:: DURGAPUR STEEL PLANT

Set up in the late 50's with an initial annual capacity oI one

million tonnes oI crude steel per year, the capacity oI Durgapur
Steel Plant (DSP) was later expanded to 1.6 million tonnes in
the 70's. A massive modernisation programme was undertaken
in the plant in early 90's, which, while bringing numerous
technological developments in the plant, enhanced the capacity
oI the plant to 2.088 million tonnes oI hot metal,1.8 million
tonnes crude steel and 1.586 million tonnes saleable steel. The
entire plant is covered under ISO 9001: 2000 quality management system.

The modernized DSP now has state-oI the-art technology Ior quality steel making. The
modernized units have brought about improved productivity, substantial improvement in
energy conservation and better quality products. DSP`s Steel Making complex and the entire
mills zone, comprising its Blooming & Billet Mill, Merchant Mill, Skelp Mill, Section Mill
and Wheel & Axle Plant, are covered under ISO: 9002 quality assurance certiIication.

With the successIul commissioning oI the modernized units, DSP is all set to produce 2.088
million tones oI hot metal, 1.8 million tones oI crude steel and 1.586 million tones oI saleable
steel annually.
PRODUCT-MIX TONNES/ANNUM
Merchant Products 2,80,000
Structural 2,07,000
Skelp 1,80,000
Wheels & Axles 58,000
Semis 8,61,000
Total Saleable steel 15,86,000

Location
Situated at a distance oI 158 km Irom Calcutta, its geographical location is deIined as 230 27'
North and 880 29' East. It is situated on the banks oI the Damodar river. The Grand Trunk
Road and the main Calcutta-Delhi railway line pass through Durgapur.

Environment control
Durgapur Steel Plant has always made relentless eIIorts to maintaining a healthy and clean
environment. The units in DSP are provided with necessary pollution control Iacilities and the
liquid eIIluents and chimney emissions Irom the plant are well within norms.

DSP has undertaken massive aIIorestation to maintain clean environment. Some 3,266 acres oI
land have been covered with 14 lakh plantations. In order to develop healthy awareness about
the environment amongst the younger generation, eco-clubs have been Iormed in DSP schools.

Centre for Human Resource Development
DSP has always attached maximum importance on proper training and development oI its
employees. Its Centre Ior Human Resource Development has all modern Iacilities including
the state-oI-the-art Electrical and Electronics laboratory, Hydraulics and Pneumatics laboratory
and workshop Ior eIIective training and development oI its employees.

Communication
The Public Relations Department publishes monthly house journals in English, Bengali and
Hindi Ior extensive inIormation oI company aIIairs to the employees. DSP also has an in-house
TV studio (DSTV) along with all modern Iacilities, which telecast news and a gamut oI other
programs covering various aspects oI plant and township activities.

Durgapur - The Happening City
Durgapur, which is on the main Kolkata New Delhi line, is Iast turning into the most
happening city in the region. From a sleepy settlement, the town today boasts oI a variety oI
educational institutions, posh shopping malls, complexes with eateries and a multiplex, etc.
With the change in the mindset oI the people has come a change in the liIestyle also. Quality
consciousness has steeped in, accompanied with quality brands making their presence Ielt in
the market. Durgapur is Iast turning into the central location Ior the entire region with the
entry oI big business houses and entrepreneurs, the city is all set to undergo a change in its own
liIestyle and in the outlook oI its residents.

Contact Us :

Durgapur Steel Plant
BR Kanungo
DGM (Comm.) & ChieI oI Communications
Email :cocprdspgmail.com
Tel : 91 - 0343 - 2574368/2574318 (teleIax)









Raw Materials
Iron ore, coal and limestone are the three basic raw materials Ior the steel industry. Durgapur
Steel Plant draws its coal Irom the adjacent Jharia-Ranigunj coal belt. A good amount oI prime
coking coal, having Iairly low ash content, is also imported. Bulk oI iron ore lumps and Iines
come Irom the mines at Bolani in Orissa. Lime stone comes Irom a variety oI sources:
Birmitrapur (Orissa), Jaisalmer (Rajasthan), and Jukehi and Nandwara (Madhya Pradesh).
Raw Materials Handling
To improve and ensure consistency in raw material quality, the Iacilities, which have been
installed, are:
O BeneIiciation/washing Iacilities, both Ior lump ore and Iines at Bolani
O Screening oI lump iron ore inside the plant,
O Selective crushing oI coal at Coal Handling Plant,
O Base blending Iacilities Ior Sinter Plant,
O Silo-cum- Blending bunkers
As part oI the modernisation programme, new raw material handling storage and blending
Iacilities with selective crushing oI coal have been installed in order to ensure consistency in raw
material quality.
The beneIiciation/washing Iacilities, both Ior lump ore and Iines at Bolani, have a capacity to
process 3.44 million tonnes (wet basis) per annum so as to be capable oI catering to the entire
requirement oI the plant aIter modernisation.
Durgapur is the only steel plant in the country to have a coal washery at the plant site.
Raw Materials Handling Complex
Durgapur Steel Plant consumes about 7.4 million tonnes oI diIIerent raw materials annually
which comprises over 1.84 million tonnes oI coal and 2.9 million tonnes oI iron ore lump and
Iines. Besides the two major raw materials, the plant also requires limestone, dolomite,
manganese ore, bauxite, silico manganese, Ierro manganese, Ierro silicon, etc.

Coke Ovens & Coal Chemicals
No oI batteries - 5
No. oI ovens per battery - 78
The coke ovens and coal chemicals zone is divided into Iour basic sections namely coal
preparation plant, coal carbonisation plant, coke handling plant and coal chemicals. Presently,
DSP is operating only three batteries.
The Blast Furnace grade coke produced in Coke Ovens is directly used in Blast Furnaces while
the undersized coke is used Ior sinter making.
The volatile matters, which emanate during the process oI coke making subsequently produce a
variety oI by-products like naphthalene oil, heavy creosote oil, light oil, crude tar partially
distilled tar, 'Raja brand Iertiliser, nitration grade benzene, nitration grade toluene, industrial
grade toluene, light solvent naphtha etc.
The coke oven gas is generally used in combination with the Blast Furnace gas and BOF gas as
Iuel and is carried through pipelines to the diIIerent areas oI the plant. The adjoining Alloy Steels
Plant under SAIL is also supplied with this Iuel gas Irom DSP.

Sinter Plant
In order to enhance the productivity oI blast Iurnaces, a high percentage oI sinter charge is a
prerequisite. Sinter is an agglomeration oI iron ore Iines, coke and limestone in the Iorm oI
cakes. To ensure sinter burden in the blast Iurnaces at 75 per cent, a total oI 3 million tonnes oI
sinter was envisaged Ior a production oI about 2 million tonnes oI hot metal. A technologically
modern and Iuel eIIicient sintering machine having 198 sq metres sintering area has been added
as part oI the modernisation scheme to produce 1.7 million tonnes oI sinter. The balance
requirement will be met Irom the revamped old sinter plant.
Sinter mix, a mixture oI Iines oI iron ore, limestone, coke, dolomite and Ilue dust, blended
proportionally at the RMHC, is a prepared material which is selI Iluxing. In ignition strands it is
burnt under controlled conditions to Iorm a porous cake type substance called sinter, which used
in blast Iurnaces enhances productivity and reduces coke rate.

Raw Material Preparation & Handling
Raw Material Handling Plant
Durgapur Steel Plant requires annually over 7.4 million tonnes oI diIIerent raw materials,
which comprises over 1.84 million tonnes oI coal and 2.9 million tonnes oI iron ore lump
and Iines. Besides the two major raw materials, the plant also requires limestone,
dolomite, manganese ore, bauxite, silico manganese, Ierro manganese, Ierro silicon, etc.


Blast Furnaces
Blast Furnaces
Blast Iurnaces are reIerred to as the mother unit` oI an integrated steel plant. Iron ore as
available in nature is basically an oxide. It is charged into a blast Iurnace either as lump ore or in
the Iorm oI sinter and reduced to molten iron by the coke at temperatures ranging Irom 1, 200
1, 400 degrees centigrade. The limestone, acting as Ilux, absorbs the impurities in the molten
iron and goes out as slag. The major portion oI liquid hot metal is transIerred to steel melting
shop Ior conversion to steel and the rest portion is cast into pig iron in pig casting machines.
Blast Iurnace slag high in lime-content is used Ior cement making.

There are three numbers oI blast Iurnaces operating presently at DSP. The useIul volume oI two
Iurnaces is 1,400 cubic meters each and that oI the other one is 1,800 cubic meters. The Iurnaces
are presently operating at a productivity level oI 1.3-1.4 tonnes/cubic meter/day. The Iurnaces
are equipped with sophisticated and modern computerised control system and are operated with
high blast temperatures (1,100 degree centigrade) and high top pressure (0.7 Kg/ sq. cm). The
cast houses are provided with Iacilities like twin tap holes, rocking runners etc. There are also
two numbers oI Slag Granulation Plants, which convert molten blast Iurnace slag into granulated
Iorms Ior ready use in the cement industry. There are three pig casting machines, with a total
capacity oI 2,12,000 tonnes/year.
Blast Iurnaces
No 1 No 2 No 3
(being modernised)
No 4
Capacity (t/day) 1, 250 1, 820 1, 820 2, 340
UseIul volume (cum) 1, 323 1, 400 1, 400 1, 800
Stoves 3 3 3 3
Productivity (t/cu m/day) 1.000 1.3 1.3 1.3


Steel Melting Shop
Mixers - 2 x 1, 300 t
Converters - 3 x 110 t (nominal heat size)
Molten iron is Iurther reIined at the Steel Melting Shop (SMS) to produce steel, which is hard
and malleable.

At DSP, there are 3 converters (Basic Oxygen Furnace) oI 110-130 tonnes each. The SMS also
has a Vacuum Arc Degassing (VAD) unit Ior making special grades oI steel.

A major portion oI the steel is routed through the Continuous Casting Plant. Another major
portion oI the steel is taken to the teeming bay, where it is top poured into 8 tonne ingot moulds
Ior making ingot steel. A portion oI highly controlled steel is cast at the Special Casting Bay into
Iluted ingots and special quality blooms. Fluted ingots are bottom poured and are used Ior
making wheel steel Ior DSP`s Wheel & Axle Plant. A portion oI the liquid steel is also bottom
poured to make axle ingots.

Continuous Casting Plant
The state oI the art CCP has 2 Nos machines having 6 strands each. The other basic details are as
Iollows: -

Design limits- 80-150 sq .mm, casting radius- 6 metres
Casting time 85 minutes, Cut-oII lengths- 6 / 9 / 12 metre
No oI ladle treatment stations-2
Mould level controller - Automatic (Radio-active Co-60)
The steel ladle Irom BOF is taken to the ladle treatment station. At the ladle treatment station,
liquid steel is rinsed with nitrogen to homogenise its temperature and composition. AIter the
rinsing, the ladle containing liquid steel is placed on the turret and brought over the tundish. The
tundish acts as a buIIer and enables the liquid steel to move homogeneously down through the
six nozzles, provided at the bottom oI the tundish into moulds. The automatic mould level
controller controls the steel level in the mould. The subsequent primary and secondary cooling
transIorms the liquid steel into billets oI the required dimensions and is drawn out with the help
oI a withdrawal and straightener unit and cut into the required length by the shear provided in
each strand. The continuous casting process is the result oI a unique synchronisation between
Basic Oxygen Furnace and CCP. Once a ladle is emptied, another ladle is brought into casting
position and the casting continues.
The billets are gradually shiIted to the cooling beds and then stacked orderly at the despatch end
Ior outside despatch. The details about the cast number and quality oI the billets are marked on
the billet stack. The Merchant Mill oI Durgapur Steel Plant utilises billets Ior rolling TMT bars
and other merchant rounds, while a sizeable portion is sold in the domestic and Ioreign markets.



Rolling Mills
Ingots weighing 8 tonnes each are heated in the soaking pits (numbering 20) Ior about 7 to 12
hours at around 1, 200 degrees centigrade and thereaIter rolled in the 42 primary and the 32
secondary blooming mills. These are rolled Iurther into diIIerent shapes and sizes in diIIerent
Iinishing mills.
Blooming mill
Installed Mill capacity - 1.47 million tonnes/year
Ingot weight - 8 tonnes
42" Mill:
42" x 102" reversible Blooming Mill
Output bloom size (min) - 300 mm x 250 mm

32" Mill:

32" x 84" reversible Intermediate Mill
Output bloom size (min) - 180 mm x 180 mm
Billet Mill
Installed Mill capacity - 0.957 tonnes / yr.
Type - Continuous Morgan design
Horizontal stands - 6, Vertical stands - 2
Product Range
Billets - 100 mm square to 125 mm square
Sleeper bars - 352 mm x 12.5 mm
Skelp slabs - 140 mm x 75 mm to 240 mm x 90 mm
The ingots aIter heating are rolled in the Blooming Mill to make blooms oI the sizes mentioned
in the table and then a part oI the same are then Iurther rolled in the Billet Mill Ior making rolled
billets or slabs as per the above details.

Section mill
The Section Mill rolls out light and medium structural like joists, channels and angles.
Mill capacity - 0.2 million tonnes / year
Re-heating Iurnaces - 2 x 40 t/hr
Roughing Mill - 2 high reversible
Intermediate Mill - 2 stands oI 3 high non-reversible
Finishing Stand - 2 high non-reversible
Product range:
Joists - 200 mm x 100 mm, 175 mm x 85 mm
150 mm x 75 mm, 116 mm x 100 mm
Channels - 200 mm x 75 mm, 175 mm x 75 mm
150 mm x 75 mm, 125 mm x 65 mm
Angels - 150 x 150 mm, 130 x 130 mm
110 x 110 mm, 100 x 100 mm
Fish plate bars Ior 52 kg rails

Merchant Mill
Merchant mill
The Merchant Mill produces plain round and Thermo-Mechanically Treated (TMT) bars in the
range oI 16mm - 28mm. The entire product range oI TMT bars and rods at DSP is branded and
has been able to create a niche market.
Capacity - 0.28 million tonnes / year
Type oI mill - continuous Morgan design
Horizontal stands - 13, Repeaters - 4

Product range
Plain rounds - 12 - 32 mm dia
TMT bars - 12 - 25 mm dia
Skelp Mill
The Skelp Mill produces skelp in the range oI 146 to 235 mm primarily Ior tubes and pipes
making industry.
Capacity - 0.25 million tonnes / year
Type oI Mill - Continuous Loewy design
Horizontal stands - 11
Vertical stands - 6

Product range
Strips & Skelps - 75-242 mm wide to 1.47-2.34 mm thick

Railway Products

Durgapur Steel Plant is the only major indigenous supplier oI wheel sets, loco wheels, carriage
and wagon wheels, and axles to the Indian Railways. As per demand oI the Railways, the plant
has developed loco wheels, which were imported earlier. The Wheel & Axle Plant is producing
wheels manuIactured as per the latest IRS speciIications, i.e. R-19/93 Ior carriage and wagon
wheels, R-34/99 Ior loco wheels and R-16/95 Ior axles.
The wheel plant oI the Wheel & Axle Plant is provided with six PLC controlled band saws Ior
accurate slicing oI the 14 and 16 Iluted ingots. A Iully computerised 63/12 MN oil hydraulic
press is there Ior Iorging and punching oI the wheel blanks along with a Iully computerised
vertical wheel mill and other down stream Iacilities. All the wheels are 100 per cent rim-
quenched, tempered and tested as per IRS speciIications.
Machining oI these Iorged rolled and heat-treated wheel blanks are carried out in the 15 CNC
machines. All the wheels are ultrasonically tested and inspected by RITES on behalI oI the
Indian Railways. A number oI sophisticated and modern online testing Iacilities are there to
conIorm to the stringent testing requirements oI the Indian Railways.
Wheel & Axle Plant
Annual production oI Iinished wheels - 1,00,000 nos.
Production rate in rolling/Iorging - 25 nos./hr
Production rate in machining - 22 nos./hr


Engineering shops
Durgapur Steel Plant has a number oI captive engineering shops Ior repairs and supply oI spare
parts. The Central Engineering Maintenance has a Machine Shop, Structural Shop, Fitting and
Assembly Shops. The Foundry produces Ingot moulds and bottom plates Ior the steel melting
shop. There are also Auxiliary Repair Shops such as Electrical, Wagon and Loco repair.


Research and Control laboratories

The Research & Control laboratories are entrusted with the responsibility oI maintaining quality
oI products and also developing new products. It is well equipped Ior carrying out sophisticated
chemical, metallurgical and other tests.


Computerisation
An extensive computerisation has been undertaken in DSP Ior personnel, commercial, process
control, production and maintenance applications. The Production Planning and Control network
is thoroughly used Ior tracking oI customer orders, material, monitoring oI quality parameters
and ensuring availability oI accurate, real time data to all agencies needing access to the data.


Quality Assurance
In order to be Iully competitive on the quality Iront, Durgapur Steel Plant has set out to acquire
ISO 9000 certiIication Ior all its units. The Merchant Mill is the Iirst to secure the prestigious
ISO 9002 certiIicate. Subsequently, steel melting shop, basic oxygen Iurnace shop, continuous
casting plant, and wheel and axle plant were also awarded the ISO 9002 certiIication and
recently the Skelp Mill has been awarded the ISO 9002 certiIication.
Durgapur Steel Plant
PRODUCT-MIX TONNES/ANNUM
Merchant Products 2,80,000
Structural 2,07,000
Skelp 1,80,000
Wheels & Axles 58,000
Semis 8,61,000
Total Saleable steel 15,86,000



Durgapur Steel Plant
Community & Development
The abode of steelmen
The Durgapur Steel Plant township is spread over a sprawling 40 kms and has more than 25,000
dwelling units. And it has housing Iacilities Ior the employees oI DSP, ASP and other business
associates. The other amenities include schools, both primary and secondary, a modern 640 beds
hospital with modern medical Iacilities, the picturesque park, a number oI cultural centres, a
stadium with a sitting capacity oI 15,000, etc.
Peripheral Development
Contribution to the region's development
Over the years, it has contributed in a major way Ior providing tube well Iacilities in the water-
scarce peripheral areas. Another notable contribution has been the eIIorts taken towards
enlightenment oI the region through up-gradation or additions to educational Iacilities in
basically rural areas surrounding the steel township. It has also assisted in developing roads and
other Iacilities.
Durgapur Steel Plant has played a major role in encouraging and developing small-scale
industries in the region.