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PREPARED BY: - A.Aditya Sharma

Aditya Pratap Singh

Anand Prakash Singh

Ankita Agrawal

Anurag Gupta

Bhupendra Kumhare

Deepak Patel

-: ACKNOWLEDGEMENT: -

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I want to express my gratitude towards all the seniors and associated members of SMS-2 who have given me guidelines and their valuable times during my training period.

Moreover, I want to thank all the persons of HRD department of J.S.P.L. for such a wonderful cooperation during this period.

Last but not the least, my thanks to all my dear batch mates and all the people who have directly or indirectly contributed towards successfully completion of this report.

-: Contents: -1.About JSPL

2.Function of SMS department 3.Equipments & Capacity of:- Electric arc Furnace

Ladle Refining Furnace

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Vacuum Degasser & RH degasser

Casters {Billet, Combi, Slab}

4.SMS processes

5.Raw Materials

6. Different sections at SMS: -PQ Bay

Electric Arc Furnace:- Tapping

EAF processes

EAF Advantages

7.Ladle Refining Furnace:- LRF processes

8.Vacuum Degasser

9.RH Degasser

10.Continous Casting:-Billet Caster

Combi Caster

Slab Caster

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ABOUT J.S.P.L: -Corporate profileJindal Steel and Power Limited is the most valuable private steel producer in India, with an annual turnover of over US $2.1 billion (Rs. 10,000 crore), Jindal Steel & Power Limited (JSPL) forms a part of the US $12 billion (over Rs. 60,000 crore) Jindal Group. JSPL is a leading player in Steel, Power, Mining, Oil & Gas and Infrastructure. Mr. Naveen Jindal, the youngest son of the legendary late Shri. O P Jindal drives JSPL and its group companies Jindal Power Ltd, Jindal Petroleum Ltd., Jindal Cement Ltd. and Jindal Steel Bolivia with a belief in the concept of self-sufficiencyTechnical Profile

2 MTPA cement plant. Additional power generation of 540 MW.

Medium structural mill.

Pipe conveyor from mines to plant.

Mini blast furnace up-gradation

Fabrication unit in the industrial estate.

AWARDS: - JSPL India ‘s fastest growing large size company by dalal street, 2006 Gold prize –greenstick environmental excellence award 2006 Golden peacock environmental award 2006 IIM quality award 2002-2003, by the Indian institute of

metals

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National safety award2003-2004, by ministry of labour and many more awards

Function Of Department...Steel Melting Shop: Pig iron, sponge iron, limes and ferroalloy is charged from the top of Electric Arc Furnace. Arcing melt the contents. Oxygen blowing is done. Steel is tapped and chemistry correction is done in ladle refining furnace. Liquid steel is casted. Slag is taken out from slag door.

The basic function of the Steel Melting Shop is the refining of steel before casting. Basically the refining of steel in SMS can be divided into two segments:

1. Primary Refining- It is done at Electric Arc Furnace, where the hot metal is De-Phosphorised, De-carburized, and melted along with charge (i.e. DRI, Lime and Dololime) and CPC (calcined petroleum coke)

2. Secondary Refining- It is done at Ladle Refining Furnace, where the molten steel from EAF is De-sulphurised, & De-oxidized, in an oxidizing atmosphere

Electric Arc Furnace

EQUIPMENT CAPACITYElectric Arc Furnace Alternating Current By

DANIELITapping Weight 100MTTransformer Capacity

100MVA

Active Power Input 23MWSecondary Voltage 500 V

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Secondary Current 33KAShell Diameter 5.6 meterElectrode Diameter 24 inchLADLE REFINING FURNACE EQUIPMENT CAPACITY LADLE FURNACE 100T

TRANSFORMER CAPACITY 18MVA

ELECTRODE DIAMETER 16INCH

TREATMENT TIME 30-35 MIN

VACUUM DEGASSING EQUIPMENT CAPACITY

VACUUM DEGASSING UNIT 100T

MAKE GA DANIELLI

CASTER EQUIPMENT CAPACITY BEAM BLANK/BLOOM/ROUND 4 STRAND 12 METER RADIUS SLAB CASTER 12 METER BILLET 12 METER 6 STRAND

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SMS Processes

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RAW MATERIALS HOT METAL DRI SKULL SCRAP LIME DOLOMATIC LIME

HOT METAL (COMPOSITION &ELEMENT USE) C- 3.5-4% SI- 0.7-0.8% MN- VERY LESS S- 0.02-0.05% P- 0.08-0.1% FE- 98.50-99.75%

DRI (50-55 TONN) FE- 81% OXIDE- 9-10% C- 0.2% SI- 3.2-3.5%

SCRAP(1.54-2.0%)

LIME(CAO) CAO- 83-84% MGO- 1.65% SI – 1.5%

DOLOMATIC LIME CAO- 63-66% MGO- 16-18% SI- 3.5-4.0%

DIFFERENT SECTIONS AT SMS

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PQ B ay (Torpedo)

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The torpedo ladle transfers the pig iron from the blast furnace to the steel plant. It is used for transportation over greater distances.

Steel Ladle

The steel ladle is very demanding on refractory products:As the liquid steel is dropped from an enormous height, it requires the greatest possible mechanical resistance. Metallurgical processes at temperatures of over 1,600°C require maximum refractoriness.

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EAF (Electric Arc Furnace)

EAF AT J.S.P.L.

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Tapping Process

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An electric arc furnace (EAF) is a furnace that heats charged material by means of an electric arc.Arc furnaces range in size from small units of approximately one ton capacity (used in foundries for producing cast iron products) up to about 400 ton units used for secondary steelmaking. Electric arc furnace temperatures can be up to 1,800 degrees Celsius.

EAF Processes DephosphorizationDecarburizationMelting

Advantages of electric arc furnace The use of EAFs allows steel to be made from a 100% scrap metal feedstock, commonly known as 'cold ferrous feed' to emphasize the fact that for an EAF, scrap is a regulated feed material. The primary benefit of this is the large reduction in specific energy (energy per unit weight) required to produce the steel. Another benefit is flexibility: while blast furnaces cannot vary their production by much and are never stopped, EAFs can be rapidly started and stopped, allowing the steel mill to vary production according to demand. Although steelmaking arc furnaces generally use scraps steel as their primary feedstock, if hot metal from a blast furnace or direct-reduced iron is available economically, these can also be used as furnace feed.

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A typical steelmaking arc furnace is the source of steel for a mini-mill, which may make bars or strip product. Mini-mills can be sited relatively near to the markets for steel products, and the transport requirements are less than for an integrated mill, which would commonly be sited near a harbor for access. to shipping

EAF Productivity The EAF - productivity depends on:

Ö Metallic Input: - Hot Metal (60-65 tonn) DRI (50-55 tonn)

Scrap (adequate(up to 5 tonn))Ö Equipment (Transformer capacity 100MVA/T)

Ö Oxygen blowing

Ö CPC & Lime Addition

All these contributes to Tap To Tap Time (Minimum- 40-50min(approximate))Working Temperature (1550-1600˚C)

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L.R.F. (Ladle Refining Furnace)

Function of LRF The Ladle furnace is used to heat the steel and achieved the final composition of steel by adding Ferro alloy, Argon bubbling is applied to homogenize the steel composition and temperature. Heating of up to 3˚C per minute is achieved by a set of graphite electrode, which are lowered into the slag layer, Just above the molten steel surface

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Another purpose of the ladle furnace is to act as a holding furnace between the EAF and continuous casting machine.

LRF Processes DeoxidizationDesulphurization (through lime addition)Chemical Adjustments (through addition of Fe alloys)RefiningTemperature ControlHomogenization of Compositions (through Argon Purging)

V.D. (Vacuum Degassing) Function of V.D. Vacuum treatment of the steel is the most important secondary metallurgical process. The tank degasser is used to remove gaseous element, non-metallic inclusion and Sulphur from the steel. The removal of Non-metallic inclusion is achieved through slag metal interactions, which are promoted by strong argon flushing within the vacuum tank.

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Internal Structure of V.D.

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RH-Degasser

Sectional View of R.H. Degasser

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Function Of RH-Degasser

The main functions of the RH degasser are for hydrogen removal, forced decarburization and the chemical heating of the steel.The widespread use of the RH-degasser makes extraordinary demands on the refractory material.

Continuous Casting

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.This process is used most frequently to cast steel (in terms of tonnage cast).

Equipments

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1. Ladle 2. Stopper 3. Tundish4. Shroud 5. Mold 6. Roll support 7. Turning zone 8. Shroud 9. Bath level 10. Meniscus 11. Withdrawal unit 12. Cutting zone

A. Liquid metal B. Solidified metal C. Water-cooled copper plates D. Refractory material

Types of Casting

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Billet Casting

Billet casters cast smaller section sizes, such as below 200 mm square, with lengths up to 12 m long. Cast speeds can reach up to 4 m/minute.

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Combi casting

The machine will be modified in such a way that it will be capable of simultaneously casting up to four bloom strands. External mold stirring will be provided to ensure a homogeneous internal strand quality of the high-carbon rail-steel and tube-steel grades to be produced. Installation and modification work will be carried out to the greatest extent possible during regular casting operations; however, a caster-shutdown period of about 60 days will be necessary.

The caster design is characterized by curved molds, radius of caster 12 m and a metallurgical length of 17.1 m.

Slab Casting

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Slab casters tend to cast sections with an aspect ratio that is much wider than it is thick: Conventional slabs lie in the range 1500-2600 mm

wide by 180–250 mm thick and up to 12 m long with conventional casting speeds of up to 1.4 m/minute, (however slab widths and casting speeds are currently increasing).

Thin slabs: 1520×215 mm

Slab Segments

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Safety rules & precautions

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Wearing Helmet(ISI certified) properly is a must. Wearing Thick jeans Jacket for protecting body parts Roaming here and there inside the industry without

having proper guidance could be dangerous. Following the safety precautions written in every

section would be beneficial. Observing the surrounding changes by listening &

watching carefully could save us from any accident