Beruflich Dokumente
Kultur Dokumente
SUBMITTED BY:
ASHISH JAISWAL
USN : 1DS15ME019
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ACKNOWLEDGEMENT
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ABOUT COMPANY:
INTRODUCTION:
A multi-billion-dollar conglomerate, JSW Group is a part of O.P. Jindal Group
and played a key role in India's growth story. Ranked among India's top business
houses, JSW's innovative and sustainable forays into the core sectors of Steel,
Energy, Cement and Infrastructure are helping build a new nation. The Group
continues to strive for excellence with its strengths, differentiated product mix,
state-of-the-art technology, excellence in execution and focus on sustainability.
The flagship company of JSW Group - JSW Steel, is India’s leading primary and
integrated steel producer. It has a production capacity of 18 MTPA with plants
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located across six locations in South and West India, namely, Karnataka, Tamil
Nadu and Maharashtra.
Incorporated in 1994, JSW Energy is the power utility arm of the JSW Group. The
Company is engaged in power generation, power transmission, mining, power
trading and equipment manufacturing. JSW Energy operates 4,531 MW of power
generation capacity with the vision to achieve 10,000 MW by 2020. The
Company’s presence extends across several Indian states and includes stakes in
natural resource companies in South Africa.
JSW Group's new business foray- JSW Cement, envisions a self-reliant India. Since
its inception in 2009, JSW cement entered the market with a vision to ensure a
sustainable future for the country by producing eco-friendly cement. At
Vijayanagar in Karnataka, Nandyal in Andhra Pradesh and Dolvi in Maharashtra,
JSW Cement utilises slag cement from Group's steel plants to produce green
cement. It is currently upgrading production capacity to 30 MTPA by 2020.
Recently, JSW Group diversified into new age businesses like fund management.
JSW Ventures partners with ambitious and growth oriented entrepreneurs who
leverage technology to build long-term capital efficient businesses. The fund
supports ventures and ideas with JSW Group’s expertise in building scalable and
profitable businesses.
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Unique features:
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Milestones:
Founded in 1984
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COKE OVEN:
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Introduction:
A world class blast furnace operation demands the highest quality of raw
materials, operation, and operators. Coke is the most important raw material fed
into the blast furnace in terms of its effect on blast furnace operation and hot
metal quality. A high quality coke should be able to support a smooth descent of
the blast furnace burden with as little degradation as possible while providing the
lowest amount of impurities, highest thermal energy, highest metal reduction,
and optimum permeability for the flow of gaseous and molten products.
Introduction of high quality coke to a blast furnace will result in lower coke rate,
higher productivity and lower hot metal cost.
Coke Production:
The coke making process involves
carbonization of coal to high
temperatures (1300°C) in an oxygen
deficient atmosphere in order to
concentrate the carbon. The
commercial coke making process
can be broken down into two
categories: a) Recovery Coke
making and b) Non-Recovery Coke
making.
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Pellet
Plant:
• CAPACITY
• 4.2 MILLION TONNE PER YEAR,
• RAW MATERIAL
• ORE FINES FROM JVSL MINES
• DRYERS EACH
• 2 NOS OF 4.6 M DIA 27.5M LONG, 225 TPH
• GRINDING
• BALL MILL (2 NO) 208 TPH
• MIXER
• LITTLE FORD MAKE 600 TPH
• BALLING DISCS
• 5 NOS , 7.5 M DIA
• INDURATION
• GRATE AREA -464 M2, 4 M WIDE CARS
• STACKER/RECLAIMIN
• 700 TPH / 1100 TPH
G
• < 0.2 GigACal/TONNE
• FUEL CONSUMPTION
• < 54 KWH/TONNE
• POWER CONSUMPTION
• < 100 mg/Nm3
• EMISSION
• < 80 microgram/nM3
• PARTICULATE
Raw material
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Sinter Plant:
Salient Features :
2
Sinter Machine Suction Area 204 m
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3
Process Gas Volume 1.2 x 10 ^6 m /h
2
Effective Cooling Area 202 m ; Diameter: 22.5 m
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• The suction of air makes the combustion zone travel through the bed
raising its temperature layer by layer to sintering temperature.
• Process completes when combustion zone reaches to the lowest layer of
the bed.
• Sinter cake is tipped from the grate in hot condition, broken, screened and
cooled to produce desired fraction.
Sintering Process
• Feed preparation
• Proportion of raw materials
• Moisture addition and mixing
• Layering on sintering machine
• Ignition of top layer
• Sintering- suction of air through bed
• Discharge of sinter from machine
• Cooling of sinter
• Screening of product
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• With increase of temperature more and more hematite along with gangue
goes into solution resulting in more of slag bonded complex sinter structure
SFCA (silica-ferrite of calcium and aluminums).
• At basicity levels of more than 2 calcium ferrite and dicalcium silicate forms
and at lesser than 1.6, glassy silicate and secondary hematite and
magnetite forms.
Blast Furnace:
The purpose of a blast furnace is to chemically reduce and physically convert iron
oxides into liquid iron called "hot metal". The blast furnace is a huge, steel stack
lined with refractory brick, where iron ore, coke and limestone are dumped into
the top and preheated air is blown into the bottom. The raw materials require 6
to 8 hours to descend to the bottom of the furnace where they become the final
product of liquid slag and liquid iron. These liquid products are drained from the
furnace at regular intervals. The hot air that was blown into the bottom of the
furnace ascends to the top in 6 to 8 seconds after going through numerous
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chemical reactions. Once a blast furnace is started it will continuously run for four
to ten years with only short stops to perform planned maintenance.
Iron oxides can come to the blast furnace plant in the form of raw ore, pellets or
sinter. The raw ore is removed from the earth and sized into pieces that range
from 0.5 to 1.5 inches. This ore is either Hematite (Fe2O3) or Magnetite (Fe3O4)
and the iron content ranges from 50% to 70%. This iron rich ore can be charged
directly into a blast furnace without any further processing. Iron ore that contains
a lower iron content must be processed or beneficiated to increase its iron
content. Pellets are produced from this lower iron content ore. This ore is crushed
and ground into a Powder so the waste material called gangue can be removed.
The remaining iron rich powder is rolled into balls and fired in a furnace to
produce strong, marble-sized pellets that contain 60% to 65% iron. Sinter is
produced from fine raw ore, small coke, sand-sized limestone and numerous
other steel plant waste materials that contain some iron. These fine materials are
proportioned to obtain desired product chemistry then mixed together. This raw
material mix is then placed on a sintering strand, which is similar to a steel
conveyor belt, where it is ignited by gas fired furnace and fused by the heat from
the coke fines into larger size pieces that are from 0.5 to 2.0 inches. The iron ore,
pellets and sinter then become the liquid iron
Produced in the blast furnace with any of their remaining impurities going to the
liquid slag
The coke is produced from a mixture of coals. The coal is crushed and ground into
a powder and then charged into an oven. As the oven is heated the coal is cooked
so most of the volatile matter such as oil and tar are removed. The cooked coal,
called coke, is removed from the oven after 18 to 24 hours of reaction time. The
coke is cooled and screened into pieces ranging from one inch to four inches. The
coke contains 90 to 93% carbon, some ash and sulfur but compared to raw coal is
very strong. The strong pieces of coke with a high energy value provide
permeability, heat and gases which are required to reduce and melt the iron ore,
pellets and sinter.
The final raw material in the iron making process in limestone, the limestone is
removed from the earth by blasting with explosives. It is then crushed and
screened to a size that ranges from 0.5 inch to 1.5 inch to become blast furnace
flux.
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Since the limestone is melted to become the slag which removes sulfur and other
impurities, the blast furnace operator may blend the different stones to produce
the desired slag chemistry and create optimum slag properties such as a low
melting point and a high fluidity.
All of the raw materials are stored in an ore field and transferred to the stock
house before charging. Once these materials are charged into the furnace top,
they go through numerous chemical and physical reactions while descending to
the bottom of the furnace.
Salient Features
Availability 98%
Tuyeres 36
Tap holes 4
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Stoves 3 No.
DR plant will use 100% pellet & COREX gas for making DRI, which will be used in
Electric arc furnace & BOF as coolant.
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Associates
BAR MILL:
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Low good water cooling facilities to achieve desired microstructure as well as good
Metallurgical aspects mechanical properties.
Associates
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The CRM i.e. Cold Rolling Mill project. As the name indicating rolling is done at a
normal temperature like room temperature is called cold rolling (CRM). There are
various types of CR Mills are available like 20 Hi Mill, 6 hi Mill, 4 Hi Mill, 2 Hi Mill &
Tandam Mill. The names indicating on the basis of how many rollers are used in
the mill. In Tandam mill, series of stands are installed and coil will pass through
the mills one direction and giving the desired thickness of the coils.
Raw material for CRM is Hot Rolled Coils; it is received from HSM2/ HSM-1. The
product of CRM is called CR Coils. In CRM2, the thickness of the products varies
from 0.30 mm to 3.00 as per requirements of the customer. The maximum wide
of the coil is 1950 mm. Normal weight of each coil shall be 25-30 MT. Maximum
speed of our line is 1450mpm
The CR Coils is the raw materials for Galvanizing (GP Line) and CRCA (Cold Rolled
Closed Annealing). The GP Coils is used for making GC sheets, GP sheets,
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Insulation works, making house hold items etc. The CRCA sheet is using for mainly
automobile industries. The CRM2 is biggest plant in India by capacity 2.30 mpa.
And second biggest is M/s Tata Steel.
LEARNING:
I have learnt how the structure behaves in different circumstances
depending upon different loading conditions & the complete designing &
analysis of the steel structure.
CONCLUSION:
In review this internship has been an excellent and rewarding experience. I have
been able to meet and mingle with so many officials by which I could get help for
my internship.
One main thing that I have learned through this internship is time management
skills as well as self-motivation. When I first started I did not think that I was
going to be able to walk for eight hours a day, five days a week. Once I realized
what I had to do I organized my day and work so that I was not overlapping or
wasting my hours. I learned that I needed to be organized and have questions
ready for when it was the correct time to get feedback. From this internship and
time management I learned to inculcate the habit of being in the office for so
many hours and using the time preciously. The main thing that I came across is
about my working capacity within the given time. That really gives a good
meaning for the training. I came up with various proposals and ideas that the
company is still looking into. I am also sure that this internship training
programme will help me out in my future projects.
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