RINL

Rashtriya Ispat Nigam Limited (RINL) - a Navratna

Public Sector Enterprise (PSE) with 100% ownership of
GoI, is the corporate entity of Visakhapatnam Steel Plant
(VSP) - India’s first shore based integrated steel plant,
located at Visakhapatnam, which is now in the midst of
commissioning the 6.3 Mt expansion stage, in line with
its Mission of expanding to 20Mt.
A pioneer in the steel industry in adoption of system
standards, VSP is accredited for all three system standards
i.e. ISO 9001:2008, ISO 14001:2004 and OHSAS
18001:2007 and is the first Indian steel plant to be certified
with “Capability Maturity Model Integrated (CMMI) –
Level 3 certification for its implementation of IT systems
and the first PSE to be certified for BS EN 16001 for
Energy Management system in 2010-11.
Process Flow Chart
S.
No Department Facilities & technological features Capacity

4 coke oven batteries of 67 ovens each,

1 Coke oven of height 7m, with 100% dry quenching 2.66 Mt of blast furnace coke
2 sinter machines with 312 Sq.m grate
2 Sinter plant area 5.256 Mt of gross sinter
2 nos. 3200 Cu.m blast furnaces with bell
less top equipment and cast house slag
3 Blast Furnace granulation 3.4 Mt of hot metal

3 nos. 133 Cu.m LD converter with 6 nos. 3.0 Mt Liquid Steel 2.82 Mt Cast
4 Steel Melting Shop 4 strand bloom casters Bloom
7 strands continuous Billet Mill and 22
Light and Medium stands 2 strand continuous Bar Mill with 1.857 Mt billets 0.710 Mt Bar
5 Merchant Mill “Tempcore” technology for Rebar rolling products

4 strand 25 stands continuous mill with

6 Wire Rod Mill “Stelmor” cooling 0.850 Mt Wire rods

Medium Merchant & 0.850 Mt Medium structural

7 Structural Mill 20 strands continuous mill products
SL ZONE FACILITIES/ BRIEF SPECN. CAPACITY
NO
1 Raw Material Handling Augmentation of Ore handling and
Plant Coal handling Plant
2 Sinter Machine no.3 408 Sq.m. grate area 3.61Mt / Yr
3 Blast Furnace No.3 3800 Cu.m. useful volume with 2.5 Mt / yr hot metal
Pulverized coal injection
4 Steel Melt Shop-II 2 nos Converters of 150 t each 2.8 Mt / yr Liquid Steel
2 nos Billet Casters
1 no Round Caster
1 no Vaccum degasser(RH)
2 nos Ladle Furnace
5 Rolling Mills
i. Wire Rod Mill-2 i. 5.5 mm to 20 mm in coils i. 600,000 t/yr
ii. Special Bar Mill ii. 16 to 40 mm in coils & ii. 750,000 t/yr
straight lengths ( Stage-II)
iii. Structural Mill iii. As per market demand iii. 700,000 t/yr
( Stage-II)
6 Calcining & Refractory Two (2) Shaft Kilns 500 t/ day each
Material Plant
 Systems Certification
First Integrated steel plant to be certified for all the four system standards
which have been continuously upgraded over the years
First Certification Validity

ISO 9002: 1994 Oct. 1994 (one unit)

Sep 2014
Quality
ISO 9001: 2008 May 2000 (Entire plant)

ISO 14001: 1996 Aug 2013

Environment May 2001
ISO 14001: 2004

OHSAS 18001: 1999

Dec 2013
Health & Safety Jan 2002
OHSAS 18001: 2007

Information Waiting for

CMMI Level III Sep 2009 Reappraisal
Technology
ISO 50001:2011 Energy Dec 2010 Sep 2013
Management
 Raw Material Handling Plant (RMHP)
VSP Annually requires quality raw materials viz. Iron
Ore, fluxes (Lime stone, Dolomite), coking and non
coking coals etc., to the tune of 12-13 million tones for
producing 3 million tones of Liquid Steel. To handle such
a large volume of incoming raw materials received from
different sources and to ensure timely supply of
consistent quality of feed materials to different VSP
consumers, Raw Materials Handling Plant serves a vital
function. This unit is provided with elaborate unloading,
blending, stacking and reclaiming facilities viz. Wagon
Tipplers, Ground and Trace Hoppers, Stock yards
crushing plant, vibrating screens, single/twin boom
stickers, wheel on boom and blender reclaimers.

In VSP peripheral unloading has been adopted for the

first time in the country.
 Coke Ovens & Coal Chemical Plant ( CO & CCP)
• Coke is manufactured by heating of crushed coking coal (below 3 mm) in absence of air at
temperature of 1000 C and above for about 16 to 18 hours. A Coke Oven comprises of two hollow
chambers namely coal chamber and heating chamber. In the heating chamber a gaseous fuel such
as Blast Furnace Gas, Coke Oven Gas etc., is burnt. The heat so generated is conducted through
the common will to heat and carbonize the coking coal placed in the adjacent coal chamber.

• At VSP there are three Coke Oven Batteries, 7 metre tall and having 67 ovens each.
Each oven is having a volume of 41.6 cu. metre and can hold upto 31.6 tones of dry
coal charge. The carbonization takes place at 1000 0 1050 C in absence of air for 16-18
hours.

• Red Hot coke is pushed out of the oven and sent to Coke Dry Cooling Plants for cooling
to avoid its combustion. There are 3 Coke Dry Cooling Plant (CDCP) each having 4
cooling chambers. The Capacity of each cooling chamber is 50-52 TPH. Nitrogen gas is
used as the cooling medium. The heat recovery from nitrogen is done by generating
steam and expanding in two back pressure turbines to produce 7.5 power each.

• The Coal chemicals such as Benzole (and its products), Tar (and its products)
Ammonium Sulphate etc., are extracted in Coal Chemical Plant from C,O. Gas. After
recovering the coal chemicals the gas is used as a by product fuel by mixing it with
gases such as BF Gas, LD Gas etc. A mechanical, biological and chemical treatment
plant takes care of the effluents.
 Sinter Plant (SP)
• Sinter is a hard and porous ferrous material obtained by agglomeration of Iron Ore fines, Coke
breeze, Lime Stone fines, Metallurgical wastes viz., Flue dust, Mill scale, LD slag etc.

• Sinter is a better feed material to Blast Furnace in comparison to Iron Ore lumps and its usage in
Blast furnaces help in increasing productivity, decreasing the coke rate and improving the quality
of hot metal produced.

• Sintering is done in 2 number of 312 Sq, Metre, Sinter machines of Dwight Lloyd type of heating
the prepared feed on a continuous metallic belt made of pallets at 1200-1300 C.

• Hot sinter discharged from Sintering machine is crushed to +5 mm – 50 mm size and cooled before
dispatching to Blast Furnaces.
•
• Parameters of Sintering Machines are:
•
• - Effective area : 312 Sq. Metre
• - Sintering area : 276 Sq. Metre
• - Sinter bed height : 300 mm
• - Capacity : 450 TPH each
• - No. of wind boxes : 26
•
• The dust laden air from the machines are cleaned in scrubbers and electrostatic precipitators to
reduce the dust content to 100 mg/m3 level before allowing to escape into the atmosphere and
thus helping in maintaining a clean and dust free environment.
 Blast Furnace(BF)

Hot Metal is produced in Blast Furnaces, which are tall vertical

furnaces. The furnace is named as Blast Furnace as it is run with
blast at high pressure and temperature. Raw materials such as
sinter/iron ore lumps, fluxes (limestone/dolomite) and coke are
charged from the top and hot blast at 1100C approx. The furnaces are
designed fro 80% Sinter in the burden.

VSP has two 3200 Cu. Metre blast furnaces equipped with Paulworth
Bell less top equipment with conveyor charging. Rightly names as
“Godavari” & “Krishna” after the two rivers of AP, the furnaces
will help VSP in bringing prosperity to the state of Andhra Pradesh.
 Steel Melting Shop(SMS)
VSP produces steel employing three numbers of top blown oxygen
convertors called LD convertors or Basic oxygen furnaces. Each
convertor is having 133 Cu. Metre volume capable of producing 3
million tones of liquid steel annually. Besides hot metal, steel
scrap, fluxes such as calcined lime or dolomite from part of the
charge to the convertors.
 Rolling Mills
Blooms produced in SMS-CCD are shaped into products
such as billets, rounds, squares, angles (equal and 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 & medium merchant mills (LMMM) wire rod mill
(WRM) and medium merchant and structural mill
(MMSM)
 Light and Medium Merchant Mill (LMMM)
LMMM comprises of two units.
Billet Mill -
Bar Mill -

Billet Mill -
• Input size is 320 x 250 mm Bloom.
• Output size is 125 x 125 mm Billet.
• No. of Stands 7
• Single Strand – 2 High Continuous.
• Pass sequence is
Box-Square-Diamond-Square
• Max. Mill Speed is 1.6 m/s.
• Production Rate 480 T/Hr.
• Percentage of Yield 96.
 Bar Mill -
• Input size is 125 x 125 mm Billet.
• Output size 16mm…38mm rounds,
16mm…36mm rebars, Angles 50 and 65,
and Channel 75
• No. of Stands 22
( Roughing 8 + Intermediate 10 + Finishing 4)
• Two Strand – 2 High Continuous.
• Pass sequence is Box-Square-Diamond-Square-Oval-Round
• Max. Mill Speed is 20 m/s.
• Production Rate 192 T/Hr.
• Percentage of Yield 96.
 WIRE ROD MILL (WRM)

• Input size is 125 x 125 mm Billet.

• Output size 5.5mm…14mm rounds
and 8mm…12mm rebars
• No. of Stands 25 ( 13 Conventional+ 12 TC Rings)
( Roughing 7 + Intermediate 8 + Finishing 10)
• Four Strand - 2High continuous.
• Pass sequence is
Box-Oval-Round-Oval-Square-Oval-Round
• Max. Mill Speed is 76 m/s.
• Production Rate 192 T/Hr.
• Percentage of Yield 96.
MEDIUM MERCHANT AND STRUCLTURAL MILL
(MMSM)

• Input size is 250 x 250 mm Bloom.

• Output size 40mm…80mm rounds,
40mm rebar, Angles 75 to100, Channels 100 to 200, Beams 125
to 175 and Flats 150
• No. of Stands 20
( Roughing 8 + Intermediate 6 + Finishing 6)
• Single Strand – 2 High continuous.
• Pass sequence is
Box-Square-Oval-Round / Profiles
• Max. Mill Speed is 9 m/s.
• Production Rate 260 T/Hr.
• Percentage of Yield 96.
 Product Mix
Product Segment - Application
Wire Drawing – Barbed wire, GI Wire, Vibration Screens/ Mesh,
Screws, Nails, Electrodes, Cable,
Pins,Clips,Armour wire, PC wire, – Wheel
spokes, Umbrella ribs, Tyre bead wires

WIRE RODS Bright Bar - Bright finish bars, shaft

5.5 to 14mm Fasteners – Nuts, Screws, Chain links,
After Expansion
Upto 20 mm

Fasteners – Nuts, Screws, Bolts, Chain links, Engineering

Industries
Automobile – Axle, Shaft, Engg. Applications, Bright bar
Forging – Flanges, Gears, Hand tools
Re-rolling – Rounds & Structurals
ROUNDS Railways – Elastic Railway Clips (ERC)
16 to 80mm Construction – Reinforcement
After Expansion : Upto
45mm in Coil form as well
 Product Mix (Cont..)
Product Segment - Application

REBARS Construction – Reinforcement

8mm to 36mm
After Expansion
5.5-20 mm

Bright bar – Automobile, Engg. Industry

Forging – Automobile, Engg. Industry
Squares Re-rolling – Rounds, Rebars & Strls, Profiles, TLT
65 - 90mm Structures

Structurals 75-150 mm Construction / Fabrication / Auto leaf spring flats

After Expansion
55-175 mm
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 SPECIAL STEEL CATEGORIES
STEEL CATEGORY TYPE Typical Grades C% Mn%
Ultra Low Carbon •SAE1006 <0.10 <0.50
•SAE1008
Plain Carbon •IS-7887 < 0.30 < 0.60
(Mild Steel) •IS-2062
•IS-2830
•SAE1010-SAE1025
CARBON STEEL Plain Carbon with •SAE1010W,EN32B < 0.30 > 0.60
Medium Manganese •SAE1012S,SAE1015S but
(Restricted Chemistry) •SAE1018,C20MMn <0.90
•SAE1022,SAE1023S
•SE1025S,SAE1029S

Plain Carbon with High • A105 < 0.30 > 0.90

Manganese (Restricted •20C15,27C15
Chemistry) •SAE1524,SAE1524S
• SAE1524Cr

Medium Carbon with •SAE1030,35C8 >0.30 > 0.60

Medium Manganese •EN8D,CK45,SAE1049 and but
•EN9 <0.50 <0.90
19
 SPECIAL STEEL CATEGORIES
STEEL CATEGORY TYPE Typical Grades C% Mn%

Medium Carbon with High •SAE1043M >0.30 and > 1.00

Manganese •EN15, EN15B <0.50
CARBON STEEL •37C15, SAE1541
•SAE1547,SAE1548

High Carbon •HC55-HC85 < 0.50 > 0.50

•PC115 but
<0.80

STEEL CATEGORY TYPE Typical Grades C% Si%

CARBON STEEL WITH Electrode Quality, •IS2879/EQ >0.07 and <0.03
RESTRICTED SILICON Cable Armouring •CAQ <0.08
Quality
Cold Heading Quality •CHQ1010 >0.08 and <0.10
•CHQ1015 <0.20
•CHQ1018
21
 SPECIAL STEEL CATEGORIES
STEEL TYPE Typical C% Other major elements
CATEGORY Grades
SPRING STEEL SILICO •55Si7 > 0.50 to Mn% Si%
MANGANESE •60Si7 < 0.70
> 0.80 to < > 1.50 to <
STEEL •65Si7
1.30 2.00

CO2 CO2 •VIZAG CO2 > 0.07 to < > 1.00 to < > 0.65 to <
0.15 1.85 1.15
PLAIN CARBON •10B21 > 0.18 to < Mn% B%
BORON STEEL BORON STEEL •15B25 0.28 > 0.80 to < > 0.0005 to
1.30 < 0.003
MEDIUM > 0.36 to <
CARBON BORON •15B41 0.41
STEEL
 STEEL CATEGORIES-Applications
Product Category Grade Typical Applications
SAE1008/
General Engineering Industries
SAE1010
SAE1010W Steel wool
Plain Cold Heading Quality( Si<0.10 %)/
SAE1015
Carbon Fasteners
Cold Heading Quality( Si<0.10 %)/
SAE1018
Fasteners
WRC
IS 2879 Consumable Electrodes
EQ/CAQ EQ Consumable Electrodes
CAQ Cable Armour Wires
High Tensile Fasteners, Studs, Nuts, Bolts
SAE10B21M & Screws
High Tensile Fasteners, Studs, Nuts, Bolts
Boron Grade SAE15B25M & Screws
High Tensile Fasteners, Studs, Nuts, Bolts
SAE15B41 & Screws
 STEEL CATEGORIES-Applications
Product Category Grade Typical Applications
Cu-coated Electrodes for continuous welding
CO2 Grade VIZAG-CO2 lines
Medium EN8D Fasteners
Carbon Earthing wires, Cycle Spokes, Umbrella
35C8/EN8 wires
High Tensile Fasteners, Studs, Nuts, Bolts &
High Mn SAE1541 Screws
Earthing wires, Cycle Spokes, Umbrella
WRC HC50 wires
Aluminium Core Steel Reinforced Wires
HC55-65 (ACSR),Wire Ropes, Spring Wires
HC70/ VIZAG Tyre Bead Wires, Wire Ropes/Vibrating
High Carbon
TBQ Screens
HC75/HC80/P Pre-stressed concrete (PC) wires / Electric
C115 Pole Wires
VIZAG TBQ Tyre Bead wires
 STEEL CATEGORIES-Applications
Product Category Grade Typical Applications

SAE1008-SAE1020 Forging for General Engg. Industries

PLAIN SAE1023S/
CARBON SAE1025S Profiles for Wheel Rims / Forgings for auto sector /
Flanges

Medium 35C8/EN8D/CK45/ Forging & Bright Bars for Engineering & Auto
Carbon SAE1049/EN9 Industry

VIZAG-TLT Structurals for TLT Sector

Rounds High Mn
20C15/27C15/ 37C15 Forgings for Axles, Shafts, Link Chains etc
& Billets SAE1524S/SAE1524Cr

Chrome Steel 40Cr4/41Cr4/ Gears, Crowns and Pinion Wheels for Auto Sector
16MnCr5/20MnCr5

Spring Steel 55Si7/60Si7/65Si7 ERC for Railway Tracks, Leaf Springs for
Automobiles

Chrome Steel SUP9/SUP11A Leaf Springs for Automobiles

with Boron
25
Other Products
Pig Iron

Uses
Foundry
Steel Making
BF Slag Cement Industry

Lime Paper Industry

LD Slag Road making

Inspection & Testing

Raw Material
Intermittent products

Semi Finished products

Final Products

By Products

Special Testing
Raw Material
Coal
Iron Ore
Fluxes
Ferro Alloys
Additives
Water
 Semi Finished Products
• Blooms
• Billets
– Dimensions
– Surface defects
– Chemical
Analysis
– Spark Testing
– Macro etching
– Sulfur print
 C & S Analyzer
Chemical Testing
Coal Analyzer
OES
XRF

UTM
Mechanical testing
Upset testing

Microscopy
Metallurgical testing
NDT analysis
MAG PARTICLE TESTING
OTHERS
WATER TESTING
Expansion