INTRODUCTION :

Visakhapatnam Steel Plant is the integrated steel plant of Rashtriya Ispat Nigam Limited in
Visakhapatnam. Founded in 1971, the plant focuses on producing value-added steel,
producing 5.773 million tonnes of hot metal, 5.272 million tonnes of crude steel and 5.138
million tonnes of saleable steel in the 2021 to 2023 financial year.

FIG. RINL-VSP AERIALVIEW

Rashtriya Ispat Nigam Limited Visakhapatnam Steel Plant (RINL-VSP) popularly known as 'Vizag
Steel' the 'Pride of Steel', a leading Central PSU under the Ministry of Steel is the first shore based
Integrated Steel Plant in the country. Vizag Steel known for its 'Quality' & 'Customer Service is a
market leader in longs with a share of about 10%. It has been supplying various grades of steel for
construction of projects of National importance which include Metros, Power Sector, Bridges, Nuclear
complexes and several others, RINL-VSP has exported finished products to countries like the USA,
UAE, Thailand, Bangladesh, Nepal, Sri Lanka etc. Its products are made from 100% virgin steel,
maintaining stringent tolerances both in chemistry & physical properties. RINL-VSP has a marketing
across the country and it is the “ preferred steel Ratna' Company with a yearly turnover of over Firsts' in the
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country to its credit, viz.
• Coke Dry Quenching
• Large size Blast furnaces
• 100% Continuous Casting
• Rolling Mills with 'Tempcore' Processes
• Rolling Mills with 'Stelmor' Processes Triple Standards
Certificates, viz. ISO 9001, ISO 14001 and OHSAS 18001 for
Quality, Environment, Occupational Health and Safety
• Capability Maturity Model Integrated (CMMI) level-3
certificate from Software Engineering Institute, USA The
Plant with a capacity of 3.0 Mtpa of liquid steel has been
operating much above 100% rated capacity (120% and
higher) over the last decade
Though the plant was basically designed to produce mild steel grades, innovative in-house
improvements have helped to continuously develop 'value added' products to serve discerning
customers. The quantum of Value added production has been on the rise continuously over the
years and is now touching 80%, RINL commenced the commissioning activities for its brown
field expansion costing about Rs.12, 500 crores to almost double its capacity to 6.3 Mtpa of
liquid steel which was completed in phases during 2011-12.

Rashtriya Ispat Nigam Ltd, (abbreviated as RINL), also known as Vizag Steel, is a
public steel producer based in Visakhapatnam, India. Rashtriya Ispat Nigam Limited
(RINL) is the corporate entity of Visakhapatnam Steel Plant (VSP). VSP is India's
first shore-based integrated steel plant, located 16 Km South West of City of Destiny,
Visakhapatnam is built with state-of-the-art technology. Visakhapatnam Steel Plant
(VSP) is a 7.3 MTPA plant. It was commissioned in 1992 with a capacity of 3.0
MTPA of liquid steel. The company subsequently completed its capacity expansion
to 6.3 MTPA in April 2015 and to 73 MTPA in December 2017. The company has
one subsidiary, viz. Eastern Investment Limited (EIL) with 51% shareholding, which
in turn is having two subsidiaries, viz. M/s Orissa Mineral Development Company
Ltd (OMDC) and M/s Bisra Stone Lime Company Ltd
(BSLC). The company has a partnership in RINMOIL Ferro Alloys Private Limited
and International Coal Ventures Limited in the form of Joint Ventures with 50% and
26.49% shareholding respectively.
At there is emphasis on total automation, seamless integration and efficient upgradation, which
resulted in a wide range of long and structural products to meet stringent demands of
discerning customers within India and abroad. VSP products meet exacting International
Quality Standards such as JIS, DIN, BIS, BS etc. VSP has become the first integrated Steel
Plant in the country to be certified to all the three international standards for quality (ISO9001),
for Environment Management (ISO14001) & for Occupational Health & Safety (OHSAS-
18001). The certificate covers quality systems of all Operational, Maintenance and Service

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HISTORY & ESTABLISHMENT OF RINL-VSP :

With a view to give impetus to Industrial growth and to meet the aspirations of the people
from Andhra Pradesh, Government of India decided to establish Integrated Steel Plant in
Public Sector at Visakhapatnam (AP). The announcement to this effect was made in the
Parliament on 17th April
1970 by the then Prime Minister of India late Smt. Indira Gandhi. A site was selected near
Balacheruvu creek near Visakhapatnam city by a Committee set up for the purpose, keeping in
view the topographical features, greater availability of land and proximity to a future port.

The foundation stone for the plant was laid by Smt. Gandhi on 20.01.1971, Seeds were thus
sown for the construction of a modern & sophisticated Steel Plant having annual capacity of
3.4 Million Tonnes of hot metal. An agreement was signed between Governments of India and
the erstwhile USSR on June 12th, 1979 for setting up of an Integrated Steel Plant to produce
structural & long products on the basis of detailed Project report prepared by M/s M.N. Dastur
& Company. A. Comprehensive revised DPR jointly prepared by Soviets & M/s Dastur &
Company was submitted in Nov 1980 to Govt. of India. The construction of the Plant started on
1st February 1982. Government of India on 18th February 1982 formed a new Company called
Rashtriya Ispat Nigam Ltd. (RINL) and transferred the responsibility of constructing,
commissioning & operating the Plant at Visakhapatnam from Steel Authority of India Ltd. to

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The rationalized concept was based on obtaining the maximum output from the equipment
already installed, planned / ordered for procurement and achieving higher levels of
operational efficiency and labour productivity. Thus the plant capacity was limited to 3.0
Million tonnes of Liquid Steel per annum. In the process, one of the Steel Melt Shops and
one of the mills were curtailed. The availability of resources continued to be lower than what
was planned and this further delayed the completion of the construction of the plant. Finally
all the units were constructed and commissioned by July 92 at a cost of Rs. 8529 crores.

The plant was dedicated to the nation by the then prime Minister of India Late Sri P.
V. Narasimha Rao on 1st August, 1992. Since Commissioning VSP has already
crossed many milestones in the fields of production, productivity & exports. Coke
rate of the order of 509 Kg/Ton of Hot metal, average converter life of 2864 heats an
average of 23.6 heats per sequence in continuous Bloom Caster. Specific energy
consumption of 6.07 G Cal/ ton of liquid steel, a specific refractory consumption of
8.94 kg and a labour productivity of 265 Ton / man per year are some of the peaks
achieved (during the year 2004-05) in pursuit of excellence.

OBJECTIVES OF RINL :
• Achieve Gross margin to turnover ratio > 10% Plan for finishing mill to integrate with 7.3 Mt
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 capacity and commission the same by 2017-2018
• Achieve rated capacity of new and revamped by 2017-2018
• Capture markets for high end value added products by focusing on sector specific
applications and customer needs

consumption by achieving 5.6 Gcal / tcs by 2017-

acquisition of mines and setting up marketing in

the network abroad Diversity through operation of Bhilwara mines setting up of
pelletization plant,DRI-EAF unit,wheels and axle plant
• Create a high performance and safe work culture by nourishing talent and developing
leaders
• To grow a harmony with the environment and communities around us.

CORE VALUES OF RINL :

INITIATIVE : Have a self propelled and proactive approach

DECISIVENESS : Decide with speed and clarity

ETHICS : To be consistent with professional and moral values

ACCOUNTABILITY : Take responsibility for actions

LEADERSHIP : Lead by example

SPEED : Demonstrate swiftness and efficiency in everything we do

VSP Technology: State-of-the-Art

• 7 metre tall Coke Oven Batteries with coke dry quenching.

• Biggest Blast Furnaces in the Country -Bell - less top
charging system in Blast Furnace
• 100% slag granulation at the BF Cast House • Suppressed
combustion - LD gas recovery system
• 100% continuous casting of liquid steel.
• "Tempcore" and "Stelmor" cooling process in LMMM &
WRM respectively

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VISION:
To be the most efficient steel maker, shore based steel plant in the country.

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SOURCES OF RAWMATERIALS :

RAW MATERIAL SOURCE

Iron ore lumps and fines Bailadila, Chattisgarh

BF Lime stone Jaggayyapeta, Andhra Pradesh

SMS Lime stone Dubai

BF Dolomite Madharam, Telangana

Manganese ore Chipurupalli, Andhra Pradesh

Imported Boiler Coal Indonesia

Imported Coking Coal Australia/ US

Medium Coking Coal (MCC) Kathara/Swang/ Rajarappa

Kedla Imported LAM Coke China

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Quartzite Lump and Fines Local

Sand Sarepalli, Andhra Pradesh

MAIN PRODUCTS OF VSP :

BILLETS
CHANNELS
ANGLES
BEANS
SQUARES
FLATS
ROUNDS
WIRE RODS
REBARS
BLOOMS

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BY PRODUCTS OF VSP

NUT COKE
COKE
DUST
COAL TAR
ANTHRACENE
OIL HP
NAPHTHALENE
BENZENE
TOLUENE
GRANULATED
SLAG LIME FINES
WASH OIL
AMMONIA SULPHATE

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 SKELETON OF VSP :

COKE OVENS & COAL CHEMICAL PLANT ( CO & CCP )

RAW MATERIAL HANDLING PLANT ( RMHP )
SINTER PLANT ( SP )
BLAST FURNACE ( BF )
STEEL MELT SHOP AND CONTINOUS CASTING ( SMS & CCD )
LIGHT AND MEDIUM MERCHANT MILL ( LMMM )
WIRE ROD MILL ( WRM )
MEDIUM MERCHANT AND STRUCTURAL MILL ( MMSM )
SPECIAL BAR MILL ( SBM )
STRUCTURAL MILL ( STM )

COKE OVENS
AND COAL
CHEMICAL
PLANT (CO &
CCP)
INTRODUCTION

Coal is converted into coke by heating the prepared coal blend charge in the coke ovens in the
absence of air at a temperate of 1000c-1050°C for a period of 16 to 19 hours. The volatile matter of
coal liberated during carbonization is collected in gas collecting mains in the form of a raw coke
oven gas passing through stand pipes and direct contact cooling with ammonia liquor spray The
gas cooled from 800°C to 80°C is drawn to the Coal Chemical Plant by Exhauster. The residual
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 COKE OVEN
Coke ovens are meant for making coke from the coal. Blast furnaces, the mother units of any
steel plant require huge amount of strong, hard and porous solid fuel in the form of hard
metallurgical coke for supplying necessary heat for carrying out the reduction and refining
reactions besides acting as a reduction agent.

BATTERY
The coal is charged to batteries and gradually heated by the heating walls of the oven in the
absence of air to a temperature of 1000-1050° C. The coking period is between 16 hrs to 19 hrs. The
red-hot coke is taken to coke dry cooling plant for cooling and then cooled coke is stored in coke
storing plant. There are 5 batterie, each of 7 meters height having 67 ovens.
Each oven can hold 32 tons of dry coal charge. The volumetric capacity of each oven is 41.6 m³.
The heat for carbonization is supplied by under firing of coke oven gas having CV of 4200
Kcal/Nm³ or mixture of BF gas & CO gas having CV 900 Kcal/Nm. Temperature in heating is
between 1330 °C and 1390 °C. The final temperature of coke in ovens is 1000-1050 °C.

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RAW MATERIAL
HANDLING PLANT
(RMHP)
INTRODUCTION
Raw material handling plant is meant for transporting materials from raw material yard/Base
mix yard to various process units of the plant.

The Major Raw materials required for iron and steel making are iron ore lumps, iron ore fines,
sized iron ore, flux limestone/dolomite, manganese, quartzite coking coal, non-coking coal ( for
boiler operation & for pulverized coal injection ) and coke.

Lump iron ores, iron ore fines and flux such as lime stone and dolomite received by railway rake
are unloaded in wagon tipplers and stored in open storage yards with the help of various stockyard
machines.
Visakhapatnam Steel Plant is one of the most modern steel plant not only in the country but also in
the world. This has latest raw materials stacking and blending system. RMHP has the concept of
peripheral unloading which considerably reduces delay in taking over and handing over of rakes
bringing raw materials to the plant, there by increasing the availability of wagons.
The Raw Material Handling Plant is handling more than 24 million tons of various raw
materials for 7.3 MTA.
The Raw Material Handling Plant in any organization is needed:
 To have adequate storage capacity to store various raw materials depending upon
the capacity of the beds in the stock yard.

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. To process the raw materials and bring down the size to the size as required by the customer
departments to improve their productivity and product quality.
The various raw materials stored in RMHP which are sent to various departments are
indicated below:
 Sinter Plant: Iron ore fines, Limestone (BF), Dolomite, Sand and LD slag
 Blast Furnace: Sized iron ore, Limestone (BF), Manganese Lump, Quartzite
SMS: Dolomite (SMS), Sized iron ore, Dolo chips
 CRMP: Limestone (SMS), Dolomite (SMS), Dolo chips
 TPP: Crushed Boiler Coal
 COCCP: Coking coal (imported and blended), Medium coking coal (MCC)
The Raw Material Handling Plant (RMHP) is divided in two sections Coal Handling
and Ore Handling Plant (OHP).

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 Equipment of O.H.P
• Wagon Tipplers Track Hopper
• (3+1+1)Nos. 10 Ground and 10
• Stock Yard (12+2 Beds) Lump Ore Crushing & Screening
Plant(1+1 Units)
• Twin Boom Stackers (5+2 Nos.) 1400 TPH
• Blender Reclaimers (3+2 Nos.) 1200 TPH
• Wheel on Boom Reclaimers (3+1+1 Nos.) 450 TPH •
Conveyors & Control Rooms Transfer Car • Drier for
Sized Ore 50 TPH

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 SINTER PLANT

INTRODUCTION
Sintering is an agglomeration process of fine mineral particles into a porous mass by incipient
fusion caused by heat produced by combustion within the mass itself. Iron ore fines, coke breeze,
limestone and dolomite along with recycled metallurgical wastes are converted into agglomerated
mass at the Sinter Plant, which forms 70-80% of iron bearing charge in the Blast Furnace. The
vertical speed of sintering depends on the suction that is created under the grate. At VSP, two
exhausters are provided for each machine to create a suction of 1500- 1600 mm water column
under the grate.

RAW MATERIALS USED IN SINTERING

Raw materials used in sintering are:

Iron ore fines (0-10 mm)

i. Coke-used as fuel.
ii. Limestone & Dolomite - to maintain required sinter basicity.
iii. Sand- to maintain required sinter basicity
iv. Iron ore fines (0-10 mm)

VSP SINTER PLANT : AN OVERVIEW

1.2 Sinter plant of VSP has the capacity to produce 5.256 MT of sinter per annum which will cater for 80% of
iron bearing feed to blast furnace. Two sintering machines of Dwight Lloyd type having 312 m² totals grate
area are provided for this purpose. Sinter machine designed to operate at the rate of 1.2T/hr/M for 330 days in
a year.

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 FIG .SINTER MACHINE -2 IN RINL-VSP

M/C-1&2
Parameters of Sintering Machines are:

• Total area: 312 Sq, metre

• Effective Sintering area: 276 Sq. metre
• Sinter bed height: 500 mm Sinter Machine Capacity: 400 TPH each

Facilites

• Sinter machine-1 with 378 M2 grate area after Modernization)

• Sinter machine-2 with 312 M2 grate area.
• Sinter Machine-3 with 408 M2 grate area.

Salient Features
Base mix (homogeneous mixture of all raw materials) blending yard with six beds each of 1,
10,000 tons storage capacity

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M/C-3

Sinter Bed Height 650 mm for M/C-1 (after Modernization) & 500 mm for M/C- 2.Straight Line Sinter Cooler
• Sinter Heat Recovery Power Plant (SHRPP) with a capacity of 20.6 MW electrical power generation
by utilising waste heat recovered from Sinter Coolers of Machine 1 & 2

• Bed Height 700 mm. Chamber type Ignition Furnace with roof mounted energy efficient burners.27
m long extended hood with hot air supply through 4 feed points,
• Circular Sinter cooler with waste heat recovery system. Lime addition at Mixing and Nodulizing
Section of Sinter Machine building.

PRODUCTION CAPACITY:
● SINTER MACHINE - 1 : 3.640 MT Of Gross Sinter Per Annum
(After Modernization)
● SINTER MACHINE – 2 : 2.85 MT Of Gross Sinter Per Annum.

● SINTER MACHINE – 3 : 3.611 MT Of Gross Sinter Per Annum.

BLAST FURNACE
INTRODUCTION

Blast Furnace is the most important part of an integrated steel plant. It is considered as the heart of an ISP.
The objective of Blast Furnace is to take the raw material from RMHP, coke from Coke Ovens and Sinter
from Sinter Plant and convert it into pig iron or Hot Metal Coke serves as the heat source and Dolomite are
used as flux, which Furnace is so called because it uses air

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reducing agent while Limestone and combines with gangue to produce slag. A Blast blast as
oxygen source for the process. HOT AIR BLAST BURDEN CHARGE Blast furnace is a counter
current reactor, Process in a blast furnace is called a counter current reaction, BF is a counter
current heat and mass exchanger, in which solid raw materials are charged from the top of the
furnace and hot blast is sent through the bottom via tuyeres. The heat is transferred from the gas to
the burden and oxygen from the burden to the gas. Gas ascends up the furnace while burden and
coke descend down through the furnace.

The counter current nature of the reactions makes the overall process an extremely efficient one in
reducing the atmosphere. The real growth of blast furnace technology came with the production of
high strength coke which enabled the construction of large size blast furnaces.

Iron is produced in the Blast Furnace by smelting iron bearing materials with the help of coke and
air. The solid charge materials like sinter, sized iron ore, coke etc.. are charged in the vertical shaft
of the Blast Furnace from top and hot air blast is blown through tuyeres located at the bottom.

The oxygen present in hot air combines with the carbon of coke and generates heat and carbon
monoxide (reducing agent). The reducing gases, while ascending upwards, come into contact with
the descending charge materials. Eventually the charge gets reduced and hot metal, slag and BF gas
are produced. Hot metal and slag is tapped from the tap hole. The Blast Furnace gas which comes
out from top of furnace is cleaned and used as fuel in the plant.

PARTS OF BLAST FURNACE

• Hot blast from Cowper stoves

• Melting zone
• Reduction zone of ferrous oxide
• Reduction zone of ferric oxide
• Pre-heating zone
• Feed of ore, limestone and coke
• Exhaust gases
• Column of ore, cake and limestone Removal of slag
• Tapping of molten pig iron
• Collection of waste gases

PIG CASTING MACHINE

Four double strand pig casting machines grade metal. The machines can handle
a 75 T overhead trolley to tilt 140 T hot Facilities for lime washing of moulds and pigs including a settling
tank are provided.

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 WORKING OF BLAST FURNACE

Model BF is a counter current heat and mass exchanger, in which solid raw materials are charged
from the top of the furnace and hot blast is sent through the bottom via tuyeres. The heat is
transferred from the gas to the burden and oxygen from the burden to the gas. Gas ascends up the
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 furnace while burden and coke descend down through the furnace. The counter current nature of
the reactions makes the overall process an extremely efficient one in reducing the atmosphere.
The real growth of blast furnace technology came with the production of high strength coke which
enabled the construction of large size blast furnaces.

The main chemical reaction producing the molten iron:

Fe2O3 + 3CO2Fe + 3CO2

C+02 → CO2
CO2 + C→2CO
CaCO3 → CaO + CO2
SiO2 + CaO → CaSiO3
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Preheated blast air blown into the furnace reacts with the carbon in the form of coke to produce
carbon monoxide and heat. The carbon monoxide then reacts with the iron oxide toproduce molten
iron and carbon dioxide. Hot carbon dioxide, unreacted carbon monoxide, and nitrogen from the
air pass up through the furnace as fresh feed material travels down into the reaction zone. As the
material travels downward, the counter-current gases both preheat the feed charge, decompose the
limestone to calcium oxide and carbon dioxide, and begin to reduce the iron oxides in the solid
state.

The main reaction controlling the gas atmosphere in the furnace is called the Boudouard reaction:
The decomposition of limestone in the middle zones of the furnace proceeds according to the
following reaction: The calcium oxide formed by decomposition reacts with various acidic
impurities in the iron (notably silica), to form a fayalite slag which is essentially calcium silicate,
CaSiO3

FIG: BLAST FURANCE-2 (KRISHNA)

The "pig iron" produced by the blast furnace has a relatively high carbon content of around 4- 5%,
making it very brittle, and of limited immediate commercial use. Some pig iron is used to make
cast iron. The majority of pig iron produced by blast furnaces undergoes further processing to
reduce the carbon content and produce various grades of steel used for tools and construction
materials. Although the efficiency of blast furnaces is constantly evolving,
the chemical process inside the blast.

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STEEL SHOP &MELT
CONTINUOUS
CASTING
(SMS &
CCD)
INTRODUCTION

Steel is made in steel melting shops in refractory lined vessels called LD Converters by blowing
oxygen through the hot bath. While iron making iva reduction process, steel making is an
oxidation process. The oxygen reacts with impurities like carbon, silicon, phosphorus, sulphur etc,
present in hot metal to produce steel. No external fuel is required as the silicon & carbon releases
huge amounts of heat energy. Also the carbon reaction releases large quantities of gas rich in
carbon monoxide along with huge amounts of dust. The gases released from the converter are
collected, cooled, cleaned and recovered for use as fuel in the steel plant. The entire molten steel at
VSP is continuously cast at the radial type continuous casting machines resulting in significant
energy conservation and better quality steel. 100% Continuous casting on such a large scale has
been conceived for the first time in India.

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CHARACTERISTICS OF VSP CONVERTORS:

Capacity: 150 Tones per heat blow

Volume: 133 Cu. Meter
Convertor Sp. Volume: 0.886 meter per tonne Tap
to Tap Time:45 mts-60 mts
Liquid Steel produced in LD Convertors is solidified in the form of blooms in continuous Bloom
Casters. However, to homogenize the steel and to raise its temperature, if needed, steel is first routed
through, Argon rinsing station, IRUT (Injection Refining & Up temperature) / ladle furnace.

FACILITIES IN SMS
SMS 1:

• Three LD converters (modernized with increase in volume to 150 cum each along with
DOG House facility)
• 6 nos of 4-Strand Continuous Bloom Casting machines.
SMS 2:

• Three LD Converters of 150 cum. volume each. 1 no. of 6- Strand Continuous Billet-
cum-Round caster.
• 2 nos. of 6-Strand Continuous Billet casters.
• 1 no. of S-strand Continuous Billet-cum-Round caster. Hot Metal Desulphurization
Plant (HMDP).
• DOG House.
• RH Degasser.

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 PRODUCTION CAPACITY
SMS-1:
Original Installed Capacity is 3.0 MT of Blooms per annum. After Modernization

Liquid Steel per annum & 2.82 MT of CC

of all the 3 convertes, capacity is enhanced to
3.5 MT of Liquid Steel & 3.29 MT of CC Blooms per annum.

SMS-2:
3.8 MT of Liquid Steel per annum & 3.7 MT of CCBlooms/Rounds per annum from
Converters-D, E & F

CONTINUOUS CASTING DEPARTMENT (CCD)

Continuous casting may be defined as teaming of liquid steel in mould with a false bottom
through which partially solidified ingot is continuously withdrawn at the same rate at which liquid
steel is teamed in the mould.

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 TUNDISH CAR
Tundish car is used for the transfer of a tundish. It is a self-propelled carriage which transports a tundish.
Each tundish is heated to a high temperature by a heating apparatus at a standby position and is transported to
the casting station by the tundish car immediately before casting begins. In addition to the travelling
function, the tundish car comprises a lifting function for inserting a submerge nozzle arranged at the bottom
of each tundish into a mould, a centering function for adjusting the position of the submerged nozzle, and an
automatic liquid steel level control function for keeping the liquid steel at a constant level to separate
impurities by flotation. The size of the tundish car is normally increased as the number of strands increases,
and the interference Hence, it is required to have a mechanism with adjustment apparatus become tighter.

BLOOM YARD
In SMS Stock Yard product of the SMS1 and SMS2 are stored and then send to different mills to
produce billets, bars and angles.

• From SMS1 250 250 mm and 250*320 mm blooms are stored in stock yard and are
further send to WRM1 and LMMM department.
• From SMS2 150 150 mm billets and 120 120 mm billets are stored in the stock yard and
are further send to mills for finish product production.

ROLLING MILLS
INTRODUCTION
Blooms produced in SMS-CCD are shaped into products such as Billets, rounds, squares, angles
(equal & unequal), Channels, I-PE Beams, HE Beams, Wire rods and reinforcements bars by
rolling them in three sophisticated high capacity, high speed, fully automated rolling mills, namely
Light & Medium Merchant Mills (LMMM), Wire Rod Mill (WRM) and Medium Merchant and
Structural Mill (MMSM). The finished products include wire rods & long products like
reinforcement bars, rounds, squares, flats, angles, channels

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LIGHT & MEDIUM MERCHANT MILLS
(LMMM)
LMMM comprises two units, namely Billet Mill and Bar Mill. The Billet Mill is facilitated with 2
Walking Beam Furnaces and it is a continuous seven stand mill. In the Billet Mill 250 x 320 mm
size blooms are rolled into Billets of 125x125 mm size. Billets are supplied from this mill to Bar
Mill of LMMM, Wire Rod Mill and for sale. Bar Mill is facilitated with tempcore heat treatment
technology, automated bundling facilities and high degree of automation. Bar Mill is a 2 strand
continuous mill having a capacity of 7,10,000 tons per annum and produces rounds and rebars of
various sizes from 16 mm to 36 mm.

The cast blooms from the continuous casting department are heated and rolled in the two high
speed and fully automated rolling mills namely Light & Medium Merchant Mill (LMMM) and
Medium Merchant & Structural Mill
(MMSM). The billets produced in LMMM are further rolled in Bar Mill Wire Rod Mill (WRM)
The finished products include wire rods & long products like reinforcement bars, rounds, squares,
flats, angles, channels, billets etc.

FIG.LMMM-RINL
Blooms from the Continuous Casting Division are rolled into billets, some of which are sold and
rest are sent to Bar Mill/WRM. The continuous two-line Bar Mill comprises 8 Stand Double
Strand roughing trains, 2 nos. of 4 Stand Single Strand intermediate trains & 2 nos. of 4 Stand
Single Strand finishing trains. Loopers are provided in between the finishing stands

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WIRE ROD MILL (WRM)
Wire Rod Mill is fully automated & sophisticated mill. The billets are rolled in
4 strand, high speed continuous mill having a Annual Capacity of 8,50,000 Tonnes of Wire Rod
Coils. The mill produces rounds in 5.5- 14 mm range and rebars in 8, 10 & 12 mm sizes. The mill
is equipped with standard and Retarded Stelmor controlled cooling lines for producing high quality
Wire rods in Low, Medium & High carbon grade meeting the stringent National & International
standards viz. BIS, DIN, JIS, BS etc. and having high ductility, uniform grain size, excellent
surface finish.
WRM-1:
The Mill is high speed 4 strand No Twist continuous mill designed to produce 8,50,000 Tons of
wire rod coils per year. Rolled billets of 125 mm x 125 mm square cross section, length ranging
from 9.8 m to 10.4 m and weighing approximately 1250 kgs are used. The mill is designed to roll
steel stock of 0.9% max. carbon content.

WRM-2:
The Mill is designed to produce 6,00,000 tons per year of rounds in coil form. The Mill is designed
to roll low, medium and high carbon steel, case hardening steel, cold heading quality steel, electrode
steel, spring steel, bearing steel and free cutting steel(-5.5 to 12mm). The mill shall use continuous
cast billets of 150 mm X 150 mm. square cross section, 12 m length and weighing 2100 kgs
approximately, are used as input material.

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MEDIUM MERCHANT & STRUCTURAL MILLS
(MMSM)
The Medium Merchant and Structural Mill (MMSM) is one of the modern rolling mills of
Visakhapatnam Steel Plant. This is a single strand continuous mill having production capacity of
8,50,000 tons per year. The important feature of this mill is that Universal beams (both parallel
and wide flange) have been rolled for the first time in India using Universal stands.
Parallel flange beams have an advantage over conventional beams because, for the same weight,
the section is stronger and stiffer due to greater moment of inertia and higher radius of gyration.

FIG.Billet Rolling In MMSM Through Stands

This mill is a high capacity continuous mill. The feed material to the mill is
250x 250 mm size blooms, which is heated to rolling temperatures of 1200 "C in two walking beam
furnaces. The mill is designed to produce 8,50,000 tons per annum of various products such as
rounds, squares, flats, angles (equal & unequal), T bars, channels etc.

SPECIAL BAR MILL

The Mill is designed to produce 7,50,000 tons per year of plain rounds in straight length and in coll
form by using an input of Continuous cast billets of 150 mm x 150 mm x 12 m and weighing
approximately 2050 kgs.

The mill is designed to roll medium and high carbon steel, case hardening steel, cold heading
quality steel, electrode steel, spring steel, CAPACITY :

0.75 MT per annum. The enhanced bearing steel and free cutting steel. production capacity is 0.90 MT
per annum

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 STRUCTURAL MILL

FIG. ROLLERS-STRUCTURAL MILLS

This Mill is designed to produce 700,000 tonnes per year of structural section in straight length in
approximately 3733 rolling hours and 8,50,000 tonnes per year of structural sections in straight length in
input of Continuous cast cold bloom of approximately 3760 kgs.
approximately within 4533 rolling hours an 200 mm x 200 mm x 12 m and weighing
technology is adopted only in VISHAKAPATNAM STEEL PLANTbecause, in wet cooling, the
strength of the coke is reducing.

The advantages of DRY COOLING are:

• Waste heat recovery (by producing steam)

• Pollution control (done by closed circuit)
• Better coke strength (there is no thermal shock as in wet cooling)
29 | P a g e
 Process:
Coke from the battery falls on a loco located at the coke side, whichwill be brought into CDCP. The
loco is lifted up, and coke is chargedinto the cooling chambers. Later, the chambers are closed by a lid,
and Nitrogen gas is passed inside through a temperature of 55°C bya mill fan. The hot cake is cooled
from 1050°C to 180-200°C. There occurs no chemical reaction, as Nitrogen is an inert gas. The heated
gas is utilized for producing steam in boilers. These boilers are water tube boilers, which have a
capacity of 25 Ton/hr. The temperature and pressure of the steam are 440°C and 40 Kg/cm².
Cooled coke is conveyed to CSP (Coke Sorting Plant), and the steamis used to run the back pressure
turbine station for producing power of 15 MW.

Specifications of CDCP:

Coke temperature after cooling: 180-200 degrees CelsiusCoolant used: Recirculating air
Dry coolant temperature: 55 degrees CelsiusNo of CDCP: 4/4
Batteries
No of chambers: 4 chambers/each CDCPCapacity of each CDCP:
50-52 T/hr
Coke temperature before cooling: 1050 degrees Celsius
Coke from CDCP enters CSP Here coke is crushed, screened,BF Coke (i.e., +25-70 mm),
(Coke Sorting Plant) section. and separated into 3 fractions: which is sent to Blast Furnaces;
Coke Breeze (i.e., +0-15 mm), which is sent to Sinter making; andnut coke (i.e., +15-25 mm), which is
also used in the Blast Furnaces.

Silent features of coke oven and coal chemical plant:

• Largest and technologically unique Coke Oven Batteries in thecountry at the time of
commissioning
• 7-meter tall coke oven batteries.
• 100% Dry Quenching of coke using Nitrogen gas.
• Power generation, from the waste heat recovered, at BPTS (BackPressure Turbine Station

By Products Recovery from CO Gas

Introduction
The coke oven gas which is a mixture of harmful gas is not releaseddirectly into atmosphere.
That iswhy it is sent to recovery section.

Recovery section includes:

• Primary Gas Cooler (PGC)
• Electrostatic precipitator (ESP)
• Exhauster
• Ammonium Sulphate Plant (ASP)
• Final Gas Cooler (FGC) 30 | P a g e
TAR DISTILLATION PLANT
Tar Distillation Section and Tar and Oil Storage

Tar is various fractions obtain by cooling of CO gas with ammonia liquor. During this cooling coke
dust particles mixed with liquor and forms coal tar. It consists of large chain aromaticcompounds
which can be distilled in to light oils, phenols, naphthalene oil, wash oil and pitch.Coal tar in CO
gas is collectedfrom CPH and FGC of benzol recovery is transfer to tar and oil storage.
From there it is pumped to mechanized decanter in tar distillationplant.

Process:
The tar from the condensate pump house is fed to the tar and oil storageof TDP. The tar to the TDS is
fed from the tar and oil storage tanks. This tor contains 5% moisture, whichcan be removed in the
decanters.
. Decanters:
Tar from the TOS is fed to the decanters. It is provided with a scrapper conveyor to remove the
sludge collected at the bottomand transfer to a bunker in the decanter, some quantities of the water
and flushing liquor collects at the top layer which is continuouslyremoved.
The tar from the decanters flows through two strainers to removesuspended matter to a common
suction header of liquor plunger pumps for first stage. A plunger pump consist of three pistons,
suction and delivery valves, which pump with high pressure. Tar initially consists of chloride salts and
acid, whichcauses corrosionand damages the piping present in the furnace and the plant. To prevent
the soda ash solution of 8 % concentration is injected at the suction side of the pump.

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 2NH4CI+ Na2CO3 2NaCl + 2NH,+ CO2 + H20

2HCI + Na2CO3 2NaCl + CO₂+ H20

The ammonia formed from the above reactions vapourizes alongwith water vapour and light oil.

Furnace:
It consists of two zones, one is convection zone and the other is radiation zone. Furnace is having four
burners, where CO gas is used as fuel. Air draught is taken from the bottom of the furnace. The tar
fromthe filter is pumped to convection zone, which is at the top of the furnace. Here the temperature
increases to 120- 130 °C. Controlling the air flow can control the flame length more the air longer the
flame andhelps in controlling the zone.

In radiation zone dehydrated tar is circulated which is pumped from second stage plunger pumps. The
temperature of the tar is increased to 100°C. The temperature of the tar should not increasebeyond 400°C ns this
cause the formation of B.F grade pitch.
The flue gas from the furnace Is sent to the atmosphere throughthe chimney. It is provided with a
baffleplate is order to assure complete combustion of the gas

1st Stage Evaporator:

Evaporator is a cylindrical vessel having baffle plates, which change the direction of gases.
Evaporator isdesigned for the evaporation of water and light oils from the crude tar, which are fed at
the middle of the evaporator. The temperature of the tar at the inlet is about 120-130°c. Due to this
temperature, themoisturein the tar is evaporated. These vapours from the top of the evaporator are fed
to the twin condensed coolers. From the bottom dehydrated tar having less than 2% moisture is fed to
the dehydrator tar tank and pumped to the radiation zone of the furnace.

Pressure in the evaporator 0.3 kg/cm²

Temperature of vapours 102-105°c
Temperature of DTT <110°c
Baffle plates 3
Spilling plates.

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 Dehydrated Tar Tank:
Tar from the evaporator is fed to the DTT tank, which is used asan intermediate storage. The tank is
always maintained 100% and the over flow tar from the DTT is fed to the decanter4. Tar fed to the
DTTtank, which is used as an intermediate storage.
The tank is always maintains 100% and the overflow tarfrom the DTT is fed to the decanter 4. Tar
is fed to second stage tar pump from the bottom of the DDT. The pump discharges this tarto the
radiation zone of the furnace where it is heated up to 300-400°C. This tar is fed to the second stage
evaporator at the rate of 10m’/hr.

II Stage Evaporator:
In second stage evaporator oil vapours and pitch are separated. Dehydrated far from the radiation
zoneis fed to the evaporator. Two baffle plates are arranged below the vapour inlet and five above
the vapour inlet. Four bubble cap trays are arranged at thebottom of the evaporator. This
arrangement completely separates tar fraction from pitch. A protective plate is also installed as in
the first stage evaporator. The oil vapours from the top ofdistillation column. The tar at as pitch and
is supplied to the the evaporator are fed to the theevaporator bottom is calledpitch cooling section.

Pressure in the evaporator 0.5 kg/cm²

Number of baffle plates 7
Temperature of the fractions 40

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 -
Distillation Column:
Fractionating column is designed to separate different
fractions from tar. The column is provided with 59 trays out of which 56 are bubble cap trays and the
remaining 3 baffle plates. Each tray has 42 bubblecaps. Mixed oil vapours from the top of thesecond stage
evaporator are fed to the third tray of the fractionating column at a temperature of 360 380°C.
As the vapours rises to the top of the column different fractions areobtained from different trays.
Initially vapours enter at about 360- 400°C. Pure light oil is supplied as reflux to the top plate
rectificationcolumn to maintain top temperature of the column.
Reflux is fed as the top temperature increases. All the fractions arecontinuously drawn from the column.
The vapours which are not condensed are collected from the top of the column and fed to the twin
condenser cooler of the second stage.

Light Oil:
Light oil is obtained from the column, which is lighter than all of thefractions the top temperatures of the
column are maintained at 100°C. The light oil consists of phenol and phenol containing water
(PWC).The light vapours are cooled in twin condensed coolers and fed to the separator-II. Its uses are it
can be further processed to produce crude tar basis
Can used to prepare pyridine and heavy basis. Light oil can be fractionized to produce small amounts
ofbenzene, toluene, xyleneand heavy solvents naphtha.,

Phenol:
Phenol fraction obtain is not in pure state at 160-180°C it
contains 22% phenol and 10-15% naphthalene.Three tapings are provided on 44.46 and 48 trays. Its uses
are it is mainly used in plastic industry, in thermosetting resins made with formaldehyde, in pesticides
preparation, insecticides and pharmaceuticals, dye stuffs and Caprolactum for fibres.

Naphthalene

Naphthalene fraction can be trapped from 24, 26, 28 and 30 trays. Itis obtained at a temperature of 190-
200°C. Steam jacketed lines areprovided because decreasing temperature results in crystallization of
naphthalene. It is mainly used in manufacturing of thallic anhydride.

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 Wash Oil:
-
There are 5 tapings for wash oil on 12,14,16,18 and 20.Normally wash oil will be tapped at a temperature
of 280-290°C. It is tapped from 6 and 8 trays. Anthracene II is heavier than all fractions. Soit isobtained
from 1” or 2 trays at 320-330°C.

Anthracene:
It is purified to produce pure Anthracene. It is used to produce carbozole and phenanthracine.

Pitch:
Pitch is mainly used in making of Pitch cake, industrial pitches, roadtar and refined.

Tar:
Twin Condensed Coolers & II Stages:
These are shell and tube heat exchangers to condense the vapours.First stage coolers condenses the gas
coming from I stage evaporator and the II stage cooler condenses the gas leaving the column. The
vapours pass through the shell and service water is used to cool the vapour passing through the tube
side. The vapoursof I state cooler are cooled from 102-50°C. The vapours of second stage coolers
from100-40°C.After condensation the vapours from both 1&ll stage condensers enter into separators I
& II respectively.

Separators I & II:

Separators are used to separate light oils from other fractions (NH,water and phenolic water) obtained
from the top of the first stage evaporator and distillation column in separator I & II respectively. Light
oilobtained from the top the two separators flow to light oil
tanks by gravity. At the bottomwill be settled and at the phenolic water will be settled.

Submerged Coolers:
Submerged coolers contain a coil inside the coolers through whichthe fractions from the column are
passed. This coil is submerged inthe water. The vapours are cooled from 80-50°C are sent to the collected
tanks.

Start Up Tank:
During initial starting of the plant, the temperature of the tar does not reach up 400°c in second
stageevaporator will be diverted to start up tank until it reaches the temperature of 290°c similarly
columnbottom liquid
Will also be diverted to start up tank until the temperature of the column reaches to 330°c. Tar
thenoverflows to the decanters.
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 Flow:
-
Tar in first stage 9-10 Nm/hr
Tar in second stage 10 Nm’/hr

Analysis:
Water content in I stage Water content in II stage

tar 5-6%
tar <1

Parameters:
Temperature:
Tar in decanters 75-80° c

Tar after first stage furnace 120-130 degree celcius

Tar after DTT 1000c

Vapours from first stage evaporator 105-1000°

Tar after II stage furnace 380-4000c

Vapours after Il stage evaporator’s 300-3300c

Pitch after Il stage evaporator 330-3500c

Distillation column top temperature 100°c

36 | P a g e
 -

Pressures:

Tar after I stage pump 2.3 kg/cm

Tar after Il stage pump 4.5 kg/cm²
CO gas before furnace >100 mm WC
I Stage evaporator top 0.14-0.5 kg/cm²
I Stage evaporator bottom 0.24-0.25 kg/cm²II Stage
evaporator top 0.35 kg/cm²
II Stage evaporator bottom: 0.4 kg/cm² Distillation
column top. 0.0-4-0.06 kg/em
Distillation column 0.28-0.3 kg/e

Benzol Distillation Plant (BDT):

In BDP the benzolised oil from final absorption is pumped in thestorage tanks of the Benzol
distillation. The BO is then stripped of with steam to get the crude Benzol and DBO. This DBO is
again pumped to Benzol recovery section. Makeup solar all is added. Continuously to compensate
for the losses in the equipment. The BO is initially preheated in three pre-heaters, which are shell
and tube heat exchangers. Pre heating is first done in alt dephlegmators, ill-oil heat exchangers and
finally in steam pre heaters

37 | P a g e
 -
The temperature is slowly decreased in order to preventchemical decomposition of BO.
Thetemperature of the BO fed to the stripping column is about 130- 135°C.

TUBE SIDE SHELL SIDE

Oil dephlegmator Vapours of strippingcolumn
Oil exchangers DDO from strippingcolumn
Steam pre-heaters Medium pressure steam

Stripping Column:
Pre-heated BO from the exchangers is fed to seventeenth tray ofstripping column. The column
consistsof bubble cap trays. Low
pressure (LP) of stream at akg/cm² is injected through column.

Crude benzol in the BO is recovered by steam distillation. Steam distillation is done so that the
partial pressure of the benzol decreases and easily get vapourized. LP steam injectedat the
bottom not only maintains temperature of the column but also decreases the temperature of the
crude benzol. The crude Benzol vapours along with steam from the top of the column are fed to
the oil dephlegmators. The BDO from the bottom in which crude benzol is recovered is
pumped to the decanter through oil-oilheat exchangers.

The crude Benzol vapours are partially condensed in the oil dephlegmaters. The partial
condensation removes any higher fraction present in the vapours which further increases the purity
of the vapours. Three sets of dephlegmators are provided,two sets for oil and one set for water. The
vapours are cooledto 92-95°C in oil dephlegmator by pre heating the feed to strippingcolumn and
further cooled to 84°C inwater dephlegmator. The condensate collected in the heat exchanger is
called ‘PHLEGMA’. The phlegma from the exchangers, which contains water is collected in a
separator. Water is separated and phlegma overflows to the phlegma collecting tank, from which
tank phlegma is sent to stripping column as reflux.

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Regenerator:

The continuous circulation of BDO forms some polymer due to heating and cooling This polymer must
be removed from the BDO by regeneration. Regenerator is a hollow tank in which steam coilsare
arranged. Medium Pressure (MP) steam is circulated through these coils. Part of the stripping column is
fed to the regenerator.
Due to the pressure, CB vapours are collected at the top which inturn to the stripping column. The
bottom liquid from the regenerator is pumped out and stored in crude and finished product storage
(CFPS).

Top Temperature 110-1150c

Bottom Temperature 120-130°C
Number of trays 23

Feed tray 17th tray

Pressure in the column 0.3-0.35kg/cm²

Crude Benzol Column – 1:

The vapours containing crude benzol from the top of the strippingcolumn is fed to the crude benzol
column 1 (CB-1) through water dephlegmator where the crude benzol is separated to heavy crudebenzol
(HCB-used as furnace oil) and light crude benzol (LCB contains fractions of benzene, toluene, xylene).
This column consists of 16 bubble cap trays. Simple distillation is carried out in this column. Are-boiler
column supplies the necessaryheating media.

A CB vapour at a temperature of 80-85°C is fed to the 6-tray of thecolumn. The lighter components
arevaporized and these are collected at the top of the column.

crude Benzol Column – 11:

CB-II consists of 6 bubble cap trays. The bottom product of the CB-1which mainly contains HCB with
small amounts of CB-1 column is fed to CB-Il column. To recover the CB-I the liquid is to be distilled.
TheCB-I vapours obtained from the top of the CB-II is fed to CB-1 column as reflux. The bottom
product obtained from CB-11 is called as HCB.

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 Top Temperature 106°C
Bottom Temperature 110°C

De-benzolised Oil:
The DBO from the bottom of the stripping column is pumped through oil-oil heat exchanger to DBO
cooler. In DBQ cooler, it is cooled to 45- 50°C. Due to high temperature exposure part of thesolar
oilmay get decomposed. This decreases the absorption efficiency of the solar oil. To remove this
decomposed matter of DBO is fed to the decanter. Decanter:
It Is a horizontal cylindrical tank unlike mechanical decanters BDOis fed to decanters at a temperature of
45-50°C. Small amount of
water is fed to the decanter sludge or muck form of oil. carrying sludge with it Oil layer

The residence time in a decanter is 3-4 hrs. Water is continuouslydrained from decanters. Oil after 3-4
hrs is fed to BDO tank. Muckfrom the decanter is drained and sent to the emulsion beaker.
Due to contact of oil, water and muck oil-water emulsions and muck-water emulsions are formed.
Theseemulsions float on the surface of the water, which is fed to emulsion beaker along with themuck.

Emulsion Beaker:
This is a horizontal cylindrical vessel provided with insulation. Medium pressure sicam is fed through a
coil into the beaker. The residence time for settling the oil, muck and water in the beaker is 2hrs. Due
toheating of emulsion, oil and water gets separated which is called as ‘De-Emulsification’. Emulsion
thus formed is broken andmuck will float on water.
This muck is fed to muck tank and water is dmined. The temperatureinside theBeaker is 80-90°C.

Main Saleable Products of CCP:

• Ammonium Sulphate (PUSHKALA).

• Caprolactum grade benzene.
• Drained naphthalene oil.
• Nitrogen grade toluene.
• Heavy crude benzol.
• Medium hard pitch.
• HP Naphthalene.
• Phenol fraction.
• Wash oil

40 | P a g e
Ammonium Sulphate Plant:
Coke oven gas with a pressure of 2500 mm WC from exhauster
is fed to the ASP. Ammonia present inthe CO gas is recovered inASP as ammonium sulphate
fertilizer.

Process:
The CO gas from the exhauster is fed to pre-heater to preheat the gas to 60-70° C. But according to our
atmospheric temperature, thistemperature is obtained after the exhauster. So the gas is directly fed
thesaturator.

Saturator:
Saturator is a cylindrical vessel with conical bottom. It is provided with a bubbler hood, which is duct
prolonged to the middle of the saturator. The duct has a hood at the bottom provided with vanes like
arrangement. Another ring like structure with small openings isprovided at the conical portion, which
isused for nitrogen feeding.
Hot water rings provided at the top of the saturator. Saturator is always maintained with acid bath called
mother liquor, which contained 4-5% of sulphuric acid. The CO gas enters through bubbler hood which
is dipped in the bath. The gas rises through themother liquor.
During this period, the ammonia present in the gas reacts with thesulphuric acid in the liquor
The CO gas enters through bubbler hood which is dipped in the bath. The gas rises through the mother
liquor.

NH3+H2SO4 NH4(HSO4)
NH4(HS04) + NH3 (NH4)2SO4

41 | P a g e
 Ammonium sulphate thus formed settles at the bottom of the saturator. Pure nitrogen is purged into
the saturator through Na rings at 4-5 kg/cm². Na purging increases the crystal growth. Puresulphuric
acid (98%) is fed to the saturator to maintain the acidityin saturator.

Then the hot water is sprayed to the rings provided. The crystals attached to the walls of the saturator are
washed away. When hot water is sprayed the concentration of the liquor decreases After the reaction
mother liquor is continuously drawn to the circulating tank provided at theside of the saturator. This act as
a seal for the saturator from the circulating
Tank, mother liquor is fed to the mother liquor tank. The crystals collected at the bottom are fed to
thecrystal receiver tank by usingpump.

Acid Trap:
The outlet gas of the saturator carries some acid mist .In order to remove the acid mist, the gas is
sentto acid trap .It is a hollow cylindrical vessel The CO gas from saturator enters tangentially tothe
trap. Due to the centrifugal motion, the acid mist gets separated. The acid collected a bottom is fed to
the circulating tank. The CO gas is fed to the Benzol recovery.

Crystal Receiver Tank:

Ammonium slurry from the bottom of the saturator is pumped to thecrystal receiver tank with conical
bottom. The ammonium sulphate crystal settled at the conical portion of the tank, which is wet with liquor.
The mother liquor from the top of the receiver is fed to the saturator. The slurry from the bottomis fed to
the centrifuge.

Centrifuge:
Centrifuge is a horizontal cylindrical structure having two drums inside it. One drum moves with rotary
motion and the other inreciprocating motion.The feed enters at the centre of the rotary drum throughpipe
known as cone pipe Crystals present in the slurryare separated by the centrifugal force of the rum Hot water
is sprayed into the centrifuge to wash of the free acidity that is the acidlayer of the crystal.
The cleaned crystal Is discharged into the outer drum which is reciprocating The reciprocating
drumpushes the material into thedischarge chute.The liquor separated is then sent to the saturator.The
discharge chute of crystals opens onto a conveyor.
Drier:
Through conveyor ammonium sulphate crystals comes to drier Drier is fluidized bed type. The principle
is based on the loose materials property to acquire fluidity in the air flow under a definiteair velocity. The
crystal from the centrifuge contains some amount of moisture. To remove this moisture crystals areto be
dried. The drier is provided with a screen at the bottom, ceramic rings are arranged at the bottom of the
screen. The drier is fan and air, heated in the duct.

42 | P a g e
Forced draught fan sucks the atmospheric air and feeds to the drier. The discharge chute of the fan is divided
into 2 sections. Onefor hot air and the other for cold air. The hot air duct is provided with a steam heater.
The air is heated to 120-150°C by using steamand this hot air is fed from the bottom ofthe screen. The
ceramic rings distribute the air in all directions and allow the crystals in fluidized state. At the discharge end
of the drier, cold air is passed which cools the crystals.

When the pressure level of the fluidized bed reaches the set point (300-400 mm WC) an automatic
discharge feeder discharge the dryammonium sulphate to the bucket elevator. The elevator dischargesthe
dry product into the bunker, which in turn feeds the product to the bagging machine.

Ammonical Columns:
During carbonization of coal ammonia gets vapourized and flows along with flushing liquor in gas
collecting mains, a little amount ofammonia gets absorbed in flushing liquor. The excess ammonium liquor
after separation of tar, containing free and fixed ammonia, phenols, pyridine Base and cyanides,rodents are
pumped to the fourth plate of ammonia column for distillation of free ammonia.
The column consists of 24 bubble cap trays. 4016 of liquor level is maintained in the column. Steam is
injected at the bottom by steamcoils. The purpose of steam isdistillation. As the liquor is the flushing liquor
evolves and to supply the necessary heat for distilled, free ammonia present inrises to the top of the
column.

The distilled liquor from the bottom of the column is fed to pith tank. Certain level flushing liquor is
maintained in the tank and the overflow from the tank is fed to the MBC plant for treatment. The pHof the
flushing liquor of the discharge end of the column should be
7-7.5 and the freeammonia should be less than 50 ppm.

(NH4)2S 2NH3 + H2S

NH4CN NH3 + HCN
(NH4)2CO3 2NH3+CO2+H20
NH4HCO3 NH3 + H2O+ CO2

To remove the some content of fixed ammonia in the liquor, dilate NaOH solution is injected at the inletof
ammonia column. The NaOHreacts with the fixed ammonia compounds and forms as ammonia gas.

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44 | P a g e