8/6/2013

Project report on In-Plant Training

Submitted by: Premankur raj Phone no.- +91 8821010108 Email- premankur.raj@indiraiimp.edu.in Indira institute of management Pune (Maharashtra)

To Mr. Ram Kishore (Sr. Deputy General Manager, Marketing) Jindal Steel & Power Limited, Raigarh (C.G.)

ACKNOWLEDGEMENT
I would like to take this opportunity to express my sincere gratitude to all those who guided me in the right direction to complete this report. I wish to place on our record my deep sense of gratitude to Mr. Naveen Jindal, (Chairman and Managing Director, Jindal Steel and Power Limited), Mr. Ram Kishore, (Sr. DGM Marketing Department, Jindal Steel & Power Limited), Mr. Manish Mohan, (Manager Marketing Department, Jindal Steel & Power Limited) and Mr. Prashant Namdev, (Junior Manager, Jindal Steel & Power Limited). I also extend my thanks to other employees of respective departments for their Cooperation during my study. .

Submitted By: Premankur Raj

DRI Plant
(Direct reduced iron)
JSPL is recognised as a leader in manufacturing coalbased sponge iron in India. First commissioned in 1991, JSPL leads the Indian market in this sector and has the worlds largest coal-based sponge iron plant, with a capacity of producing 1.32 MTPA DRI. It is the only sponge iron manufacturer in the country with captive raw material resources and power generation. Direct-reduced iron (DRI), also called sponge iron, is produced from direct reduction of iron ore (in the form of lumps, pellets or fines) by a reducing gas produced from natural gas or coal. The reducing gas is a mixture majority of hydrogen (H2) and carbon monoxide (CO) which acts as reducing agent. This process of directly reducing the iron ore in solid form by reducing gases is called direct reduction. Here Coal based Sponge Iron production is done from 10 Rotary Kilns ( 6 no. in DRI I shop and 4 no. in DRI-II shop) with annual production capacity of 1.32 Million tonne. Which is the world's largest coal-based sponge iron production capability. One of the lowest cost

producer of Sponge Iron, with in-house availability of the three Key raw materials, coal, iron ore and power

Visited on: 17.5.2013 In-charge : Mr. Vivek Garg (D.G.M.; DRI 2)

Data presentation
Target of the month ( May 2013) Up to date Production of the year 54,000 Mega Tons (DRI 2) 76,952 Mega Tons (DRI 2)

Up to date Production of the month 25, 646 Mega Tons (DRI 2) Product Hopper 'A' Grade 90.91%

No of Kilns Input Materials Production

DRI 1 6 Iron ore + Pallets 300 Tons/Day

DRI 2 4 Only Pallets 500 Tons/Days

DRI #2
SERIAL NO. 1. 2. 3. 4. 5. 6. ELEMENT Sp. Water consumption Sp. Power consumption Sp. Iron pellet consumption Sp. coal consumption (pellets) Store-cost Production TARGET 201314 1.28 M3/Ton 81 unit/ton 1.475 ton/ton 1.382 ton/ton 205 Rs./ton 6,66,000 MT APR. 2013 1.34 M3/ton 86.12 unit/ton 1.437 ton/ton 1.36 ton/ton 199 Rs./ton 51306 MT

Blast Furnace
Steel is an alloy of iron and carbon. It is produced in a two-stage process. First, iron ore is reduced or smelted with coke and limestone in a blast furnace, producing molten iron which is either cast into pig iron or carried to the next stage as molten iron. In the second stage, known as steelmaking, impurities such as sulphur, phosphorus, and excess carbon are removed and alloying elements such as manganese, nickel, chromium and vanadium are added to produce the exact steel required. Steel mills then turn molten steel into blooms, ingots, slabs and sheet through casting, hot rolling and cold rolling. The principal raw materials for an integrated mill are iron ore, limestone, and coal (or coke). These materials are charged in batches into a blast furnace where the iron compounds in the ore give up excess oxygen and become liquid iron. At intervals of a few hours, the accumulated liquid iron is tapped from the blast furnace and either cast into pig iron or directed to other vessels for further steelmaking operations.

Blast furnace with the volumetric capacity of 351 m3 and annual production capacity of 0.25 Million Tonne, which supplies hot metal for steel making.

Visited on: 17.5.2013 In-charge: Mr. Arvind chauhan (D.G.M.)

Data presentation
Product: Fe Raw materials: Iron ore, Sinter, Pellets Fuel: Coke, Coal, Nut Coke, Hot Air at 1250 c No. of furnaces: 2 No. of stoves: 3

Production per day (MT) Highest Productivity (T/M3/D) Lowest Coke Rate (KG/THM) Highest PCI - Rate(KG/THM) Lowest Fuel Rate(KG/THM)

furnace 1 furnace 2 1100 tons/day 4000 tons/day 2.85 (OCT - 2012) 322.35 (FEB - 2012) 187.89 (FEB - 2013) 496.53 (OCT - 2011)

Performance Production Coke Rate Nut Rate PCI Coal Fuel Rate

On Date 3010.00 358.00 12.00 146.00 516.00

Till Date 57504.00 MT 344.00 KG/THM 14.00 KG/THM 183.00 KG/THM 541.00 KG/THM

Oxygen Plant
Very large amount of oxygen is used in steel production. To ensure safe & stable production, Jindal steel and power limited , Raigarh is equipped with the oxygen plant. The main function of oxygen in blast furnace is maintaining the high flame temperature but not participating the smelting reaction directly. The oxygen is mixed with the raw air in a certain proportion and injected into the blast furnace. The mixed oxygenenriched air reacts with the coke, generating a large amount of heat and carbon monoxide (reductant) . Therein, the heat generated by the reaction will maintain the high smelting temperature instead of bf hot stove, and the carbon monoxide will reduce iron oxide in the raw iron ore to metal iron. The gas in the top bf can be injected back to the bf to adjust the bf temperature and transform the carbon dioxide in the gas to the carbon monoxide (reductant) as recycled use. It will improve the utilization rate of gas, reduce the coke consumption, carbon dioxide discharging and production cost.

Oxygen is also used in electrical arc furnaces. As the diameter of the EAF increases, the iron material is melted much more quickly in the electrical arc area than the other area. It may cause the increasing of melting time, caving of the un-melted material and damage of the electrical pole. The oxygen is injected into the eaf to melt the material synchronously and make the electrical pole be more efficiently. In additional, the oxygen may strengthen the post-consumption of co. Therefore, the oxygen is able to decrease the melting time, reduce the power consumption and improve the eaf efficiency effectively.

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Visited on: 17.5.2013 In-charge: Mr. G. Laxminarayan (D.G.M.)

Data presentation
No. of plants: 3

GAS Oxygen Nitrogen Liquid Argon

PRODUCTION 1128 Tons/Day 360 Tons/Day 28 Tons/Day

Comparison between oxygen plant & PGP plant

Elements Gasification Temperature In Plant Customers Produced Gases Oxygen Plant High Blast furnace, SMS, Utility Oxygen Producer Gas Plant Low Plate Mills CO , CO2 , CH4 , O2

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SMS
(Steel melting shop)

Two Steel Melting Shops, no. & , having capacity of 1.15 Million tonne of continuously cast steel products. Shop has one EAF of 50/60 tonne capacity, one Ladle Refining Furnace, one Tank Degasser and two casters (one round-cum-bloom and one slab). Shop has one 100 T EAF, one LRF, one Tank Degasser and one 4strand Beam blank-cum-Round-cum Bloom caster. The products, Beam blanks for larger parallel flange beams, rail bloom for rail rolling and other products, rounds for seamless pipe application and slabs.

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Visited on: 17.5.2013 In-charge: Mr. Satyendra Singh (Sr. G.M.)

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Data presentation
No. of furnaces: 2+1 Capacity: 100 tons each furnace Tap to tap time: 45 minutes Production= 30 heats each furnace/day (1 heat=100 tons) = 3*30= 90 heats/day =90*100= 9000 tons/day

Comparison elements No. of Electric Arc Furnace Capacity Tap to Tap Time Heat size Production

SMS 2 2 100 tons each 45 minutes 100 tons 6000 tons/ Day

SMS 3 1 100 tons 45 minutes 100 tons 3000 tons/Day

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PGP
(Producer Gas Plant)

Producer gas is a flammable gaseous fuel made by the destructive distillation of coal and contains a variety of calorific gases including hydrogen, carbon monoxide, methane and volatile hydrocarbons together with small quantities of non-calorific gases such as carbon dioxide and nitrogen.

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Visited on: 18.5.2013

In-charge: Mr. K.B. Singh (Sr. Manager) Data presentation

Capacity= 50000 gallons/hour Production= 15000 NM3/hour = 15000 x 24(hours) x 29(days) = 10440000 NM3/month Raw materials:Coal 800 tons/hour Steam 4-5 tons/hour

By-product : coal tar

Waste product: ash (60%)

1 litre of liquid fuel = 9 litres of producer gas 1 litre of liquid fuel = 44 Rs. 1 litre of producer gas = 30 paise 9 litres of producer gas = 9*0.3 = 2.70 Rs.

Producer gas costs only 6.14% as compared to liquid fuel, so it reduces cost of production.

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RUBM
(Rail and Universal Beam Mill)

Commissioned in 2003, the mill has a wide range of products ranging from long rails up to 121 meter to medium and large size parallel flange beams and columns. The product mix includes: Track Rails, Crane Rails, Parallel Flange Beams and Columns and Channels. To enhance its productivity & consistency in quality, the new tandem mill, the first of its kind in India, was purchased from SMS Meer, Germany, and installed & commissioned in Nov. 2006, in which its patent X-H technology is adopted for rolling of beams and columns. Other sections like rails and channels are also rolled via the universal route. Rail & Universal Beam Mill with state of art technology, having a capacity of producing 120meter long rail and large size parallel flange Beams. Mill has annual capacity to produce 0.75 Million tonne of rolled product.

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Visited on: 18.5.2013 In-charge: Mr. Manish Jain (Sr. D.G.M.)

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Data presentation

Current Achievements Highest Ever Monthly Production in Mar' 12 Highest Ever Monthly Despatch in Mar' 12 Highest Ever Quarterly Despatch in Q4, 2011-12 Highest Ever Yearly Production in FY 201112 Highest Ever Yearly Despatch in FY 2011-12 Lowest Power Consumption in Mar' 12 Lowest Fuel Consumption in Mar' 12 Highest Rate of Rolling in Mar' 12 Highest Mill Utilization in Mar' 12

Previous records 60819 MT (Jan' 2011) 55274 MT (Nov' 2011) 150308 MT (Q-3 201112) 494751 MT ( FY 200708) 457277 MT (FY 200708)

Year 2011-12 66743 MT (march 2012) 63533 MT (march 2012) 165807 MT (Q 4, 2011-12) 568714 MT (FY 2011-12) 570113 MT (FY 2011-12) 119 Kwh/MT (March 2012) 490 Mcal/MT (March 2012) 117 MT/Hr (March 2012) 76.42% (March 2012)

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PLATE MILL
Introducing newer technologies, JSPL has a plate mill, which manufactures the widest plates of 3.5 metre in coil form and coils of 3 meter width. It commenced commercial production from April 07 and has a production capacity of 1 MTPA. The mill has been consistently producing plates and coils in various grades like EN, DNV, BS, ASTM, JIS, LRS and ABS certified by CII

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Visited on: 18.5.2013 In-charge: Mr. N. Raj Kumar (A.V.P.) Data presentation
FY 2012-13 TOTAL PRODUCTION PLATE : 298805 COIL : 34393

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22 Target of FY 2012-13 (as per ABP) Target as per ABP

24.38%

75.62%

Target achieved (as per ABP)

Shortfall

Reasons for shortfall

Mill shutdown in 1st (6 days) & 4th quarter (10 days). Slab retention inside reheating furnace in 1st quarter(44 hours). Power restriction (15 hours). Order not available in 2nd quarter (321 hours) & 3rd quarter (397 hours). Slow rate of rolling due to thinner gauge and trial rolling of coil in 2 nd , 3rd & 4th quarter. Hydraulic leakage in 2nd quarter (7.5 hours) & 4th quarter (14 hours). X-ray problem in 2nd quarter (6 hours) & 3rd quarter (9 hours). Drag chain damaged (17 hours) & top back-up roll jammed in housing (9 hours) in 3rd quarter. Power failure from MRSS (18 hours) on 19th & 20th march 2013.

LOGISTICS

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Logistics is the management of the flow of resources between the point of origin and the point of consumption in order to meet some requirements, for example, of customers or corporations. The logistics of physical items usually involves the integration of information flow, material handling, production, packaging, inventory, transportation, warehousing, and often security. Jindal steel and power has a well-established logistics department.

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Visited on: 24.5.2013 In-charge: Mr. Raj Alok (G.M.)

Data presentation

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Transportation : by road and rail 16 authorised transporters

Warehousing : stockyards at
Ludhiana Rudrapur Chandigarh Gurgaon Ghaziabad Faridabad Ahmedabad Rahuri Patna Chennai Hyderabad Visakhapatnam Nagpur Bhopal Kolkata Raipur Bhubaneswar Cuttack

Daily Dispatched quantity By road: about 4000 MTPD By rail: about 7000 MTPD

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THANK YOU