•Aaditya Chandrawanshi(16121001) 4th Sem

Submitted by: Mining Engg.

•Varad Jagam (16121906) 4th Sem Mining Engg.

Department of Mining Engineering

Topic- Minerals and Raw Materials used in Bhilai

Steel Plant(SAIL) and their sources.
ACKNOWLEDGEMENTS
The plenary culmination of this assignment would have been impossible with
pertinent and felicitous support of following people. We would firstly like to
thank our esteemed teacher and mentor Dr. D.C Jharia whose perpetual and
inquisitive support was imperative in making this project possible. We would
like to thank our family members for their enduring support. We would like to
extend a thank of sincerity to all those imbibing B.S.P. employees for their
inquisitive interactions. We would also like to thank our respective Father, with
a special mention, for providing an inside picture of functioning of the plant.
Thank you for all your support…

Contents
 Bhilai Steel Plant
 Raw Material Handling Plant
 Coke Ovens
 Sinter Plants
 Blast Furnace
 Different Sources of Raw Materials in Blast Furnace
 Mines and Quarries
Bhilai Steel Plant
 Eleven times winner of Prime Minister's Trophy for Best Integrated Steel Plant in the country,
Bhilai Steel Plant (BSP) is India's sole producer & supplier of world class rails for Indian
Railways including 260 metre long rails, and a major producer of large variety of wide and
heavy steel plates and structural steel. With an annual production capacity of 3.153 MT of
saleable steel, the plant also specializes in other products such as wire rods and merchant
products. The entire range of TMT products (Bars & Rods) produced by the Plant is of
earthquake-resistant grade and superior quality. The plant also produces heavy structural's
including channels and beams.

Raw Material Handling Plant

 It is starting point of an integrated steel plant, where all kinds of raw materials ( Except coal)
required for iron making/steel making are handled in a systematic manner, e.g., unloading.
Ore Bedding and tacking, screening, crushing, bedding, blending, reclamation, etc.
 Different Raw materials (with sources)

 Iron Ore Fines:

Iron Ore Fines is the base material for base mix preparation. Nearly 79-80% 10F is used in
base mix preparation. Fe content in IOF is around 62-64%.
 Flux:
Flux is a mixture of Lime Stone and Dolomite in certain proportion required in sinter making.
Flux acts as a binder in sinter making to increase the sinter strength. Nearly 12-16% flux
used in base mix preparation.
 Coke Breeze:
Coke for base mix preparation is received from Coke Ovens and Blast Furnace, called mixed
breeze coke. The size fraction (+ 12.5 mm.) is screened out and sent along with sinter to
blast furnace as a nut coke.

Coke Ovens
All coals are not coking coals, i.e. all types of coal can't be used for coke making. Coking
coals are classified as:-
 Prime Coking Coal (PCC)
 Medium Coking Coal (MCC)
 These are generally known as Indigenous coal, i.e., available in India. In addition to
the above coking coal the following types of coal are also used for coke making in all
SAIL plants
 Imported Coking Coal (ICC)-Hard
 Soft Coking Coal (SCC)
The different sources of coal are named after the respective washeries and are as
follows:
 PCC
 Bhojudih
 Sudamdih
 Munidih
 Patherdih
 Dugda
 Mahuda
 MCC
 Kathra
 Swang
 Rajrappa

Sinter Plant
 Sinter plants agglomerate iron ore fines with other fine materials at high
temperature, such that constituent materials fuse together to make a single porous
mass without much change in chemical properties of each ingredient.
 A large quantity of fines is generated in the mines which cannot be charged directly
into the Blast furnace. In order to consume this otherwise waste fine material, they
are mixed with Iron ore fines and agglomerated into lumps by a process known as
SINTERING
Following Approximate charge proportion will be required to make one ton of sinter (Wet
basis):-
 Ore fines- 750-800 kg
 Lime stone- 86 kg
 Dolomite- 83 kg
  Sinter return : 30 to 40 % (BF sinter return +In plant sinter return)
 Coke- 78 kg
 B.O.F. Sludge- 02 kg
 B.O.F. Slag- 20 Kg
 Burnt Lime- 04 to16 kg
 Millscale + fines- 16Kg
Note- All above mentioned data varies in different plants under SAIL unit

Blast Furnaces
 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 atmosphere.

Raw Materials
The following raw materials used for the production of pig iron:
 Iron ore:
Iron bearing materials; provides iron to the hot metal. Iron ores is available in the form of
oxides, sulphides, and carbonate, the oxide form known as hematite (red in colour) is mostly
used in SAIL plants.
 Limestone / LD Slag:
Acts as flux. Helps in reducing the melting point of gangue present in the iron bearing
material and combines effectively with acidic impurities to form slag making.
 Quartzite:
It acts as an additive.
 Manganese
Manganese ore is available in the form of combined oxides of Mn and Fe and usual content
of Mn is about 28-32 % for steel plant use.
  Coke:
It acts as a reductant and fuel.
 Sinter:
It is iron bearing material. Fines that are generated in the plant/mines are effectively utilized
by converting them to sinter. It provides the extra lime required for the iron ore and coke
ash that is charged in the blast furnace.
 Scrap (Steel / Iron):
Scrap is generated in the process of product making in a steel plant which is gainfully
utilized by back charging in the Blast Furnaces.
 Pellets:
There is a proposal to utilize the micro-fines which cannot be used for sinter making can be
used for pellet manufacturing and the pellets formed will be charged in the BF.
 Coal dust Injection:
It acts as an auxiliary fuel, reduces coke consumption in the blast Furnaces. The coal is
injected through the tuyeres
 Coal tar Injection:
It acts as an auxiliary fuel, reduces coke consumption in the BF. The tar is injected through
the tuyeres.

Different Sources of Raw Materials in Blast

Furnace

S. No Raw Material Source

Dalli
1 Iron Ore Rajhara
Raoghat
 Nandini
2 Limestone
Katni

3 Dolomite Hirri

4 Mn- ore MOL

Mines and Quarries

 Iron Ore Group of Mines
There are five working mines in IOC Dalli Rajhara. The first five of the following table.

S. no Name of Mine Reserve(M.T.) Fe % SiO2 Al2O2

1 Rajhara Mech. 30.76 67.31 1.76 0.84

2 Dalli Mech. 28.36 64.09 4.38 2.26

3 Jharandalli 7.73 63.44 4.36 1.90

4 Dalli Manual 3.10 62.33 4.70 2.61

5 Mahamaya 3.18 62.00 5.00 2.90

6 Dulki 8.52 63.57 3.60 2.76

Total 81.65 64.88 3.48 1.83

  RAJHARA MECHANISED MINE:
This mine was commissioned in 1960 as a fully mechanized mine with a capacity of 2.8 MT
per year. The hanging wall side of mine consists of shales and phyllites, and the foot wall
side consists of banded haematite quartzite (BHQ) which is the host rock of iron ore. The
high grade ore from this mine is used to improve quality of ore from Jharandalli and
Mahamaya Mines, by blending.

 DALLI MECHANISED MINE:

o This mine consists of Konde-A and Konde-B blocks.
o Working is similar to Rajhara Mechanised Mine with 150 mm dia drills,
4.6/5.5 cu.m. shovel and 50 T dumpers.
o Ore at Dalli has lower Fe content and high alumina, and thus requires
beneficiation by wet processing by two stage crushing, wet screening,
scrubbing and classification to produce lump (10-40 mm) and fines (10 mm).
o This mine is a ISO 14001 certified mine.

 JHARANDALLI MECHANISED MINE:

This is a mine working with 1.2/1.5 cu.m. hydraulic shovel and 10 T tippers. Ore from
Jharandalli is fed to Rajhara Bunker and upgraded by high quality ore from Rajhara.

 DALLI MANUAL MINE

o This is a manual mine worked by DPR worker's excavate ore from 6 meter
benches and separately stack the 8 to 250mm size ore, generated fines,
waste, etc.
o Loading and Transportation of ore/waste is done by contractual mechanized
means. The sorted ore is fed exclusively to Dalli Plant.

 Flux Group of Mines

There are two working mines producing Limestone and Dolomite.

S. no Name of Mine Reserve(M.T.) CaO % MgO %

1 Nandini (Limestone) 104.86 41.84 6.22

2 Hirri (Dolomite) 20.07 30.93 20.67

 NANDINI Mines :
o Nandini mine is producing limestone (1.0 MT annually) which is used to
remove silica and alumina contents as slag during iron and steel making.
o It is a mechanized open cast mine being operated by Shovel and Dumpers
and Shovel-Tipper combination.
o To make the blocks ready for blasting and excavation, primary drilling of 150
mm dia is done.
o The blasting is carried out mainly by large dia slurry explosives Secondary
drilling and blasting is resorted to. to reduce the oversize boulders.
 HIRRI:
o This mine is situated at the North- East extremity of Chatona Dhaurabhata
Dolomite belt in Bilaspur district of Chhattisgarh at a distance of 140 Km from
Bhilai.
o Working is done using 1.5 Cu. M excavators, 10 ton tippers and 105mm dia
drills.
o The excavated ore is processed to produce
 SP grade (0-60mm) and
 SMS grade (10-25mm).

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