Coke Oven Plant
The manufacturing process used in the plant is Eco-Friendly Stamp Charged process of CFRI. The stamp charging technology basically involves formation of a stable coal cake with finely crushed coal (85-90% - 3mm) by mechanically stamping outside the oven and pushing the cake thus formed inside the oven for carbonization. Coal moisture is maintained at 8-10% for the formation of cake. Due to stamping, bulk density of charge increases by 30-35% causing significant improvement in mecum indices and CSR values of coke. Oven productivity increases by 10-12%.
Direct-Reduced Iron (DRI) Plant
The primary function of this plant is to produce DRI from iron ore in a rotary kiln. 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.
In the process of production of sponge iron, the raw materials (iron ore, feel coal and lime stone /dolomite) are fed to the rotary kiln through feed tube in a pre-determined ratio. Due to inclination and rotary motion of the kiln the material moves from the feed end of the kiln to the discharge end. The fine coal is blown counter currently from the discharge end of the kiln to maintain the required temperature and the carbon concentration in the bed. Air is blown in the zones to maintain the required temperature profile. The material and the hot gases move in the counter current direction, and as a result iron ore gets pre-heated, and reduces gradually by the time it reaches the discharge end.
Sinter Plant - engaged in delivering sinter product by agglomerating the finer particles of iron ore to a porous mass by incipient fusion within the mass itself. It is the function of the sintering plant to process fine grain raw material into coarse grained iron ore sinter for charging the blast furnace.
Meticulously prepared mixtures are created consisting of fine ore, concentrates, extras, and under sizes arising from screening lumpy burden components at the blast furnace. Ferriferous fine grain discharged from the production chain of the entire steel works are also put into the mixtures. By igniting suitable fuel, iron ore sinter is produced by down draft process.
Mini Blast Furnace (MBF)
MBF has a working volume of 250 cum and produces about 700 tons liquid hot metal per day for steel making and casting pigs in pig casting machine.
The purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called "hot metal". The blast furnace is a huge, steel stack lined with refractory brick, where iron ore, coke and limestone are dumped into the top, and preheated air is blown into the bottom. The raw materials require 6 to 8 hours to descend to the bottom of the furnace where they become the final product of liquid slag and liquid iron. These liquid products are drained from the furnace at regular intervals. The hot air that was blown into the bottom of the furnace ascends to the top in 6 to 8 seconds after going through numerous chemical reactions.
Lump iron ore along with coke and fluxes like limestone, dolomite, manganese ore and quartzite will be charged in the mini blast furnace, to produce liquid pig iron, commonly known as hot metal. Liquid slag generated in the process will be granulated by high-pressure jet of water to make it usable for cement manufacturing.
MBF is provided with full-fledged instrumentation and control system distributed both locally and in the MBF control room, supported by automation back up.
Pig Casting Machine
Purpose of this machine is to cast hot metal into pigs.
Steel Melting Shop
- Electric Arc Furnace
- Ladle Furnace
- Vacuum Degassing
- Billet caster
- Reheating Furnace
- Rolling Mill
- Bar & Section Mill
- Finishing Facilities
Hot Blast Stoves
State-of-the-art Central Testing Lab
State-of-the-art Control Room
60 MW Captive Power Plant
A Mini Cement Plant