2. Indian Steel Industry

3.  8 th largest steel producer in the world  Production of Finished steel in 2005-06, 42.7 mT, a growth of 11%.  Apparent Consumption of Finished Steel in 2005-06 - 38.1 mT, growth of 10.8%. Apparent consumption of Longs - 16.2 mT, Flats - 21.8 mT.  Largest producer of Sponge Iron - 12.8 mT in 2005-06 (a growth of 25%).  India’s exports of Finished Steel in 2005-06, 4.4 mT, Imports 3.7 mT  Huge Iron Ore reserves – 23 bn. tonnes  Private Steel Producers are opting for Forward as well as Backward Integration  Indian Steel Producers are increasingly looking for overseas acquisitions in steel as well as raw materials. Indian Steel Industry – An Overview

4. * Year indicates FY SLOW GROWTH MODEST GROWTH HIGH GROWTH Enabled by India’s Economic liberalization process India gains independence in 1947 6.6 mT in 1973 16.2 mT in 1991 1.25 mT in 1948 41.3 mT in 2005 INDIA’S CRUDE STEEL PRODUCTION (MT)

5.  The fourth integrated steel plant in the public sector conceived in 1959.  Actually started in 1965 with the collaboration of soviet union construction.  Bokaro steel plant was originally incorporated as a limited company in January 1964.  But after the formation of SAIL in 1973, it become a wholly owned subsidiary of SAIL in terms of public sector iron and steel companies (restructuring and miscellaneous provision Act in 1978).  Bokaro steel plant has a reservoir of nearly 34000 employees. INTRODUCTION OF SAIL

6. Company05-06 (MT) SAIL9.15 Tata Steel3.8 RINL3.0 ESSAR3.3 ISPAT2.6 JSWL3.5 OTHERS17.2 Total42.7 Finished Steel Production 2005-06 SAIL in Indian Steel Industries Source - JPC

7.  Blast Furnaces  Raw Materials & Material Handling Plant  Coke Ovens & By-product Plant  Continuous Casting Shop  Steel Melting Shops

8.  Slabbing MillHot Strip Mill  Hot Rolled Coil Finishing  Cold Rolling Mill  Hot Dip Galvanizing Complex  Services - a valuable support network  Maintenance Departments  Auxiliary Shops

9. Sort description of production process Raw Materials & Material Handling Plant  The Raw Materials and Material Handling Plant receives blends, stores and supplies different raw materials to Blast Furnace, Sinter Plant and Refractory Materials Plant. Blast Furnaces  The Blast Furnaces produce molten iron - Hot Metal - for steel making.  Bell-less Top Charging, modernized double Cast Houses, Coal Dust Injection and Cast House Slag Granulation technologies have been deployed in the furnaces.  The process of iron-making is automated, using PLC Charging System and Computer Controlled Supervision System.

10. Steel Melting Shops  Hot Metal from the Blast Furnaces is converted into steel by blowing 99.5% pure Oxygen through it in the LD converter. Suitable alloying elements are added to produce different grades of steel. Continuous Casting Shop  The Continuous Casting Shop has two double-strand slab casting machines, producing high quality slabs of width ranging from 950 mm to 1850 mm.  CCS has a Ladle Furnace and a Ladle Rinsing Station for secondary refining of the steel.  The Ladle Furnace is used for homogenizing the chemistry and temperature. Slabbing Mill  Slabbing Mill transforms ingots into slabs by rolling them in its 1250 mm Universal Four-High Mill.

11. Hot Strip Mill  The mill is equipped with state-of-the-art automation and controls, using advanced systems for process optimization with on-line real time computer control, PLCs and technological control systems. Hot Rolled Coil Finishing  All the Hot Rolled coils from the Hot Strip Mill are received in HRCF for further distribution or dispatch. Cold Rolling Mill  Cold rolling is done to produce thinner gauge strips of very smooth and dense finish, with better mechanical properties than hot rolling strips. Hot Dip Galvanizing Complex  The Hot Dip Galvanizing Complex integrated with the CRM produces zinc-coated Cold Rolled strips resistant to atmospheric, liquid and soil corrosion.

12.  In power circuits  In automatic control on production level  For speed control of motor’s used  In communication channel (telephonic line) Use of e lectronics in a steel industry

13.  Programmable logic unit  Circuit relays  Programmable miniacher circuit breaker

14. plc  The development of low cost computer has brought the most recent revolution, the Programmable Logic Controller (PLC). PLCs have been on the factory floor because of the advantages they offer.  Cost effective for controlling complex systems.  Flexible and can be reapplied to control other systems quickly and easily.  Computational abilities allow more sophisticated control.  Trouble shooting aids make programming easier and reduce downtime.  Reliable components make these likely to operate for years before failure. Discharge line controller

15. Programmable logic unit  The development of low cost computer has brought the most recent revolution, the Programmable Logic Controller (PLC). PLCs have been on the factory floor because of the advantages they offer.  Cost effective for controlling complex systems.  Flexible and can be reapplied to control other systems quickly and easily.  Computational abilities allow more sophisticated control.  Trouble shooting aids make programming easier and reduce downtime.  Reliable components make these likely to operate for years before failure.

16. Circuit relays  Relay is used to control a high-power load when a low-power control circuit is used.  It keep high voltage away from the user's switch, for instance.  It allows circuitry to automatically shut down the motor or circuit if it stalls, overheats, etc.

17. Programmable miniacher circuit breaker It is a miniacher circuit breaker which is used to cut the supply voltage when  Voltage is high  Current is high

18.  Temperature control  Pressure control  Level control  Flow control

19. Temperature control  To detect the temperature in steel industry we use thermocouple.  A logic device witch is full controllable with a specified written program is used to control it.

20. Pressure control

22. Level control

23. Flow control

24. For speed control of motor’s used

25. In Communication Channel (Telephonic Line) In Communication Channel (Telephonic Line)

27. Programmable logic unit  The development of low cost computer has brought the most recent revolution, the Programmable Logic Controller (PLC). PLCs have been on the factory floor because of the advantages they offer.  Cost effective for controlling complex systems.  Flexible and can be reapplied to control other systems quickly and easily.  Computational abilities allow more sophisticated control.  Trouble shooting aids make programming easier and reduce downtime.  Reliable components make these likely to operate for years before failure.

28. The Separation of Controller and Process  When a process is controlled by a PLC it uses inputs from sensors to make decisions and update outputs to drive actuators, as shown in Figure.  The control loop is a continuous cycle of the PLC reading inputs, solving the ladder logic, and then changing the outputs. Like any computer  this does not happen instantly.

29. Programmable logic unit plc  The development of low cost computer has brought the most recent revolution, the Programmable Logic Controller (PLC). PLCs have been on the factory floor because of the advantages they offer.  Cost effective for controlling complex systems.  Flexible and can be reapplied to control other systems quickly and easily.  Computational abilities allow more sophisticated control.  Trouble shooting aids make programming easier and reduce downtime.  Reliable components make these likely to operate for years before failure.