The Bokaro Steel Plant (BSL), located in Jharkhand, India, is one of the largest integrated steel plants in the country and is operated by Steel Authority of India Limited (SAIL). The plant follows a systematic integrated steel production process, which involves multiple stages from raw material processing to finished steel products. Here’s an overview of the working process:
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1. Raw Material Handling & Preparation
– Iron Ore: Sourced from mines (mainly in Jharkhand and Odisha), crushed, and beneficiated.
– Coal: Converted into coke in the Coke Ovens (by heating coal in absence of air).
– Limestone & Dolomite: Used as flux materials to remove impurities.
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2. Iron Making (Blast Furnace)
– The Blast Furnace (BF) produces molten iron (pig iron) by reducing iron ore using coke and hot air.
– Raw materials are fed from the top, while hot air (blast) is injected from the bottom.
– Chemical reaction:
\[
\text{Fe}_2\text{O}_3 + 3\text{CO} \rightarrow 2\text{Fe} + 3\text{CO}_2
\]
– Molten iron is tapped and sent to the Steel Melting Shop (SMS).
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3. Steel Making (LD Converter / BOF)
– The molten iron is refined into steel in the Basic Oxygen Furnace (BOF) or LD Converter.
– Oxygen is blown into the furnace to remove impurities like carbon, silicon, and phosphorus.
– Alloying elements (like manganese, chromium) are added for desired steel grades.
– Output: Liquid steel cast into slabs/blooms/billets via continuous casting.
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4. Rolling Mills (Finished Products)
The semi-finished steel undergoes further processing:
– Hot Rolling Mill: Produces sheets, plates, coils.
– Cold Rolling Mill: Refines hot-rolled products for better surface finish.
– Other mills produce structural steel, rails, bars, etc.
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5. Power & Utilities
– Captive power plants supply electricity using waste gases (BF gas, Coke 
n gas).
– Water treatment plants ensure efficient water recycling.
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6. Quality Control & Dispatch
– Strict quality checks at every stage.
– Finished products are dispatched via rail