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Dam Shutter

The document summarizes an industrial visit to the Thermal Department of Chaliyama Steel Plant. It describes the key steps in steel production including mining raw materials, reducing iron in a blast furnace, processing in a basic oxygen furnace. It discusses the role of control systems and instrumentation to monitor temperature, pressure, gas composition. Waste management techniques are also summarized.

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2000520320051
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46 views

Dam Shutter

The document summarizes an industrial visit to the Thermal Department of Chaliyama Steel Plant. It describes the key steps in steel production including mining raw materials, reducing iron in a blast furnace, processing in a basic oxygen furnace. It discusses the role of control systems and instrumentation to monitor temperature, pressure, gas composition. Waste management techniques are also summarized.

Uploaded by

2000520320051
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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You are on page 1/ 15

INDUSTRIAL VISIT IN THERMAL

DEPARTMENT OF CHALIYAMA STEEL PLANT

Department of Electronics And Instrumentation


Institute Of Engineering And Technology Lucknow

SUBMITTED BY:
SAUMYA RAI

( 2000520320051)
OVERVIEW
 Introduction

 Steps involved in production

 Role of control and


Instrumentation involved

 Waste management of the


Industry

 Benefits of the internship

 Refrences
INTRODUCTION
 CHALIYAMA STEEL PLANT IS A PROJECT OF RUNGTA
MINES LIMITED . LOCATED IN THE BANKASI VILLAGE OF JHARKHAND , IT IS ALSO
CONSIDERED TO BE IN THE RICH MINERAL BELT OF ODISHA .

 THE TOTAL PLANT AREA IS 592.16 ACRES .

 MAINLY THE RAW MATERIALS FOR THE PLANT ARE IRON ORE , OXIDE , DOLOMITE .

 T HE ORE IS REDUCED IN TWO WAYS :


1. DRI – CAPACITY 0.62 MTPA
2. BLAST FURNACE – CAPACITY 0.48 MTPA .

 SOURCE OF WATER IS THE KHARKASI RIVER .

 TOTAL POWER GENERATED IS 158 MW.


STEPS INVOLVED IN PRODUCTION OF
STEEL
STEP 1. : MINING OF RAW MATERIALS

 MINING IS THE PROCESS WHERE THE ORE IS DIGGED FROM THE


EARTH.
 THE ORE CONSIST OF IMPURITY AND THE RAW MATERIALS .

 TO REMOVE THE IMPURITIES THE ORE IS CRUSHED INTO SMALL


PIECES AND THEN MIXED WITH THE SOIL .

 THEN WITH THE HELP OF MAGNETIC SEPERATION FROM


PALLETISATION AND THE CONVEYOR BELTS THE IMPURITY AND
THE RAW MATERIALS ARE SEPERATED.
STEP 2 : REDUCTION OF IRON FROM
BLAST FURNACE
 BLAST FURNACE IS A LARGE VERTICAL AND CYLINDRICAL FURNACE
USED FOR SMELTING OF IRON TO PRODUCE MOLTEN IRON , WHICH
CAN THEN BE PROCESSED TO PRODUCE STEEL .

 THE IRON ORE ,COKE AND LIMESTONE IS PUT INTO THE FURNACE
ALONG WITH SOME HOT AIR IS PASSED TO INCREASE THE
TEMPERATURE OF THE FURNACE .

 THE LOWERMOST PORTION OF THE FURNACE CONTAINS THE


MOLTEN IRON CALLED THE HEARTH.

 THE MIDDLE MOST PORTION IS MADE WIDER SO THAT THE


REDUCTION CAN TAKE PLACE AND IT IS THE HOTTEST OF ALL THE
REIGIONS .

 THE UPPERMOST PORTION WHERE THE GASES LEAVE THE FURNACE .


STEP 3 BASIC OXYGEN FURNACE
 THE MOLTEN IRON FROM THE BLAST FURNACE CONTAINS THE
IMPURITIES SO THIS IRON IS CALLED AS PIG IRON .

 THE PIG IRON IS THEN PASSED THROUGH THE BASIC OXYGEN


FURNACE SO THAT WHICH CONSIST OF PURE OXYGEN AND IT
REACTS WITH THE IMPURITIES TO FORM THEIR OXIDE WHICH
IS FURTHER COLLECTED IN THE COLLECTOR .

 THE IRON IS COOLED AND THEN CONVERTED IN STEEL .


ROLE OF CONTROL AND INSTRUMENTATION
IN THERMAL DEPARTMENT
 1. BLAST FURNACE : THE THERMAL DEPARTMENT IS
RESPONSIBLE FOR MAINTAINING THE TEMPERATURE INSIDE
THE FURNACE .

 SO THE CALIBRATED AMOUNT OF AIR NEEDS TO FLOW INSIDE


THE FURNACE WHICH IS MAINTAINED BY THE USE OF
THERMOCOUPLE .

 2. PRESSURE SENSOR : INORDER TO MEASURE THE PRESSURE


OF THE GASES THAT ARE ENTERING IN THE PRESSURE WE USE
THE BOURDON TUBE , CHEMICALLY SEALED DIAPHRAGMS .

 3.CONTROL SYSTEM : THE CONTROL SYSTEM INVOLVED IS TO


ADJUST THE REQUIRED AMOUNT OF AIR SO THAT THE
REACTION IS CARRIED OUT.
4. GAS ANALYZER : THESE ARE USED TO MAINTAIN THE
COMPOSITON OF THE GAS WITHIN THE FURNACE .

5. PLC’S ( PROGRAMMABLE LOGIC CONTROLLER) : USING THE


PLC’S WE CAN GET THE REAL TIME DATA AND ALLOW THE
SENSORS AND THE ANALYZER TO MAKE REAL TIME
ADJUSTMENTS .

THESE ARE WIDELY USED TOOLS IN AUTOMATION INDUSTRY AS


THIS HAS REPLACED THE HARD WIRED RELAY CIRCUIT .

WHICH MAKES THE CIRCUIT SIMPLER AND THUS ANY CIRCUIT


BREAKDOWN CAN BE EASILY CORRECTED .
 6. SAFETY : SAFETY IS THE PARAMOUNT CONCERN FOR THE
THERMAL DEPARTMENT AS THE HIGH PRESSURE AND HIGH
TEMPERATURE IS INVOLVED IN THE REDUCTION OF THE STEEL .

 7. ENERGY EFFICIENCY: THE ENERGY EFFICIENCY CAN BE


INCREASED IF THE RIGHT AMOUNT OF GAS IS USED AND THIS
CAN BE ACHIEVED BY THE MEASURING INSTRUMENTS WITH
HIGH ACCURACY .

 8. MAINTENANCE : INSTRUMENTATION ALLOWS A REGULAR


CHECKUP OF THE INSTRUMENTS SO THAT ERROR IS REDUCED .

 9. QUALITY ASSURANCE : IT IS THE MAJOR TASK OF THE


INSTRUMENTATION AS IT CONTROLS THE VARIABLES TO
PRODUCE THE DESIRED OUTPUT .
WASTE MANAGEMENT
1. RECYCLING AND REUSE : SCRAP IRON IS USED WITH THE ORE
SO THAT THE REMAINING IRON IS RECYCLED WITH THE ORE.

2. SOLID WASTE MANAGEMENT : STEEL PLANT GENERATES


VARIOUS SOLID WASTE INCLUDING SLAG , CHARCOAL, SILICA.

1. CHARCOAL – USED IN POWER GENERATION .


2. SILICA – USED IN SINTER PLANT TO MIX THE ORE WITH
IT.
3. SLAG – IT IS CONVERTED IN AGGREGATES AND USED IN
THE PROCESS OF MAKING ROADS.
 3. RECIRCULATORY : THE COOLING WATER SYSTEM IS
PRESENT . ENTIRE WASTE WATER IS USED FOR AFFORESTATION ,
EXCEPT DURING THE MONSOON .

 AIR MANAGMENT : THE AIR FROM THE FURNACE IS PASSED


THROUGH THE SCRUBBER , PRECIPITATORS ,BAY HOUSE TO
REMOVE THE IMPURE GASEOUS .
BENEFITS OF THE INTERNSHIP
THIS INTERNSHIP GAVE ME A VALUABLE INSIGHT
ABOUT THE CORE INDUSTRIAL PROCESSES .

 IT WAS VERY BENEFICIAL IN IMPROVING MY


PRACTICAL KNOWLEDGE.

 IT HELPED ME WITH THE ABILITY TO BE ABLE TO


COMMUNICATE WITH THE PEOPLE INVOLVED IN
SENIOR POSITIONS.
REFRENCES
1. PRE FEASIBLITY REPORT OF CHALIYAMA STEEL PLANT

 https://www.therungtagroup.com/

https://www.rungtasteel.com/about-us/

https://chat.openai.com/c/29f034d3-bec3-4a1d-8f2
d-2c8a7bcff6a3

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