The document provides an overview of the Bokaro Steel Plant located in Jharkhand, India. It details the plant's background, founding, collaboration with the Soviet Union, facilities, production processes and capacities. Key points include: - The plant was established in 1964 and merged with Steel Authority of India Limited (SAIL) in 1978. - It has a total area of 33,045 acres and produces flat steel products like coils and sheets. - Major facilities and production units include 5 blast furnaces, coke ovens, sinter plant, slabbing mill, hot strip mill and cold rolling mills. - Current liquid steel production capacity is 4.5 million tons per year with

1. Overview of
Bokaro Steel
Plant
SUMAN SOURABH
06570104910
B.TECH(EEE)
FINAL YEAR

2. BACKGROUND
•Fourth Integrated Steel Plant in Public Sector,well known as
Swadeshi Plant, maximum indigenisation in equipment,materials &
know-how
•Originally incorporated as a Limited Company on 29.01.64
•Collaboration agreement with Soviet Union (USSR) on 25 th Jan, 1965
( SAIL Foundation Day)
•After formation of SAIL on 24th January 1973, merged with SAIL on
01.05.78
•Collaboration with the then USSR
•Total area 33,045.35 acres
•Flat Product : HR Coil, HR Sheet, CR Coil, CR Sheet, TMBP, GP&GC

3. • Capacity
–
–
–
–
F P
irst hase : 1.7 M of ingot steel
T
Second P
hase : 4.0 M of ingot steel
T
After modernization : 4.5 M of liquid steel
T
E
nough scope for further expansion (P for 7 M )
lan
T
• M
ilestones
–
–
–
–
–
–
Start of construction : 06.04.68
Start of hot metal production : 02.10.72
Completion of 1.7 M stage : 26.02.78
T
Completion of 4 M stage in phases
T
Start of last modernization : 23.07.93 (completed in 1997)
Next modernization for 7 M : E
T valuation P
rocess started

4. Basic Information
•
Location
•
Latitude
: Southern bank of ; approx. 50 kms from Dhanbad and 140 kms
each from and
: 230 39'
•
Longitude
: 860 09'
•
Altitude
: 210 metres (average) varying from 195 to 224 metres
•
Climate
: Extreme
•
Annual Rainfall
: Average 157 cms; Maximum 195 cms
•
Temperature
: Maximum 48½0 Celsius
: Min. 2½0 Celsius
•
Wind direction
: South-West to North-East
•
Type of Soil
: Loamy up to 1 to 2 metres, sandy soil below that
•
Total land area
: 33,045.35 acres
•
•
Plant, Slag-dump, Cooling
: 17,208.01 acres
Ponds, Ancillaries,
Marshalling Yard
Township(including Airstrip) : 10,114.53 acres
Garga Reservoir
: 3,886.87 acres
•
Railways
•
: 1,835.94 acres

5. UTILITIES & SERVICES
WATER SUPPLY
-
GARGA DAM & TENUGHAT DAM
DVC CHANDRAPURA
-
200MVA (Contract)
Bokaro Power Supply Co. Ltd.
-
1 x 12 MW (back pressure)
POWER SUPPLY
2 x 55 MW
3 x 60 MW
Total Road length
392 Kms.

6. PROCESS FLOW
Fluxes
COKE OVEN BATTERIES
Coking Coal
SAIL
Bokaro
Iron Ore, Lime Stone
& Dolomite Fines
BF Coke
Iron Ore
Coke Breeze
BF1
Sintering Plant
130T
Con-1
Pig Casting Machine
BF2
BF3
BF4
BF5
OHP
Blast Furnace
130 T
Con-2
130 T
Con-3
130 T
Con-4
130 T
Con-5
Steel Melting Shop - 1
300 T
Con-1
Continuous
Casting
Department
300 T
Con-2
Steel Melting Shop - 2
HR Coil
Soaking Pit
Reheating
Furnace
Hot Strip Mill
ll
Slabbing Mill
PL-II
Tandem Mill-2
PL-I
Tandem Mill-1
A
N
N
E
A
L
I
N
G
HRCF
DCR Mill
HR PLATE /
SHEET
Galvanized Sheet Corrugation Line
Hot Dip Galvanizing Line
SPM 1 & 2
CRCF
CR Coil
CR Sheet
Galvanized Sheet Shearing Line
GP Coil
Galvanized Corrugated
& Plain Sheet

7. Commissioning dates and Capacity of Major Units
Unit
Date of
Commissioning
Agreement with UUSR
Number
Capacity
(MT)
Product
25 Jan, 1965
Coke Ovens
Sep'72 – Dec'85
8 Batteries of 69 Ovens
3.48
BF Coke
Sinter Plant
Sep'72 – Dec'82
3 Machines of 252 m2 area
6.20
Skip sinter
Blast Furnaces
Oct'72 - Jun'85
5 furnaces of 2000 m3 volume
4.585
Hot Metal
Steel Melting Shop I
Jan'74 – Dec'78
5 LD converters of 130 T
2.20
Ingot Steel
Steel Melting Shop II
Jun'83 - Jan'85
2 LD Converters of 300 T
2.25
Liquid Steel
Continuous Casting
Sep'97 - Mar'98
2 Double Strand casting m/c
2.16
Cast Slab

8. Commissioning dates and Capacity of Major Units
Unit
Date of
Commissioning
Number
Capacity
(MT)
Product
Slabbing Mill
Dec'74
8X4 Soaking pits of 160 T & one
1250 mm universal Slabbing Mill
1.90
Rolled slab
Hot Strip Mill
Dec'75
4 reheating Furnaces, 5
roughing & 7 finishing stands
3.36
HR Coil
Hot Rolled Coil
Finishing
Jan'76
2 Shearing line
1.1
HR Plate/Sheet
Cold Rolling Mill 1
Jun'77
Pickling Lines, Tandem Mills
Cold Rolling Mill 2
Sep'91
Annealing Lines, Skin Pass
Mills-2, Temper/DCR Mill-1,
Shearing lines-5, Slitting lines-3
& Hot Dip Galvanising Complex
-1
Saleable CR
1.66
Product CR
coils/Slit coil/
sheet, slit coil,
Black Plate,
GP&GC

9. Raw Materials coming from Mines

10. Wagon Tippler – Tippling a wagon

11. ORE HANDLING PLANT(RMHP)
Basic functions:
 Receive different raw materials from various mines through
wagons and their unloading & stacking with the help of
tipplers & stackers
 Blend raw material by making layers in beds & cross sectionwise cutting beds by re-claimer
 Keep buffer stock to take care of irregularities and supply raw
materials to different Units as per their requirements
Basic facilities:
 4 Rotary W
agon Tipplers - 20 Wagons/Hr each
 7 Twin boom Stackers - 1200 T/Hr each
 5 Barrel Type Reclaimers - 1000 T/Hr each
 1 Bucket Wheel Type Reclaimer - 500 T/Hr
 2 Transfer Cars, 10 Shuttle Conveyors, 11 Cranes, 8 Telphers

12. Sources of R Material
aw
Material
No. of Beds
(240 M)
Stock
No of Days
Source
Iron Ore Lump
4
24
Kiriburu, Meghataburu, Bolani, Barsua
Iron Ore Fines
6
16
Kiriburu, Meghataburu, Bolani, Gua
Lime Stone
BF Grade
4
13
Bhawanathpur, Khanabanjari, Purnapani
Lime Stone
SMS Grade
2½
21
Kuteshwar, Jaisalmer, Nanwara
Dolomite Lump
16
Bhawanathpur Birmitrapur, Tulsidamar,
Sonakhand
Dolomite Chips
50
Bhutan, Salwari

13. Sources of R Material
aw
Material
Manganese Ore
No. of
Beds
(240 M)
Stock
No of Days
½
Barbil, Banspani
Imported Coal
Prime Coking Coal
Medium Coking Coal
Coal Middlings for
Power Plant 38 M
high, 12mm dia
Source
Autralia, NewZealand , Haldia, Paradeep,
Vizag
46
Dugda, Munidih, Jamadoba, Belatand
Silos
2500T
Kathara, Kedla, Rajrappa, Mahuda, Swang
7
Kathara, Rajrappa, Kedla, Swang, Giddi,
West Bokaro, Kargali, Mahuda, Dugda,
Katrasgarh etc.

14. Coke Oven Battery

15. Quenching of Coke

16. Coke Ovens
•
•
•
•
•
8B
atteries of 5 met er height , 69 Ovens each
The pr ocess of coke making consist s of dest r uct ive dist illat ion of coal in
absence of air . The phenomenon is called high t emper at ur e (above 1200 0c
-1300 0c carbonisation of coal
Volat ile mat t er s ar e dr iven out leaving behind t he r esidue called COK
E
B P
y- roduct P
lant:
- Gas Condensat e Sect ion
-
Ammonium Sulphat e Plant
Benzol Recover y Plant
Tar Dist illat ion Plant
Sulphur ic Acid Plant
Desired Analysis vs Indian Coals:
Desired Analysis
Indian Coals
Imported Coals
Ash%
< 16
19-24
3-12 (Av 9)
Volatile Matters
%
> 25
24-26
19-28 (Av 23)
Moisture%
7-9
7-8
8-11 (Av 9)
Sulphur%
< 0.05
0.56
< 0.05
Phosphorus%
< 0.05
0.09
< 0.05

17. Material Flow Diagram : Coal & Coke
Coking Coal
From
Various Source
Wagons
Coke Sorting Plant
Blast Furnace
Coke
+ 25 -80 mm
Blast Furnace
Coal Handling Plant
Coke
Nut
Coke
Coke
Breeze
-15 mm
Sold
Sinter Plant
Battery
( 8 Nos.)
Coke Oven
Gas
By Product
Plant

18. By-Product Plant
It consists of :
• Gas Condensate Section
• Ammonium Sulphate Plant
• Benzol Recovery Plant
• Tar Distillation Plant
• Sulphuric Acid Plant
Products produced from by product plant.
•
•
•
•
•
•
•
•
•
•
•
N G Benzol
N G Toluene
Xylene
L S Naptha
S B Oil
PCM
Road Tar
Coal tar wash oil
Extra hard pitch
Hard medium pitch
Hot Pressed naphthalene
All by products of By Product Plant are sold through e- auction.

19. Tech-economic factors
CO Gas yield
:
325.0 Nm3 / TDC
:
505.0 Kg / THM
Sp. Heat Consumption
:
0.583 Gcal / TDC
Sp. Power consumption
:
29.50 KWh /Ton of BF Coke
Ammonium Sulphate yield
:
10.50 Kg/ TDC
Crude Tar yield
:
30.80 Kg/ TDC
Coke Rate
---

20. A view of Sinter belt

21. Sintering Plant
• 3 Sinter Machines: Capacity 6.25 million tonnes per annum
• Sintering is the process where incipient fusion takes place by
combustion of Coke within moving bed of loosely packed fines of
mainly Iron ore, Coke & Flux so as to agglomerate into a compact
porous mass called Sinter
• 75-80% Sinter is being used in the burden of BF
• Area of each Siter belt is 252 sq.m.
• Productivity of Sintering Band : 1.2 T/M2/hr
• Three Sections
a) Raw Material Section
b) Stock Bin & Proportioning Section
c) Sinter Machine Section

22. Hot Rolling Mill
Refractory Mat Plant
Mill
Scale
Lime Dust
Coarse
Waste Bins
Section
Ore Handling Plant
Iron OreFines, LimeStone,Dolomite,
Lime Dust
Sand
Raw Mat Section
Fine
LimeStone Fine ,Coke Fine, Dolomite
Fine
Mill Scale, Flue
Dust, Lime Dust
Coarse
Coke Breeze
Slime
Thickening
Section
Lime Sludge
Stock Bins
Mixed Raw Charge
Material Flow
Diagram
Sintering Plant
Palletizing/Balling Drums
Cleaned Water
Raw Charge
(Moist & Balle)
Sinter Machine Building
Sinter
Hot Sinter
Return
Blast Furnace Deptt
Flue dust to waste
bin
Coke Ovens
Return Sinter to Stock
Bin
Cold Sinter
Return
Raw material sinter
Screened coke return to raw
material section

23. Technical Specifications of some critical equipments
Sl.no Name
01 Hammer crushers
02
03
04
05
06
07
08
Coke crusher
Flux Screen
Sinter Machine
Sinter area
Pallets
Vacuum chambers
Exhausters
Quantity
05
Capacity
250 ton/hour
08
10
03
252 square metre
130 in each m/c
26 in each m/c
6nos(2nos/m/c)
Installation Area
Raw material
16 ton/hour
150 ton/hour
300-450 ton/hour
Raw material
Raw material
M/c building
M/c building
M/c building
M/c building
M/c building
12000 m3/minute
 Technical Specifications of some critical equipments
Sl.no Parameters
Norms
Actual in 2007-08
01
Specific fines consumption
1093kg/t of hot metal
1025kg/THM
02
Specific flux consumption
255 kg/THM
244kg/THM
03
Specific Coke consumption
85 kg/THM
86kg/THM
04
Specific Power consumption
45KWH/Tgross sinter
48.33KWH/TGS
05
Specific Heat consumption
0.024Gcal/TGS
0.025Gcal/TGS

24. A view of Blast Furnace

25. A Closer view of Blast Furnace

26. Blast Furnace
• The iron oxide of ore and sinter is reduced to iron with the help of
carbon monoxide & Coke
• Functions of coke in BF are manifold. It provides strong porous
bed to burden and supplies the heat load. Part of the heat load is
supplied by the hot air blast
• 5 Furnaces each of 2000 cubic meter useful volume and 2640T/day
HM capacity
• All furnaces have Bell-less Top charging System for continuous
charging & better distribution of charge
• Coal Dust Injection in Fce.# 4 & 5
• CHSGP in Fce. # 4 & 5
• Capacity of B F 4.585 MT of Hot Metal per annum
• Hot Metal Temperature 1460-14800C
• BF Productivity: 1.4 T/m3/Day
• Coke Rate 520 Kg/THM

27. MATERIAL FLOW DIAGRAM FOR BLAST FURNACE
Iron Ore
Lime Stone
Mn Ore
Sintering
Plant
Flue Dust
Dust catcher
In BF
Quartzite
Raw BF gas
Sinter
Coke
Partially
Cleaned BF
Gas Gas Cleaning
Blast Furnace
Plant
Process
Steam
Cleaned
BF Gas
Hot air
For
Distribution
For
Sale
Charging
Section
of
Blast
Furnace
Cold Pig Pig Casting
M/C
Mixer of
SMS
IMF
Hot Metal
Iron Ore
(Lump)
RM
Lime Stone,
Mn Ore,
Quartzite
Sinter
& MHP
SP
Coke Coke Ovens
Process
Steam
Net work
Stove of
BF
Cold
air TBS
Slag
Slag Dump
Yard
BFCHSG
/SGP
Slag Granules
for Sale

28. Hot Metal being charged into the converter

29. BF
HOT METAL
SSD
SCRAP
RMP
LIME
BMS
IRON Ore, BAUXITE, Mn Ore, Lime Stone
FAS
O2 Plant
Fe-Mn, Fe-Si
99.5 % pure O2

30. Steel Melting Shop
•
SMS-I: 5 Converters each of 100/130T capacity, 2 Mixers each of 1300 T
capacity (Rated Capacity 2.5 MT/Yr)
•
SMS-II: 2 Converters each of 300 T capacity, 2 Mixers each of 2500 T
capacity (Rated Capacity 2.25 MT/Yr)
•
Total capacity 4.5 MT of liquid steel
•
Oxygen of high purity(99.9 %) is blown into the converter from the top
through water cooled lance so as to remove the impurity of hot metal
through oxidation
•
Impurities of Si, C & P are oxidised and Forms slag with lime
•
Killed, Semi-killed and Rimming steels are made
•
SMS-II has got suppresed consumption system
•
Lining life :
SMS-I = 800 – 1000 heats
SMS-II = 2000 – 2500 heats

31. Concast Slab coming out of Caster

32. Continuous Casting Shop
•
•
•
•
•
•
•
•
•
Two Twin strand curvilinear casters with capacity to produce 2.16 MT
of Slabs
Steel Refining Unit (SRU) with LF/LRS for treatment of steel before
casting
On-line slab cutting
Steel Killed with Al/Si to O2<5ppm + Argon purging sulphur reduced
<0.015%
Slab size : Thickness
200, 225 & 250 mm
Width
950-1850 mm
Length
9-10.5 mtr.
MgO lined Tundish of 50 T capacity
Tundish Capacity = 50 T
Slide Gate System
Slab Produced
Mild Steel : DD, EDD, Bioler Plate etc.
Low Alloy Steel : LPG, WTCR, SAILCOR & API grades

33. Slabbing Mill
12 groups of Soaking pits with each group having 4 pits ; total
48 pits wherein ingot are heated to a temperature above 13000C
• On line hot & cold scarfing M/c for surface scale/defect removal
• One 1250 mm Roll dia 2-high Reversible Universal Mill to
produce slabs of thickness 150-300 mm, width 950-1850 mm
and length 2.5 – 10.5 mtr.
• 2800 Ton Hydraulic Shear (6 cuts/min)
• 4MT Capacity (Rolling Rate 600-800T/Hr)
• Main Sections
a) Ingot Storage Yard
b) Soaking Pit
C) Mill Proper
d) Slab Storage Yard
•

34. Reheating Furnace of HSM

35. Strip Coming out of Finishing stands

36. Hot Strip Mill
• Hot Rolling involves plastic deformation of a metal under
squeezing force (a pair of Rolls) above its re-crystallization
temperature.
• This mill is designed to roll thin & wide strips for use in
various industries such as wagon building, tube & pipe
industry, drum & furniture manufacturing and further
rolling in Cold Rolling Mill
• 3 Walking Beam Reheating Furnaces & 1 Pusher type
furnace
• Vertical Scale Breaker
• 5 Roughing Stands, 7 Finishing Stands
• Hydraulic AGC in last four Strands

37. • 4 Hydraulic Coilers with automatic strapping & Robot
marking
• Capacity: 3.955 MT of HR Coils
• Coil Dimensions
– Strip thickness
1.6 to 16.0 mm
– Strip Width
910 to 1,850 mm
– Coil inside dia
650 mm
– Max Coil outside dia 2,300 mm
– Max coil weight
32 T
• Rolling Speed:
20 m/sec Max.

38. Material Flow Diagram of HSM
Slab
yard
Furn
aces
Roughing Stands
Coilers
Finishing Stands
F6
R5
F7
C
R4
F8
C
R3
F9
C
R2
F10
C
R1
F. Shear
F11
VSB
F12
Furn
aces

39. Hot Roll Coil Finishing (HRCF)
•Functions : To shear the coils into plates and
sheets
•Facilities :
•Shearing Line I : 5-10x1800 mm, 2.5-12 mtr.
plates capacity 6,45,000 T/year
•Shearing Line II : 1.6-4x1500 mm, 1.5-4.5 mtr
length sheets capacity 4,75,000 T/year
•Slitting Line : 1.5x8x1800 mm, 150mm Min.
width capacity 4,00,000 T/year
•Maximum Pkt. Wt.: 15 T

40. 5-Stand Tandem Mill

41. Zinc coating on Cold Rolled Coil - HDGL

42. Cold Rolling Mills
•
•
•
•
•
•
Cold rolling is done to produce thinner gauge strip of smooth finish
with better mechanical properties than those obtained by Hot Rolling
Uses : Automobile Bodies, Steel Furniture, Drum & Barrels, bending
and shaping applications.
Capacity: 1.66 MT of CR saleable
CRM I: H2So4 Pickling Line, 4-Stand Tandem Mill (2-4.5mm thick into
0.63-2mm thick) Annealing Furnaces, SPM-I & SPM-II, Shearing Line I
& II, Slitting Line and Shipping-I
CRM II: HCl Pickling Line, 5-stand Tandem Mill (1.4-2mm thick into
0.63-1.6mm thick) , ECL, CAL, DCR Mill, HDGL and Shipping-II
Besides Continuous Annealing furnace103 Annealing Furnaces and
230 Bases are available in three areas. Annealing is done at 680-720 0C
in inert atmosphere (95% N2+5%H2) with the help of mixed Gas of
1550-1600 CV

43. GC Sheets

44. Ancillary Development
• Bokaro Industrial Area Development Authority
(BIADA)
– 253 SSI Units registered with BSL
– 81 accepted as Ancillary Units
• Various Concessions/Exemptions in
– Tender cost, earnest money, security deposit etc.
– Price matching and purchase preference
– BSL Laboratories offers testing facilities, help in
developing new designs and products and awareness
on ISO 9000 System

45. • Last Moder nizat ion
– Con- cast f acilities integrated with SMS- II
• Ladle Fur nace & Ladle Rinsing St at ion f or Secondar y Ref ining
• Two Double St r and Slab Cast er
– Up- gradation of Hot Strip Mill including
• Change of Pusher Type Reheat ing Fur naces t o Walking Beam Type
• Quick Wor k Roll Change Syst em
• Addit ion of f our t h Coiler
• Next Phase Moder nizat ion (by 2010-11)
– New SMS- III with 3. 8 MT Capacity
• 3 x 160T Conver t er s wit h 3 x 160T Ladle Fur naces & Degassing
f acilit ies
• 2 Single St r and Thin Slab Cast er s (1.2 MT each) & 1 convent ional
Slab Cast er (1.4 MT)
• 7- St and Compact St r ip Mill & new Coil Yar d
– New CR III with 1. 2 MT Capacity
M-
• Coupled Pickling and Tandem Mill
• ECL, Bell Annealing Fur nace (100%
Galvanizing Line wit h Galvanneal f acilit ies
Hydr ogen
Annealing)

46. • Up gradation of 3 BF to 4900T/day capacity by enhancing
volume from 2000 to 2365 M3 and installing CDI & CHSGin
all BFs (presently 4&5 only)
• Sintering Area 252 m2 to 312m2 and productivity
1.2T/m2/hr
• Rebuilding of 3 CO batteries, computerised combination
control system etc.
• Conversion of H2S04 PL-I to HCL Pickling Line
• Enhancing capacity of SMS – II from 2.16 to 3.12 MT by
schemes
• Addition of O2 generating capacities

47. Result of Expansion
Sl. No.
Description
Capacity
1.
Hot Metal (MT)
7.44
2.
Crude Steel (MT)
7.00
3.
Saleable Steel (MT)
6.53
4.
Yield of Saleable Steel from Liquid Steel (%)
91.4
5.
Specific Energy consumption (Gkcal)
5.5
6.
Coke rate Kg/THM
395

48. THANK YOU