high sense of concern for the safety of its employees. The management also makes sure that every employee including outsourced employees undergo industrial safety training before they actually take up their assignments in the company.

Periodical health check-ups are conducted to all the employees every 6 months working in the plant area.



JSW has tie up with DuPont for maintaining world class safety standards. DuPont standards and corrective measures are being implanted across the organization.

An effective occupational safety and health program includes the following four elements: Management commitment and employee involvement Worksite analysis Hazard prevention and control

On the first day of our internship, we were given the safety training. They explained us about the various accidents that might happen in an industry and possible methods to prevent them. Then we were introduced to various Personal Protective Equipment(PPE) that one should use in the steel plant.

PRSONAL PROTECTIVE EQUIPMENTS (PPE’s)

1. Helmet2. Goggles3. Ear Plug/Muff4. Jacket5. Hand gloves 6. Safety Shoes7. Welding Shields8. Safety Belts9. Dust Mask

SAFETY HELMET SAFETY SHOES DUST MASK



SAFETY GOGGLE HAND GLOVE SAFETY BELTS

RAW MATERIAL HANDING SYSTEM (RMHS):

The RMHS is designed to handle iron ore, pellets, non-coking coal, coking coal, coke, lime stone, dolomite, quartzite and manganese ore. Major equipments are wagon tipplers, stacker cum re-claimer and barrel re-claimer. There are two units in RMHS, the first serving the needs of 4MTPA and the second one for the 10MTPA facilities which includes base mix (preparing feed to sinter plant). The RMHS takes the raw materials from the wagons (goods train) using tipplers. As the instructor explained, the tippler holds the rail car to a section of track and rotates the track and car together to dump out the contents into an underground stacking area from where the raw materials are sent to the required destination by means of conveyor belts. There are two types of tipplers, Rotary type and Side tippler(in pic). The difference between the two tipplers is the angle of rotation of the tippler. The Rotary tippler rotates by an angle of 1750(max) while the side tippler rotates by an angle of 1540(max).





A stacker is a large machine used in bulk material handling. Its function is to pile bulk material such as limestone, ores and cereals on to a stockpile. A reclaimer can be used to recover the material.

We visited the Tippler operation area where they explained us the various electrical and electronic components involved and their operation. The whole mechanism of the tippler is automated. The movement of the wagon is done by side arm charger whose position is dictated by proximity sensors, while the temperature changes are detected by Resistance Temperature Detectors(RTD) . Each sensor has got a supply of 24V. A PLC(Programmable Logic Controller) system is used to set the parameters of the sensors and check continuously the movement of the side arm charger, the forward movement of the wagon, the angle of rotation of tippler and temperature. Whenever a condition fails, the input trips and hence the mechanism stops. Each tippler has a 3 transformer with a capacity of 2MVA, 6.6kV/415V. The various motors that are used in the tippler mechanism get a supply of 415V and rated for a capacity of 5.5kW



BENEFICIATION PLANT:

The job of the Beneficiation Plant is to concentrate the low grade iron ore to high grade ones. Various processes involved are milling, washing, filtration, sorting, sizing, gravity concentration, magnetic separation, flotation. In JSW plant we saw milling, magnetic separation and flotation in operation.

MILLING : This is a process of grinding and crushing of the ore to a required size for magnetic separation. The major instrument used is Ball Mill.

The Ball Mill rotates at a speed of about 30-35 rpm which uses Induction Motor, whose speed is controlled by Variable Voltage Variable Frequency drives (VVVF). The power output of the Induction Motor during operation is 25kW. The output of the ball mill is sent to the magnetic separator.



MAGNETIC SEPARATOR : Magnetic separation is most commonly used to separate natural magnetic iron ore (magnetite) from a variety of less-magnetic or nonmagnetic material.

The Magnetic Separator consists of a conveyor belt and free magnet. The motor used in the rolling of the conveyor belt is given a 415V supply. It rotates at a speed of 225 fpm. The whole process is depicted in the pic given below:



PELLET PLANT:

Pellet plant: JSW has two pellet plants with a rated capacity of 4.2MTPA each and the pellet size ranges from 8-16mm. The major units are dryers, ball mills, pelletizers of 7.5m dia, indurating furnace, electro-static precipitator and water re-circulation system. We can see the process flow in the fig below.

FLOW DIAGRAM OF PALLET PLANT



FLOW DIAGRAM OF PALLET PLANT

As seen in the above figs., we were given a brief explanation about the process. The pellet plant takes its input from the RMHS site along with the wastes produced by various plants like corex, blast furnace, coke oven. Hence it also acts as a scavenger. The balling disc is the main device in a pellet plant. It gives a shape to the ore. The balling disc is shown below,



The balling disc runs on an induction motor of capacity 0f 5.5kW and rotates at a speed of 1470-1480 rpm, but the required speed of the disc is 7-8 rpm. This is obtained by using a gear box.

We can see the IM above connected to disc through gear box.



The final product of the pellet plant is shown:

This is the major input for the corex plant and Blast furnace.



SINTER PLANTS

JSW steel plant has 4 sinter plants. SP 1 and 2 are each rated for a capacity of 2.3MTPA, SP 3 is of 5.75MTPA and SP 4 is of capacity 2.78 MTPA to produce suitable agglomerates for iron making. Sinter plants agglomerate iron ore fines (dust) with other fine materials at high temperature, to create a product that can be used in a blast furnace. The final product is 8mm to 25mm, and <8mm sinter is used as return fines with raw materials for sinter making process. Sinter is irregular nodule of iron mixed with small amounts of other minerals. The process, called sintering, causes the constituent materials to fuse to make a single porous mass with little change in the chemical properties of the ingredients. The process of the sinter plant is similar to that of pellet plant but there is no balling disc. Hence the output has irregular shape.Why Sinter is preferred for Blast Furnace

It decreases coke rate. Increase productivity. Improves hot metal quality. Brings in smoothness in Operation.

Sintering Reactions:

The sintering reaction starts with reduction of the hematite and formation of the low melting liquid - mono calcium ferrite (CaO.Fe2O3) - at around 1200ºC by reaction with lime which absorbs silica and more of iron oxide.

The melt so formed attacks the grain boundaries of hematite and the grains dislodge into the melt forming CaO.2Fe2O3, 2FeO.SiO2, CaO.FeO.SiO2, 2CaO.Fe2O3 , etc..

With increase of temperature more and more hematite along with gangue go into solution resulting in more of slag bonded complex sinter structure SFCA (silico-ferrite of calcium and aluminum).

At basicity levels of more than 2 calcium ferrite and di-calcium silicate forms and at lesser than 1.6, glassy silicate and secondary hematite and magnetite forms.

Major Equipment at Sinter Plants & their Capacities:

Sinter Machine – 204 Sq Mtrs.Sinter CoolerMixing DrumNodulizing Drum.Double Roll Crusher.Sinter Screens (HL & RF).Waste Gas FanDe-dusting & Other Process Fans.Conveyors.Lubrication Systems & Utilities.



Dust Handling Systems.ESP (Electrostatic Precipitator)

Final product of Sinter



COKE OVENS : A coke oven is a device used to produce coke, a product that is derived from coal. The mixing and heating of bituminous coal at temperatures ranging from around 1832° to 3632°F (1000° to 2,000°C) within the airless oven yields the coke by-product. This device is a crucial part of the coke-making process. JSW has both recovery and non-recovery type coke making facilities. The total installed capacity of non-recovery type coke making facilities is 1.2MTPA. Coke oven 1 having 139 ovens, and coke oven 2 has 140 ovens. The salient features of non-recovery coke making is the waste heat recovery for power generation. Coke ovens 3&4 are recovery type coke oven with installed capacity of 1.5MTPA and 1.95MTPA respectively. Coke oven 3 has four batteries each of 56 ovens and coke oven 4 has 4 batteries each of 72 ovens. The salient features of recovery type coke ovens is extractions of value added products like coal tar, ammonia and sulphur. After the coke is obtained it is sent to the quenching plant where both wet and dry quenching techniques are used.



BLAST FURNACE

Blast Furnace is a typical metallurgical furnace whose inputs are pellets and sinter. There are 4 blast furnaces at JSW. The BF-1 is of 1250 cubic metre and a capacity of 0.9MTPA, BF-2 is of 1680 cubic metre with a capacity of 1.3MTPA while BF-3 and BF-4 are of 4019 cubic metre with a capacity of 3MTPA each. The blast furnaces 3 and 4 are the largest in India.

The process flow is depicted in the following picture



The output of both the corex and blast furnace is same i.e. pig iron, which is taken out as shown



STEEL MAKING SHOP (SMS): Steelmaking is the process for producing steel from iron and ferrous scrap. In steelmaking, impurities such as silicon, phosphorus, and excess carbon are removed from the raw iron, and alloying elements such as manganese, nickel, chromium and vanadium are added to produce different grades of steel. The process of steel making used in JSW is Basic Oxygen Steelmaking. The rated capacity of the Basic Oxygen Furnace shop is 10MTPA liquid steel and this has seven converters in two separate shops SMS-1 & SMS-2. SMS-1 has a heat size of 130 tonnes (3 converters) and SMS-2 has 175 tonnes (2 converters). The major units are Hot metal de-sulphurising station, basic oxygen furnaces (converters), scrap yard, ladle preparation, handling bay, ladle refining furnace, gas cooling and cleaning plant, and a water re-circulation system. The salient technical features are pre-treatment of hot metal, bottom stirring in BOF, adjustment of chemistry and temperature in ladle furnace, automated container laboratory for quick analysis of bath samples, utilization of converter gas as fuel and slag splashing system to enhance converter lining life.

Continuous Casting Plant: Continuous casting, also called strand casting, is the process whereby molten metal is solidified into a "semi finished" billet, bloom, or slab for subsequent rolling in the finishing mills. In JSW there are six slab casters and one billet caster which produces caster of dimension 220mm*800 to 1300mm. Maximum casting speed of 1.8m/min. Major units of CCP are casting machine, gega torch cutting unit, marking machine and a water re-circulation system.



These are the end products of the SMS plant. 1. Slab, 2. Billet.

*Slab Handing at SMS.



MILLS:

The slabs and billets obtained by SMS are sent to the Mills where the total end products are generated. The end products are steel strip, steel rods and steel wire.

HOT STRIP MILL (HSM): The rated capacity of the HSM-1 is 3.2MTPA HSM-2 is 3.5MTPA of hot rolled coils. The major units are walking beam re-heating furnaces, reversing roughing stand, coil box, high finishing stands, down coilers, roll grinding shops and water re-circulation system. The salient technical features are high pressure de-scaling (180 bar), AGC control in three finishing stands, work roll bending, online thickness and width gauge, roll bite lubrication system and online marking system. The end product is as shown



COLD ROLL MILL (CRM):

The CRM complex has a capacity of 1MTPA. The CRM complex is focussed on the value added products geared towards automobile and white goods industry. The major units are continuous pickling liners, six high twin strand cold compact mill, electrolytic cleaning line, batch annealing, accumulator, stress reliving and four high skin pass mill, recoiling line and auto packing line. The output of the CRM is similar to that of HSM but a difference in its thickness (.3mm)



BAR ROD MILL (BRM):

Rated capacity of 0.9MT capable of rolling rebar in the range 8mm to 32mm, angles, RCS etc. This is the first three stranded mill to be installed in India. M/s Morgan is the technology supplier of both the long product mill.



WIRE ROD MILL (WRM):

Rated capacity of 0.6MT and is considered to be the fastest mill in India (110ms -1). It is capable of rolling the wire end and rebar in the range of 5.5mm to 22mm dia. Equipped with the latest equipments like reducing and sizing mill- 1st of its kind in India.

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