VT Presentation 2016

7/26/2019 VT Presentation 2016

1/74


2/74

Indias first 3 public sector steel plants startedproduction in 1959 under HSL, which was laterincorporated in the year January 24, 1973 and

known as SAIL. In May 2010 it has been accorded with a highest

status called Maharatna Company.

It is the 4th largest steel producer in the worldleading in Asia.

In 2014 total turn over was 51,866 Crore andManpower around 96,047.

A vibrant, market-driven enterprise managing 5Integrated Steel Plants, 3 Special Plants and 01Ferro-Alloy Plant and 01 SAIL Refractory Unit

across the country.


3/74

5 Integrated Steel Plants

1. Bhilai Steel Plant(BSP),Chhatisgarh

2. Rourkela Steel Plant(RSP),Odisha

3. Bokaro Steel Plant(BSL),Bokaro

4. Durgapur Steel Plant(DSP),WB5. IISCO Steel Plant(ISP),WB


4/74

3 Special Steel Plants

1. Alloy Steels Plant(ASP),Durgapur2. Salem Steel Plant(SSP),Tamil Nadu

3. Visvesvaraya Iron & Steel Plant(VISL),

Bhadrabati,Karnataka.

01 Ferro-Alloy PlantFerro-Alloy Plant at Chandrapur, Maharastra

SAIL Refractory Company Ltd at Salem,

Tamil Nadu

01 Subsidiary


5/74


6/74

6


7/74

Commissioned in 1959 in collaboration with theleading steel makers from the Federal Republic of

Germany

Installed Capacity1.00 MT

1stBF commissioned in 1959

2ndBF commissioned in 1960

3rdBF commissioned in 1962

Capacity enhanced to 1.80 MT by commissioning

BF#4 in 1967

Now again capacity enhanced to 4.5MT by

commissioning BF#5 in 2014

HISTORY OF RSP


8/74

SSM with technical collaboration fromARMCO,USA was commissioned in 1984.

CPP-II was commissioned in 1987 now it

is under joint venture of NTPC and SAIL.

Last modernisation had taken place during

1988-1997 in two phases.

Capacity enhanced to 2.00 MT of HM.

This modernisation again capacity enhanced

to 4.5 MT by commissioning BF#5 in 1914

HISTORY OF RSP


9/74

First Plant in Asia to adopt LD process of steelmaking.

First Plant to producing large diameter ERW/SW

Pipes.First Plant to adopt external desulphurisation ofhot metal by adding magnesium powder.

First Plant to produce Cold Rolled Non Oriented

(CRNO) Steel sheets for use in the electricalindustries.

SPECIAL FEATURES OF RSP


10/74

First Plant to have a system of vacuumdegassing metallurgy.

First Plant to adopt the cost effective andquality centered continuous casting route toprocess 100% of steel produced.

All the major production units and some

service departments are certified underIntegrated Management System(IMS) policy.

SPECIAL FEATURES OF RSP


11/74


12/74

We have 74 departments workingunder one roof.

Total Man Power strength of RSP is

17,781

Total Executives = 2,112

Total Non-Executives = 14,529 Trainees(Excludes MTs)= 1140

Labour Productivity = 240.27(Mar)


13/74

RAW MATERIALS


14/74

OBBP

COSP-IISP-I

CP-I & II

PBCC

BF

CCD

Iron Ore(L&F), Mn

Ore, L/S & DoloCoking Coal

Coke

CO

Gas

Amm.

Sulph.

& Coal

Chem.

HM, Slag

& BF gas

Fuel

Gas

Base Mix

Sinter

Lime & Dolo

L/S & Dolo

(SMS Gr.)

I/O Lumps &

L/S BF Gr.

PROCESS FLOW CHARTRAW MATERIAL HANDLING TO IRON MAKING


15/74

SMS-I

SGPCCM-I

SMS-II

BF

CCM-II

Lime, Dolo & O2

Hot Metal

Slab

Lime, Dolo & O2

Slag

Slab

HSM & PM

STEEL MAKING


16/74

HSM

Div.

Line

PM

Slab From

CCM-I & II

CRM SSM ERWPP SWPP SPP

HR CR C/S CRNO ERW SW plates Spl.

Plates ETP Pipes Pipes

Plates GP/GC

ROLLING MILLS


17/74

Af i R


18/74

5 . 0 M T C a p a c i t y, 1 4 0 C o n v e y o r B e l t s o f 4 5 K m s L e n g t h . 2

W a g o n T i p p l e r s ( 2 0 W a g o n s / H r e a c h ) , 2 T r a c k H o p p e r s

( 6 0 0 0 T o n s e a c h ) , 1 4 B e d s ( 5 0 , 0 0 0 T e a c h ) , 4 S t a c k e r s

( 1 2 0 0 T / H r e a c h ) , 3 B a r r e l R e c l a i m e r s ( 6 0 0 T / H r e a c h ) a n d

2 B u c k e t R e c l a i m e r s ( 6 0 0 T / H r e a c h )

Come up in 1994,Ph-I & 1996,Ph-II during Modn

To meet raw material needs of various units of RSP

Main task is unloading, stacking, blending of IronOre, Limestone, Dolomite, Manganese and preparebase mix then send it to different units throughconveyor belts.

After expansion Raw

material requirement of

RSP will increase from

5 MT/yr to 12 MT/yr


19/74

Proximate Analysis Blended Coal BF Coke

Ash 14.5

0.5% 19.7

0.7%Volatile Matter 23 - 24% < 0.7%

Gross Moisture 6 - 8% 4.5 0.5%

Fixed Carbon 61 - 63% > 80%

1stproduction unit, to make good quality of coke to be used in BF to make Hot Metal.


20/74

Coke Making Unit

3 Batteries of 70 ovens each and 2 Batteries of 80 ovens each.

Length 13.59 Mtrs., Height 4.5 Mtrs, & Volume 21.6 M3

New CO Battery #6 with 7 Mtr Tall and 67 ovens.

Old Battery oven pushing 70/day and new 90/day


21/74

It handles the by-products of Coke Ovens.

Site AHandles CO gas from Batteries 1,2 & 3

Site BStorage Facilities

Site CHandles CO Gas from Batteries 4 & 5New CCD handle CO Gas generated from new CO Battery 6

Products: Coal Tar, Road Tar, Soft Pitch, Hard Pitch,Naphthalene Oil, H2SO4 , Ammonium Sulphate, Benzol,Carbolic Oil, Light Oil, Wash Oil, Anthrasene Oil.

Biological Oxidation and Dephenolisation (BOD) facility exist.

Coal Chemicals Department


22/74

Sinter Plants

Sinter Plant I:2 Sinter Machines of 1.5 MT/year

Sinter Plant II:1 Sinter Machine of 1.57 MT/year

New SP-III with 3.70 MT/year

Make good quality sinter to use in BF,

Reduce coke rate &

Increase BF productivity etc..


23/74

Raw Materials & Inputs:Iron Ore, Sinter, Coke, Lime Stone or LD Slag, Quartzite, Hot Air &

Water for Cooling.

To produce good quality of liquid hot metal.

3 BFs of 1139 M3 useful volume and 1 BF of 1658 M3 useful volumeNew BF#5 coming up with 4060 M3 useful volume & 7924 TPD capacity

Blast Furnaces


24/74


25/74

Tonnage Oxygen Plant I(To produce gaseous oxygen+nitrogen)

3 Air Separation Units of 100 TPD each

and 1 unit of 200 TPD

Tonnage Oxygen Plant II(To produce liquid oxygen+nitrogen)

2 Air Separation Units of 180 TPD each

Captive Power Plant-I5 units to produce 125 MW of power

TONNAGE OXYGEN PLANTS

Tonnage Oxygen Plant III(To produce both liquid & gaseous

oxygen+nitrogen)

1 Air Separation Units of 700 TPD


26/74

Lime Plant

For producing Metall-urgicalLime for use in LD Converters

of SMS-I as flux..

Brick Plant

To produce Magnesia Carbon

Bricks used as working lining in

LD Converters of SMS-I & II and

in the ladles of CCM - I & II.

LIME DOLOMITE BRICK PLANT

New LDBP with 350 TPD capacity


27/74

Steel Melting Shop I:

2 mixers of 1100 Ton each,

2 LDs of 60/66 Tons/ blow &1 single strand slab caster of

0.305 MT/year

Steel Melting Shop II:

2 mixers of 1300 Ton each,

2 LDs of 150 Tons each &

2 single strand slab casters of

1.355 MT/year

STEEL MELTING SHOPSTo produce good quality of steel and slabs

Fi t t l l t i A i t


28/74

First steel plant in Asia tocommercially use Basic Oxygen

steel making process


29/74


30/74

Produce good quality of HR Coil/ Plates

To send to CRM, SSM, Pipes plant, Dividing line for further processing


31/74

To produce good quality of Plates of different sizes

like 880 mm thickness, 15002500 mm width & 450012500 mm length.

PIPE PLAN

TS


32/74

To produce API pipes uptograde API-5L-X70 & IS-3589of 8.5/818 dia and wallthickness 3.212.7 mm usinghigh frequency welding (400

KHz)

To produce API pipes upto gradeAPI-5L, IS-3589, IS-5504 Pipes of1672 dia and wall thickness

5.6-14.2 mm using double sub-merged arc welding.

Both units are made by West

Germany.

PIPE PLANTS


33/74

To produce various grades of high

hardness and abrasion resistant steelplates like SPADE, JACKAL, DMR-249A.

Follow Stringent Quality Control Norms

of CQA (MET) to produce Armour Platesand Components for Defence Units.

SPECIAL PLATE PLANTS (SPP)


34/74

Input:Hot Rolled Coils from HSM

Output:

CR Coils(Width 920

1270 mm, Thickness 0.35

1.6 mm),

CR Sheets(Length 2500 3600 mm, Width 1250 mm max.,Thickness 0.51.6 mm),

Tin Sheets(Width 560 1040 mm, Thickness 0.150.31 mm,Coating Weight 5.6 22.4 gm/m2)and

GP/GC Sheets(Width 610 1220 mm, Thickness 0.31 1.6 mm)


35/74

Input: HR Coils from HSM

Output: Cold Rolled Non-Oriented(CRNO) coils as

well as sheets to be used in Electrical Industries.

Other 56 units are also working in different locations under RSP


36/74


37/74

PLATES


38/74

SHEETS


39/74

COILS


40/74

PIPES


41/74

EXTENSIVE TESTING


42/74

RIGOROUS INSPECTION


43/74

IMPROVED PACKAGING


44/74

CUSTOMER DELIGHT

Use of VCI Stretch Film with TENAX Polyesters Strap for CRNO


45/74

CUSTOMER DELIGHT

Use of Inner Eye Protector for HR Coil


46/74

Product Application


47/74

Product Application

HR Coil LPG Cylinders,automobile, railway

wagon chassis and manytypes of high-strengthapplications

Plates Pressure vessels, ship

building and engineering

structures

ChequeredPlates Flooring and staircasesin industrial sectors and

railway platforms

P d t A li ti


48/74

Product Application

CR Sheets

and Coils

Steel furniture, white goods,railway coach paneling,drums, barrels, deep drawingsand extra deep drawings

Galvanised

Sheets

Roofing, Paneling, industrial

sheeting, air condition

ducting and structural

ElectrolyticTin Plates

Container for packaging ofvarious products including

edible oils and confectionary

items


49/74

Product Application

Silicon Steel

Sheets andCoils

Small generators, starters

for high efficiency rotatingequipment and relays etc.

SW Pipes High pressure transportation

of crude oil, natural gas andslurry.

ERW Pipes High pressure transportation

for oil, water, sewage

disposal, and tube wells etc.


50/74


51/74

Sl.

No.

FACILITIES

1 AUGMENTATION AND MODIFICATION IN OBBP

2 NEW 7Mtr Tall BATTERY # 6 (1 X 67 OVENS)

3 NEW SINTER PLANTIII (1 X 360 M2)

4 NEW BLAST FURNACE # 5 (4060 M3)5 OXYGEN PLANT

6 SMS-II - 3RDBASIC OXYGEN FURNACE(150 T),

RH-OB, 3RDLADLE HEATING FURNACE & CASTER

7 NEW LIME & DOLOMITE PLANT ( 2 X 350 TPD)

8 NEW 4.3 M WIDE PLATE MILL

9 AUXILIARY PACKAGES, UTILITIES, LOGISTICS FOR

WHOLE PLANT


52/74


53/74

53

Chairman SAIL inaugurates modernenvironment friendly Coke Ovens

Battery complex on 1st June 2013.


54/74

54

Coke Pushing on 12/4/2013

Coal charging on 10/4/2013


55/74

ASU-III of TOP-II

New OBBPHot Blast Stove of new BF-5


56/74

56

Sinter Plant (SP-III)


57/74

57

OBBP- Raw Material

Handling Section (RMHS)


58/74

Blast Furnace (BF-V)

Blow in of BF#5,


59/74

DURGA on 5th

August 2013


60/74

Blast Furnace-5 Complex


61/74

61

Hot trial of the new Slab Caster in SMS-II was tested successfully on 14th

June.

During the hot trial 8 slabs were cast using a full ladle of steel,

with all the systems running perfectly.


62/74

Inauguration

of 3rdSlab

Caster atSMS-IIby

Chairman

SAIL on10th

August, 2013


63/74

63

New Plate Mill


64/74


65/74

HAVE A NICE TIME

IN


66/74

ROURKELA


67/74

Length of Ring Road 23 KMs

RSP Works Area37.83 Sq. KMs.

Area of Steel City 47.38 Sq. KMs.

ROURKELA

TOWNSHIP & MEDICAL FACILITIES


68/74

25,000 quarters of 14 categories spread over 18

sectors.

16 market areas in different sectors comprising

about 1,800 shops and 1,000 hawkerssheds

Utkalmani Gopabandhu Ispat Library, A/cAuditorium called Civic Centre, Bhanja Bhawan,

several Social Homes and Community Centres.

Social Welfare Unit which organises celebration of

National Festivals and other Socio-Cultural

activities.




69/74

12 Schools run by RSP and many private schools

with different facilities extended by RSP.2 Outdoor Stadiums - Ispat Stadium, Biju Patnaik

Hockey Stadium with Synthetic Turf and one Ispat

Indoor Stadium.

Indo German Club and Rourkela Club

Indira Gandhi Park with Musical Fountain and

Jubilee Park

A 685 beded Ispat General Hospital with state of artdiagnostic facilities and equipment

Four Health Centres located in different sectors.

Contd.TOWNSHIP & MEDICAL FACILITIES


70/74

We the employees of RSP willprovide defects free products

and services to our internal &external customers on time,

every time through continual

improvement of our processes

and systems.

Separate units engaged in Research &


71/74

p g gDevelopment, Engineering & Technology,Consultancy, Environment Management, Coal

Supply, Logistics & Management Training. 04 operating collieries at Chasnalla, Jitpur,

Ramnagar and Tasra located in the states of

Jharkhand and West Bengal. 01 Captive Washery at Chasnalla whcih supplies

washed coking coal to all SAIL units.

37 Brach Sales Offices

10 Customer Contact Offices

67 Warehouses

2837 Dealers spread across the nation.

Major Mines of SAIL are :


72/74

Kiriburu Iron Ore Mines(KIOM) in Jharkhand

Meghahatuburu Iron Ore Mines(MIOM) inJharkhand

Bolani Iron Ore Mines(BOM) in Odisha

Barsuan Iron Ore Mines(BIM) in Odisha Kalta Iron Ore Mines(KIM) in Odisha

Manoharpur(Chiria) Iron Ore Mines(MOM) inJharkhand

Gua Iron Ore Mines(GOM) in Jharkhand

Dalli-Rajhara Iron Ore Mines in Chhatisgarh

j

Major Mines of SAIL are :


73/74

Nandini Limestone Mines in Chhatisgarh

Kuteshwar Limestone Mines in Madhya Pradesh

Bhawanathpur & Tulsidamar(Dolomite) Mines inJharkhand

Hirri Dolomite Mines in Chhattisgarh

j


74/74

CAPACITY FROM TO

Hot Metal 2.0 MT 4.5 MT

Crude Steel 1.9 MT 4.2 MT

Saleable Steel 1.671 MT 3.9 MT

EXP NSION PL N

VT Presentation 2016

Documents

Transcript of VT Presentation 2016