DURGAPUR STEEL PLANT

The integrated steel plant, spread over an area of 6.5 sq km, employs a workforce of about of 17 thousand people. The largest industrial complex in West Bengal, Durgapur Steel Plant has introduced the latest state-of the-art technology that would ensure production of better quality of steel at a lower production cost that would enable it to operate as a viable unit. The modernization programme, undertaken with an expenditure of around Rs. 5000 crores, is the biggest such programme for any single unit in the country. It has brought about a complete transformation of the organization. After the completion, of modernization, the plant is envisaged to attain higher levels of annual production: hot metal – 1.92 million tons, liquid steel – 1.876 million tons and saleable steel – 1.586 million tons.
SMS, BOF, Merchant Mill, Wheel and Axle Plants are covered by ISO9002 Quality assurance certificate. With the successful commissioning of the modernized units DSP is all set to produce 2.088 tons of hot metal, 1.802 MT of crude steel and 1.567 MT of saleable steel.

The salient features of DSP are given below:



SHOPS/UNITS: PRINCIPAL PRODUCTS
(Size in mm)
A. BLOOMING MILL Blooms Slabs 190×160,210×160,250×250,356×18
B. BILLET MILL Billet Slabs 100×100,125×125,75×100,140×75,155×75,210×75
C. MERCHANT MILL Round and Thermo mechanically treated bars 12,14,16,18,etc.
D. SECTION MILL Joists Flats Channels Angle 116×100,200×100,150×75,225×100
40,55 thickness of 6-12 mm.
125×65,175×75,150×75,200×75,280×82
150×150,130×130,110×110,100×100
E. SKELP MILL Strip & Skelp 147,181,184,196,205
F. WHEEL & AXLE PLANT Wheel
Wheel sets : For Diesel engines.
: For Railways coaches.

SEMI FINISHED STEEL (Blooms and Billets): 65,70,90,160 to 250 mm.

DSP AT A GLANCE:

A dream child of Dr. B. C. Roy, Durgapur Steel Plant was set up in the late fifties with an initial capacities of one million tons of crude steel per annum. Its standards and norms were determined by the raw material characteristics available then. In the late sixties, the capacity of the plant was enhanced to 1.6 million tons of crude steel per annum and further enhanced to 1.876 million tons.

• Coke ovens: 4 batteries of 78 ovens each.
• Blast Furnace:
  FURNACE NO. NAME USEFUL VOLUME CAPACITY
  1 Kasturba 1323 cu m. 1250 T/Day
  2 Kamala 1400 cu m. 1820 T/Day
  3 Sharada 1400 cu m. 1820 T/Day
  4 Durga 1800 cu m. 2340 T/Day
  
• Steel Melting Shop: 3 × 110 tons BOF converters to produce 1.876 MT of liquid steel.
  
  
• New Lime Calcination Plant: 2 × 300 T per day lime kilns to produce soft burnt lime.
  
  
• Rolling Mills: Primary two strands 42” & 32”, Blooming Mill and a Billet Mill, Section Mill, Merchant Mill, Skelp Mill, Wheel & Axle Plant.
  
  
• Service Units: Central Engineering Maintenance, Foundry, Oxygen Plant, and Power Plant, Electrical Repair Shop, Research and Control Laboratory, and Training Department.
  
  
• Railways Tracks: 180 km.
  
  
• Roadways: 32 km.
  
  

INTRODUCTION

A BRIEF HISTORY OF SAIL:

The Government of India decided in December 1972 to set up a holding company for steel and the associated input Industries under the name of Steel Authority of India Limited (SAIL). To be registered in the Union Territory of Delhi. The company with an investment of Rs. 13,972 crores is the largest industrial enterprise in India. With a turnover of Rs. 16,000 crores a year, SAIL figures in the list of the top Industrial corporations of the world.

SAIL FAMILY:

At present SAIL manages the following Plant Units and subsidiaries:

• Bhilai Steel Plant.

• Bokaro Steel Plant.

• Durgapur Steel Plant.

• Rourkela Steel Plant.

• Alloy Steel Plant, Durgapur.

• Salem Steel Plant.

VERSATILITY OF ITS PRODUCTS:

SAIL is today India’s largest steel producer and the world’s ninth largest. It’s five integrated plants have a total capacity of 11 tons of crude steel. The ASP, SSP and VISL are engaged in the production of special and alloy steel and MEL is the only producer of ferro-alloys.
SAIL produces about 500 grades of mild and special alloy steel which caters the need of several industries like the automobile industries, Ship building, Indian Railways, ONGC, Power Sector, Defense, Construction, etc. The product not only finds market in India but have also found ready acceptance in about 70 countries. Product export to various countries include mild steel Billets, slabs, hot rolled plates, coils, sheets, wheels, etc. In 2001 SAIL plans to achieve an export level of 155 of its products.

ACKNOWLEDGEMENT

We express our sincere thanks and gratitude to the Training Department, D.S.P. for giving us an opportunity to visit the plant and to learn varied aspects of the plant.

We would like to thank all the employees of D.S.P. for their co-operation and giving knowledgeable technical explanation and advices, without which the training would have been meaningless.

We also like to thank Dr. Ananta Kumar Das (Head Of The Department, Chemical Engineering) and all the faculty members for their useful guidance regarding the preparation of project report.

ABHRA DAS
PRANTIK KARMAKAR
SOUDIPTYA KUMAR BASU
Chemical Engineering Department
DIATM, Rajbandh, Durgapur, W. B.

A REPORT ON:
OVERVIEW OF THE PLANT
PREPARED BY:

ABHRA DAS

Process Engineer

Himadri Chemicals & Industries Limited

Mahistikri, Haripal, Hooghly (W.B.)

Prantik Karmakar
Chemical engineer


Soudiptya Kumar Basu
Chemical Engineer
Pursuing M.Tech from NIT.