INPLANT TRAINING REPORT

- M.DHINESH
B.E(MECH) GCT COVAI-13.

ACKNOWLEDGEMENT

Thanks to the management of JSW steel works private limited for having taken personal interest during my in-plant training . I express my gratitude to Mr.S.BALAKUMAR(ASSISTANT MANAGER HR),Mr.S.VIJAYARAJ (MANAGER SINTER PLANT),Mr.R.KANNADASAN(SENIOR MANAGER COKEOVEN PLANT) for having facilitated the training process and for making this training a purposefulone.

INTRODUCTION:
I have undergone inplant training in your plant and visited sinter plant -2 and coke oven for the past few days .Here I have furnished the report of what I have learnt .

COMPANY PROFILE:
JSW steel works is the only integrated steel plant in the state of Tamil Nadu. The Company has facilities for production of Pig Iron, Steel, Billet and Rolled Steel products in the long product category. It has adopted the Sinter plant Blast furnace(BF 1 &BF 2) Energy Optimising Furnace(EOF 1&2) Ladle Furnace, Vacuum Degassing Continuous Casting Machine(CCM 1&2) bar rolling mill(BRM) and rod mill route with iron ore as the basic input material. It also has plants for generation of power and production of Coke and Oxygen. The expected annual CO2 reduction is around 291368 tones.

SINTER PLANT
The main raw materials used in this plant are limestone,iron ore fines,dolomite.First the raw materials are crushed using hammer mills,two and four roll crushers then to screening house and proportional house.The movement of materials is carried out mainly through conveyors made of fabric.The capacity of sinter plant 2 is 90 metre cube and sinter plant 1 is 18 metre cube.The former plant is designed by Chinese where as the later one is by Germans. The function of the Sinter Plant is to supply the blast furnaces with sinter, a combination of blended ores, fluxes and coke which is partially cooked or sintered and thereby to increase the productivity. In this form, the materials combine efficiently in the blast furnace and allow for more consistent and controllable iron manufacture. Figure 1 shows a simplified diagram of a sinter plant.Materials enter the sinter plant from storage bins. They are mixed in the correct proportions using weigh hoppers, one per storage bin, except for the return fines for which an impact meter is used instead. Weighing is continuous, as is the whole
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sintering process. The weighed materials pass along a conveyor to the mixing drum where water is added either manually or as a calculated percentage of the weight of material entering the drum. The mix material is fed onto the strand from the hopper by a roll feeder. The bed depth is set and kept constant by adjusting the cut-off plate which is fitted with probes to sense the depth of material and automatically vary the roll feeder speed. The quantity of material in the feed hopper itself is held constant by automatic adjustment of the feed rates from the individual raw material bins.

Figure 1 Simplified diagram of a sinter plant

SINTERING:
The raw mix is ignited by the ignition hood, which is fuelled by a mixture of coke oven gas, blast furnace gas and sometimes natural gas. The calorific value of the mixture and the set hood temperature are controlled. A separate control system is provided to maintain a fixed hood pressure by adjusting the windbox dampers immediately under the ignition hood.An important part of the sintering process is burn-through.. Burn through should be achieved but must not occur too soon after the ignition hood. The draught on the strand is maintained at a preset value by controlling the main fan louvers from pressure measurements in the wind main. This governs the point at which burn through occurs.

SINTER HANDLING:

After the end of the strand, the sinter passes through a spiked roll crusher and the hot screens to the rotating circular cooler. A number of fans are usually used for cooling, and the speed of the cooler is determined by:The fines removed by the hot screens are conveyed to the return fines bin.After cooling, the sinter is passed into the discharge bunker. At this stage, the level is controlled by varying the outlet feed rate .The sinter then passes to the cold screening area, where it is passed through crushers and screens to produce particles in a specific size range. Sinter below the required size passes over a belt weigher and returns with the hot fines to the return fines bin.The difference between the weight of the cold fines, and the weight of the total fines produced, gives a measure of the hot fines. Any abnormal variation in the rate of production of hot or cold return fines indicates a possible plant fault.Two important properties of sinter are basicity, which is controlled by the amount of limestone, and strength, which is controlled by coke content.

PRIMARY AND SECONDARY MIXING HOUSE:

The amount of primary water added is proportional to the weight of raw mix entering the mixing drumThe secondary water feed setpoint is frequently taken as a proportion of the raw mix belt weigher PV. For greater accuracy, the moisture meter reading is used to trim the material/water ratio. This corrects the water flow rate according to the measured moisture content of the raw mix.Cascade control is not always used but since the water flow loop responds faster than the moisture loop it does produce better results. On the other hand, with variable ratio air lead temperature control, the air flow is fixed and the hood temperature controller output (the heat demand signal) feeds the ratio setpoint trim input of the gas controller. This method is normally used when there is a readily available source of cheap fuel e.g. blast furnace gas.

COOLER:
After leaving the strand, the hot sinter is cooled on a rotary cooler.The speed of the rotary cooler is controlled to
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match the strand demand defined by the bed depth and the strand speed.

COKE OVEN PLANT

The main purpose of coke oven plant is to convert coal to coke and use the produced coke in the blast furnacenow let us see the processes that take place in the coke oven plant.

Schematic Diagram of Coke Oven Battery

Coal contains about 60 to 65% carbon content.Here in this plant it is increased by 20 to 25% ie it is converted into coke.Here in this plant we use four types of coal viz:hot coking coal,semi soft coal,semi hot coal,non coking coal. From the yard the coal is manually charged through the ground hopper and it is taken to the blending bin through M30 conveyor.In the blending bin the required ratio of
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different types of coal are blended and they are sent to each bin through shuttle conveyor.From the blending mill it is passed to the hammer mill through M70 conveyor.Here the hammer mill is operated in reverse and forward direction and the coal is crushed to-3mm.From the hammer mill it is sent to coal tower 1 through M130 and M140 conveyor after passing through magnetic separator.In the coal tower the coal is stamped for 20 min to increase its density and then it is taken to the coke oven through pushing car.Coal tower 2 is also used for this purpose. In the coke oven it is heated at 750 to 1000degree Celsius for 65 hours durijg which the coal is converted into coke.It is known as carburizing time.The oven is here heated through negative heating.Then it is taken to the quenching house through quenching car.In quenching house the coke is handled through machine driven hydraulically.From the quenching house the coke is taken to blast furnace after screening through single deck and doudle deck screen house.

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During carbonisation, coking coals undergo transformation into plastic state at around 350o-400o C swell and then resolidify at around 500o-550o C to give semi-coke and then coke. In coke ovens, after coal is charged inside the oven, plastic layers are formed adjacent to the heating walls, and with the progress of time, the plastic layers move towards the centre of ovenfrom either side and ultimately meet each other at the centre. During cokemaking, two opposite reactions take place, viz. condensation and pyrolysis. The quality and quantity of plastic layer is of extreme importance and it determines the inherent strength of coke matrix. For producing coke of good quality, coals should have certain degree of maturity (rank 1.1-1.3), good rheological properties (about 200-1000 ddpm by Gieseler Plastometer), wide range of fluidity and low inerts.The various modification in the coke making which have improved coke yield and reduced sp. Energy consumption are :

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STAMPING OF COAL:
The technology basically involves formation of a stable coal cake with finely crushed coal (88-90% - 3mm) by mechanically stamping outside the oven and pushing the cake thus formed inside the oven for carbonisation. Coal moisture is maintained at 8-10% for the formation of cake. Due to stamping, bulk density of charge increases by 3035% causing significant improvement in micum indices and CSR values of coke. Oven productivity increases by 1012% & there is a possibility of using inferior coking coals to the extent of about 20%.

QUENCHING:
Dry quenching of coke is a major technology for the post-carbonisation treatment which has come up in a big way. Here the red-hot coke is cooled by inert gases, instead of conventional water quenching. It not only effectively utilises the thermal energy of red-hot coke (80% of the sensible heat of coke can be recovered & made use of for production of steam) but also results in improvement of the coke quality (M10 index can be improved by 1 point).
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In

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