ISSUE #1
JSW STEEL DOLVI RMHS
ADVAITAM QUARTERLY VOLUME
RMHS Newsletter February 2025
Content: Note from editors
Dear Colleagues,
Message from
Leader’s Desk We are pleased to present the very first edition of the
...............................................2 RMHS Newsletter! This marks an exciting new step for
the Raw Materials Handling & Services (RMHS)
department at JSW Steel Dolvi, and we are thrilled to
share this inaugural issue with you.
RMHS at Glance .......3 In this edition, we aim to highlight the achievements,
updates, and key initiatives within our department.
From operational milestones and safety practices to
team successes and upcoming projects, we hope this
newsletter serves as a valuable resource for keeping
Journey of RMHS .........5
everyone informed and connected within the RMHS
family.
Our vision is to create a platform that fosters
communication, celebrates the hard work of our teams,
Significant and shares the collective efforts that contribute to the
Achievements ..........7 growth and success of the department. We look
forward to your feedback and contributions as we
continue to build this publication.
We extend our heartiest gratitude to senior leadership
Improving flowability
of JSW Dolvi & JSW Group for their valuable guidance
of Raw material and continual support.
during Monsoon ......8 Thank you for being a part of this exciting journey!
We hope you enjoy this first edition, and we look
The Journey of forward to bringing you more in the future!
Conveyor Systems in
the Steel Industry Best regards,
.............................................10
The RMHS Newsletter Editorial Team
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From our Leader’s Desk
I am excited to welcome you to the first edition of Through this newsletter, we aim to highlight key
our department’s newsletter. As we begin this new developments, celebrate our collective
initiative, our goal is to keep you informed, achievements, share best practices, and foster a
engaged, and connected to the ongoing deeper sense of community among all the team
advancements and achievements within the Raw members. Every individual in our department
Materials Handling System at JSW Steel. contributes to the success of our operations, and
Our department plays a critical role in ensuring the it is important that we recognize both the hard
smooth and efficient transportation, storage, and work and the passion that drives us toward
handling of raw materials that are the foundation excellence.
of our steel production process. With the I urge each of you to actively engage with the
continued growth of JSW Steel, we face both journey, share your feedback, and contribute
challenges and exciting opportunities to innovate, ideas that will help us grow and thrive together.
improve efficiency, and sustain our operations at Let’s continue to strengthen our systems and
the highest standards and value addition by ensure we remain at the forefront of the steel
enhancing quality improvements. industry.
Warm regards,
Vurity Sai Babu
HoD-RMHS O&M (VP)
JSW Steel Limited, Dolvi Works
From the desk of Cluster Head, Agglomeration:
It gives me an immense pleasure to welcome you This newsletter will serve as a vital platform for
to the first issue of the RMHS newsletter. This sharing updates, recognizing achievements, and
initiative is a testament to our ongoing reinforcing our collective drive towards
commitment to fostering open communication excellence.
and strengthening collaboration within our
department. I look forward to seeing how this platform
evolves and continues to unite us in our shared
We all know that the Raw Material Handling mission.
System is the backbone of our operations at JSW
Steel Dolvi. The importance of our work cannot be Together, let’s continue to achieve new heights
overstated, and the challenges we navigate daily and shape the future of JSW steel dolvi with
are part of what makes our team exceptional! pride and determination.
Best Regards,
Manoj Kumar Agrawal
Cluster Head-Agglomeration (SVP)
JSW Steel Limited, Dolvi Works
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RMHS AT GLANCE
The Raw Material Handling System termed RMHS caters to Raw Material Handling in
the tune of 40 MTPA to meet the requirements of various internal customers of JSW
Dolvi unit. The internal customers are mainly BF1, BF2, SIP, Pellet-1, Pellet-2, SP-1&2,
COP-1&2 and LCP-1,2,3,4 & LCP-5,6,7, CIP 1 &2. RMHS is spread over the area across
0.38 sq.Km consists of bulk raw material handling equipment and a conveyor
system.
Material Handling
Qty(Tentative) : Receipt -
88000MT/DAY(By sea &
Road) and Dispatch -
115000MT/DAY(including
product and by products)
Area of RMHS at Dolvi -
275232 Sq. M. (68 Acres)
Yard Capacities:
3
Facilities:
Process Overview:
4
JOURNEY OF Capacity Enhancement
through:
RMHS Commissioning of
BWSR-3 at SIP Yard.
2024 Strengthening of C-
131/131A conveyor
gallery
RMHS expansion work.
O&F yard
2023 mechanization &
commissioning of
covered shed
Coal covered shed Inside
2022 Plant
O&F yard mechanization
2021 Mechanized Feeding for 10
MTPA
Jetty Covered(IBRM) shed for
2.5 Lakh MT
RMHS O&M
2019 Implementation(TKII)
Fifth C/C conveyor commissioned
2018 Commissioning of BWSR-4(Coal)
Covered shed at Jetty(coal) with 1.1 lakh tons
2017 Storage & one BWSR commissioned
Third C/C conveyor commissioned
2016 Debottlenecking of RMHS
RM handling facilities for SP-2 commissioned
RM handling facilities for LCP3, COP-1 & PP-1
2013-14
1.2 Lakhs tons IOF storage yard & BWSR for PP-1
2005 RM handling facilities for SP-1 commissioned
2000
2000 RM handling facilities for BF-1, LCP-1&2 commissioned
1994 RM handling facilities for SIP commissioned with one BWSR
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RMHS PHASE III EXPANSION PROJECT
RMHS PH III expansion project from 10 MTPA to 15 MTPA has been initiated at Dolvi. The raw
material required for an additional 15 MTPA will be to the tune of 35000T/day. To cater to
additional raw material requirements, JSW Steel has planned for vertical storage facilities in
place of conventional yards due to the limited space availability viz. land.
The concept of raw material storage in vertical silos with mechanized arrangement for uniform
stacking as well as reclaiming of RM which is a proven design across the globe is now adopted
in JSW, Dolvi for the first time in India which will be the benchmark for other steel industries.
Following are the details of facilities for additional 5MTPA expansion:
Pellet Storage : Two Silos of 80,000 MT Each (Non-mechanized)
Coal Storage : Two Silos of 40,000 MT Each (Mechanized)
Flux Storage : One Silo of 52,000 MT (Mechanized)
Pellet Screens : 4 Nos screens of 1000 TPH each capacity (3 working + 1 standby)
Conveyor :
Plant Area: Pipe conveyors in two-tier configuration (2 No x 1KM each) + 67 No.
Trough conveyors
Jetty Area: Pipe conveyors (3 No x 750M each) + 68 No. Trough conveyors
SILO DETAILS
•Screening facility along-with DE systems for screening of purchase pellet is planned at jetty
to feed screened pellet to BF3 and to address the environmental issues
•Mechanized silos for Flux and Coal have been planned to have smooth flow of material.
SILO Infeed Process
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Significant Achievements of RMHS
PP2C1 ,GUBC-31,32&33, PPRC-1, TTF4RC1&2,OFJ6RC-1&2,
TTF16ARC-1&2- AVERAGE LIFE IMPROVED BY 100% IN
RESPECTIVE OF OLD LIFE
SUCCESSFULLY COMPLETION OF SPILLAGE CONTROL 580
POINTS AT VARIOUS CONVEYORS
SIGNIFICANT IMPROVEMENT SPILLAGE CONTROL
THROUGH CLIT AT JH-21,TTF-8,TTF-4,JH-J6&TTF-2
CANOPY PROVISION AT ALL BUCKET WHEEL MACHINE AT
INSIDE YARD EQUIPMENT
SIGNIFICANT IMPROVEMENT SPILLAGE CONTROL AT 06
CROSS COUNTRY CONVEYORS
Take-up Modification in last Month
Problem Benefits
Tilting of take up unit resulting following impact 1.Zero breakdown due to take up pulley tilting
•Stoppage of belt 2.Reduce maintenance time for take up pulley
•Damage of conveyor belt related jobs.
•Feeding of flux, pellet and fines hampered. 3.Ease in pulley related maintenance and
•Approx 12 to 15 hours required each time to inspection work.
resume the system for operation.
•Maintenance and inspection for take up pulley
takes 08 hrs shutdown.
Solution implemented
1.Relocation of take up guide pipe
2.Take up pulley design change and fixed with
counter weight itself.
3.Fixing of greasing hose to plummer block for
lubrication.
BEFORE AFTER
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Take-up Modification: Changes in Design
STANDARDIZE
Significant achievement during last monsoon by Improving
flowability of Raw material through Chemical Dosing
At JSW Dolvi, Raigad, Maharashtra, the Monsoon In FY23, rainfall was 3324 MM & ib FY24 it was
is a challenging period. More than 3500 MM 3556 MM, Moisture% in the raw material varied
rainfall is reported in this area. Even rainfall from 8 to 15 % .
continues for days together without any To mitigate the issue of jamming and to have
interruptions. This results in disruptions in flow of better flow of material, Flow aid chemical dosing
material thereby causing jamming of transfer has been implemented in Iron Ore Fines and
chutes & grizzly and choking of bunkers. On the Coking coal.
other hand, as materials get wet heavily and turn After satisfactory results, in current financial year
into slurry, bunker splashing occurs which is we are continuing the dosing process.
highly dangerous and puts the persons working
nearby into an unsafe condition. Equipment and Like above, for handling the raw materials at
process get affected badly. Most affected plants 3500 MM rainfall with Moisture% varying from 8
during monsoon are Pellet Plants, Sinter Plants, to 15% and to sustain the production level during
Coke Ovens which ultimately affects Hot Metal monsoon period in this FY24, addition of Flow aid
production in Blast Furnaces. shall be carried out in a more effective manner.
Unloading of MBCs and Barges at Jetty get
affected due to frequent jamming of chutes.
Thus, the TAT of the barges increases and high
demurrage is incurred in the Mother Vessel.
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More achievements:
4 GOLD AWARD
BELT LIFE
WINNER AT CCQC
IMPROVEMENT MUMBAI CHAPTER IN
FROM 40 TO 02 QCC, 01 QIP & 01
55.13% JH CATEGORY
5 EQUIPMENTS
SECURED GOLD
IN DEPARTMENT
WISE CLIT
COMPETITION
FRESH EMPLOYEES FROM
O & M contract with TKIL DIFFERENT CORNERS OF
successfully implemented INDIA HAVE BEEN
& executed, same is RECRUITED & DEPLOYED TO
further continued for next CONTINUE THE JOURNEY OF
5 years. RMHS THROUGH LEARNING
& INNOVATION .
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The Journey of Conveyor
Systems in the Steel Industry: DID YOU
Advancements and
Challenges
KNOW ?
Conveyor systems have played a pivotal
role in shaping the efficiency and
productivity of the steel industry, evolving
from basic mechanical systems to
advanced, automated solutions. These
systems have been crucial in the
handling, transportation, and processing
of raw materials and finished products, Technological
contributing to the massive scale and Advancements: Automated
operational efficiency of steel production.
However, their journey has been and High-Capacity Systems
accompanied by numerous challenges,
including technological hurdles, As the steel industry became more
maintenance issues, and operational mechanized and industrialized in the
demands. This article explores the 20th century, conveyor systems
historical development of conveyor underwent significant technological
systems in the steel industry, their current advancements. Key innovations
state, and the challenges they continue to included the introduction of electric-
face. powered motors, more durable belt
materials, and automated control
systems that allowed conveyors to run
continuously without human
intervention. These developments were
Early Days: The Birth of especially important as steel production
Conveyor Systems in Steel processes, such as continuous casting
and rolling, demanded more efficient
Manufacturing and reliable transportation of hot
materials, scrap metal, and finished
The use of conveyor systems in products.
industrial settings dates back to the late The shift towards automation and high-
19th century, with the steel industry capacity conveyors coincided with the
being one of the earliest adopters. The trend toward large, integrated steel
first conveyor systems were simple, plants where raw materials,
gravity-fed tracks used for transporting intermediates, and final products
raw materials like iron ore, coal, and moved through multiple stages of
limestone to blast furnaces. These production. At these facilities, conveyors
systems were relatively low-tech, became essential for handling
relying on manual labor or basic everything from the movement of
mechanical assistance to move molten metal to the final dispatch of
materials from one location to another. steel products. Furthermore,
As the steel industry grew, the need for advancements in conveyor belt
more efficient material handling materials, such as heat-resistant
solutions became apparent. The compounds and anti-abrasive coatings,
expansion of steel mills led to an made it possible to transport hot, heavy,
increasing demand for better logistics and abrasive materials safely and
to handle the high volumes of materials efficiently.
being processed, as well as to improve
the safety and efficiency of labor.
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4. Environmental Impact and Energy
Challenges Facing Efficiency
Steel production is energy-intensive,
Conveyor Systems in Steel and conveyor systems are no exception.
Manufacturing The need for energy-efficient conveyor
solutions has become more
pronounced, particularly with the
growing emphasis on sustainability in
While conveyor systems have undeniably
the steel industry. Finding ways to
revolutionized the steel industry, they still
reduce energy consumption while
face numerous challenges that impact
maintaining throughput and
operational efficiency, safety, and cost-
minimizing environmental impact
effectiveness. Some of the key challenges
remains a significant challenge.
include:
5. Maintenance and Downtime
1. Wear and Tear
Regular maintenance is critical to
Given the harsh conditions of steel
keeping conveyor systems running
production, including high temperatures,
smoothly, but it can be costly and time-
corrosive substances, and heavy loads,
consuming. Predictive maintenance
conveyor systems are subject to frequent
technologies have improved this
wear and tear. The belts, pulleys, and
aspect, but the complexity of modern
rollers often experience significant
conveyor systems means that any
degradation, requiring frequent
downtime can still lead to substantial
maintenance or replacement. In high-
production delays and lost revenue.
volume production environments, this
Planning and executing effective
downtime can have significant financial
maintenance schedules are essential to
implications.
keeping operations running at peak
2. Safety Concerns
efficiency.
Steel plants are inherently hazardous
environments, and conveyor systems can
pose safety risks to workers. Moving
materials, heavy loads, and high
temperatures make it essential to ensure
that the conveyors are properly shielded,
and operators are trained to deal with References:
emergency situations. Advanced safety
features, such as automatic shut-offs,
Schraufnagel, R. (2019). "The Evolution of
emergency stops, and real-time
Conveyor Systems in Industrial Settings."
monitoring, are crucial to mitigate these Journal of Industrial Engineering, 32(4),
risks. 127-134.
3. Integration with Modern Kumar, V., & Patel, A. (2020). "Advances in
Technologies Conveyor Technology for the Steel
As the steel industry integrates more Industry." International Journal of
modern technologies such as artificial Manufacturing Technology, 48(5), 545-
557.
intelligence, big data, and robotics,
Miller, S., & Green, J. (2021). "Automated
conveyor systems must evolve to
Systems in Steel Manufacturing: A Case
integrate smoothly with these Study of Conveyor Integration." Steel
technologies. This can be a complicated Technology Review, 19(3), 42-49.
and costly process, requiring the Jones, L., & Taha, S. (2022). "Predictive
development of new interfaces, systems, Maintenance and IoT in Conveyor
and data-sharing protocols. Ensuring Systems." Industrial Automation Today,
seamless communication between 14(7), 88-95.
American Institute of Steel Construction
conveyors and other automated
(AISC). (2023). "Steel Production and
equipment can be challenging but is
Automation Trends." AISC Journal, 30(1),
necessary for the future of smart steel 72-80.
manufacturing.
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HIGHLIGHTS:
DATE: 15/02/2025
MASS COMMUNICATION ON SAFETY
THE RMHS NEWSLETTER EDITORIAL TEAM
Mr. Madan Mukherjee
Ms. Vedashree Patil
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