Name of the

organization you
intend to visit

Organization-wise general learning

Name of the department / Major
expectation (Know your
Activity Center
organization and industry it
belongs to)

A. Ore Bedding and Blending Plant

B. Coke Oven

C. Sintering Plant

D. Steel Melting Shop

E. Continuous Casting

F. Blast Furnace

Observation based learning expected from student.

List down assignment / project based learning expected from each department.

A.1. Source and types of raw materials

A.2. Identifying ways to maximise use of raw materials from captive sources
A.3. Beneficiation techniques
A.4. Iron core scenarios and slimes, effects of lean/low grade ores
A.5. Wagon unloading mechanisms
A.6. Process of receiving, unloading, stacking and blending, reclaiming and transporting the raw materials required for Blast
Furnace-5
A.7. Supply of base mix to sinter complex
A.8. Transportation of Flue dust, Mill scale, crushed coal and flux for trimming addition to Sinter Complex, transportation of
Calcining Plant grade limestone and dolomite to consuming units.
A.9. Types of crushers used
A.10.Technological innovations
A.11. Automation techniques, equipment, capacity, breakdown and shutdown analysis, preventive maintenance procedures

A.3.1. Review of the status of beneficiation and agglomeration of raw materials.

A.8.1. Reduction of the ash content in washed coking coal
A.10.1. Determining the efficiency of the blending process. Formula for checking the Blending of Iron Ore for Blast
Furnace Fluid Bed Mixers
A.10.2. Study of technologies used to convert non coking coal into coking coal including synthetic production of
coking coal.

B.1. Functions of coke and its importance in steel making, non recovery/heat recovery type coke ovens
B.2. Primary inputs and outputs of coke oven, their source and destination
B.3. Process and chemical reactions. How coke is made?
B.4. By products, cause of pollution
B.5. Materials balance calculation, heat balance,
B.6. Technological innovations
B.7. Automation techniques, equipment, capacity, breakdown and shutdown analysis, preventive maintenance procedures

B.4.1. Study of Pollution control in Coke Ovens and Coal Chemical Department
B.4.2. Effluent control in coke ovens through bio-chemical / microbial treatments
B.6.1. Stamp charging, partial briquetting of coal charge (PBCC), Coke Dry Quenching (CDC)
B.6.2. Review of the technologies to reform coke oven gas.
B.6.3. Review of the technologies to produce improved coke and Hydrogen reduction of required Iron ore.
B.6.4. Review of the technologies to recover unused sensible heat.

C.1. What is a captive sinter plant?

C.2. Process and technology used
C.3. Primary inputs and iutputs, source and destination
C.4. Energy consumption
C.5. multi slit burners, addition of MgO process
C.6. Understand the purpose of adding super fines in sinter mix (HPS) process, granulation equipment, high agitating
mixture, extension of grate width, increase bed height/width, suction
C.7. Pellet sintering technology
C.8. Automation techniques, equipment, capacity, breakdown and shutDown analysis, preventive maintenance procedures

C.2.1. Effect of High phosphorous Iron Ore Distribution in for the deterioration of permeability of sinter bed during
sintering.
C.2.2. Effect of high porosity and fusibility of iron ore fines on sintering process
C.2.3. Study on Sustainable raw material preparation
C.4.1. Study of process development techniques for beneficiation of lean grade ores, low grade ores, low grade
fines and tailings/slimes
C.5.1. Study of Ore mineralogy- particularly, complex and difficult to treat ores such as goethitic and the limonitic,
oxidized ore.

D.1. Primary inputs and outputs, source and destination

D.2. Process
D.3. Types of furnaces used, their technology
D.4. Technological Innovations
D.5. Water requirement and management
D.6. Source of pollution and preventive measures
D.7. Automation techniques, equipment, capacity, breakdown and shutown analysis, preventive maintenance procedures

D.2.1.Study of BOF, EAF, EIF processes

D.7.1. Study of PLC based converters.
D.6.1 Study of pollution control techniques in SMS II plant.
D.5.1 Study and improvement techniques in waste water treatment plant.
D.4.1 Development of customized zonal lining design and programme maintenance to reduce refractory
consumption in LD converter and steel ladles
D.4.2. Concurrent top and bottom blowing techniques, slag splashing, gas recovery system
D.4.3 Use of gadgets like smart-lance and sub-lance for prediction of end blow conditions
E.5.1. Enhancement in energy efficiency, water utilisation and reduced emmissions
E.4.1. Study of vertical bend mould, liquid core reduction, EMBR, mould and strand stirrers, shrouded casting,
mould powders for high speed casting, water models for smooth casting
E.4.2. Dynamic Soft Reduction Technology to improve internal soundness of cast products, i.e. reduction in
centerline segregation
E.7.1. Study of automation techniques
E.7.2.Mathematical analysis of shutdown and breakdown reports, preventive maintenance procedures
E.2.1. Near net shape casting technique

E.1. Primary inputs and outputs, source and destination

E.2. what is casting and its types
E.3. why continoous casting is more popular
E.4. Technological Innovations
E.5. Water requirement and management
E.6. Source of pollution and preventive measures
E.7. Automation techniques, equipment, capacity, breakdown and shutown analysis, preventive maintenance procedures

F.1. Understand types of furnaces, the requirement and structure of blast furnace.
F.2. Process and chemical reactions
F.3. Primary inputs and outputs, their source and destination
F.4. Managing waste impurities
F.5. Functions of coke in blast furnace
F.6. Alternative iron making process
F.7. Technology Innovations
F.8. Automation techniques, equipment, capacity, breakdown and shutdown analysis, preventive maintenance procedures

F.8.1. Study of hydraulics based equipment. (science, pumps, circulatory system, leakage, seals, actuators, valves,
circuit diagrams, troubleshooting and safety)
F.8.2. Study of various automation based equipments with reference to in-house developed automation done for
changeover of stoves.
F.8.3. Study of automation techniques in Blast Furnace 5.
F.2.1. Thermodynamics of FeO and TiO2 in blast furnace slags .
F.2.2. Understanding of the intricacies inside blast furnace using probing techniques.
F.4.1. Using real time process simulator to facilitate better Blast Furnace operation and improve its productivity,
reduce coke rate etc.
F.4.2. Effect of slag formation on furnace efficiency and techniques to minimize slag volumes
F.7.1. Technology for modification of coal blending covering utilization of high ash non coking coal, waste plastics
for optimum coke consumption in blast furnace.

G. Plate Mill

Steel Sector

1. Company profile,
2.Technology profile of steel
industry,
3. Background and history,
4. Board and Organization,
Chairman, Registereed Office,
5. Vision, Company policies,
6. Financial performance,
7. Awards and Accolades,
8. ISO certification,
9. Right to Information Act,
10. Grievances redressal,
11. Vigilance structure,
12. Steel links,
13. Contact details and sitemap,
14. Employee pay services,
15. Environmental reports,
16. Good practices,
17. Research and development
activities

H. Hot Strip Mill

I. Cold Rolling Mill & Silicon Steel Mill

J. Water Management Department

K. M/C Shop Forging and Welding

G.1. Understanding the chemistry, process and elements used in plate mill process.
G.2 Primary inputs and outputs, their source and destination
G.3. Heat treatment processes
G.3. Process of thermo-mechanical controlled processing
G.4. Corossion and weathering perfomance
G.5. Quenching and tempering process
G.6. Cold, warm and hot forming process
G.7. Thermal cutting, burning, oxy fuel cutting (OFC) techniques and welding techniques
G.8. Technology Innovations
G.9. Automation techniques, equipment, capacity, breakdown and shutown analysis, preventive maintenance procedures

G.9.1. Study of IEGT based drives and preparing concised documentation.

G.1.1. Study of manufacturing of special plates.
G.9.2. Suggest techniques to automate the furnace process.
G.1.2. Preaparation of animation based power point presentations of complete process of Plate Mill.
G.9.3. Study and automate the process of plate yard management--segregating plates according to their
dimensions and thickness to increase efficiency.
G.3.1. Study of slab head management.
G.8.1. Study and prevention of leakage from O2 and water pipelines.
G.8.2. Development of intelligent mill setup model for dynamic and adaptive control of plate mill resulting in
rolling of plates with much closer tolerance

H.1. Understand the process and importance of hot rolling/stripping mill and final products
H.2. Reheating process and technology
H.3. Descaling and roughing, edging, cropping processes
H.4. Technology aid and Innovations
H.5. Automation techniques, equipment, capacity, breakdown and shutdown analysis, preventive maintenance procedures
H.6. Process of temperature, gauge control, flatness, crowning, laminar cooling, coiling,
H.7. Technology and process of 'walking beam type furnace'
H.8. Water and waste management techniques

H.6.1. Study of automation related equipment mainly in gauge/shape and width control of slabs
H.3.1. Study of de-scaling process and suggest improvement measures.
H.2.1. Study and suggest techniques to improve life of reheating furnace
H.5.1. Build animation based power point presentations for complete process of HSM.
H.6.2. Study of Thermal Imaging techniques.
H.1.1. Study and suggest improvement techniques to reduce delay in complete process flow of HSM.
H.4.1. Simulation of thermo-mechanical processing and hot workability of high strength steel.
H.1.2. Modeling and control of microstructure and mechanical properties during hot strip rolling to control quality
and productivity of hot rolled strip.
H.1.3. Minimizing transportation errors due to internal disturbances or noise like mill thermal variation, electric
subsystems functioning and improper operator adjustments

I.1. Understand the process and importance of cold rolling mill and study product standards, characteristics and application
I.2. Friction and pressure maintenance techniques and deformation processes.
I.3. Open die and closed die forging techniques, gain orientation
I.4. Techniques like fullering, cogging, swaging, cladding, radial forging, extrusion, T-roll processing technology
I.5. Packaging, labeling techniques
I.6. Technology Innovations
I.7. Automation techniques, equipment, capacity, breakdown and shutdown analysis, preventive maintenance procedures
I.8. understand technology and process of painting methods, causes of faulty paint coating, pickling process, checking
surface cleanness, rust prevention, minimizing stretcher strains and aging

I.7.1. Study the process of galvanizing line and suggest improvements using automation techniques.
I.7.2. Study and modification of SAIL logo printing machine.
I.8.1. Analysis and improvement techniques for Zinc coating machine.
I.8.2. Improvement of shape by immersion pickling line and tandem root.
I.4.1. Study of furnace temperature control.
I.8.3. Improvement of surface conditions of pickled coil.
I.6.1. Enhancing efficiency of H2SO4 regeneration and comparing ammonia vs brine system.
I.7.3. Optimizing the freight car loading of slabs for a subsidiary rolling mill
I.6.2. Edge Drop Control strategies to minimize the undesired thickness drop in the edge zone of cold rolled strips

J.1. Major water resources, consumption, cost, recovery techniques, dumping effluents back in the source, is it completely
safe for agriculture, drinling purpose, aquatic life?
J.2. Quality checks on water for its usability in various departments of steel industry.
J.3. Quality checks on effluents before dumping (serial dilution, spread plate method, gram staining, Mannitol motility test,
Citrate utilisation test, Nitrate reduction test, Malonate utilisation etc.
J.4. Water distribution, conservation methods across various departments
J.5. Technology Innovations
J.6. Automation techniques, equipment, capacity, breakdown and shutdown analysis, preventive maintenance procedures
J.7. In compliance with all environment-relevant requirements?
J.8. What are stringent regulatory measures and monitoring processes?
J.9. Rainwater harvesting
J.10. Reusability of discharged water from various departments

J.4.1. Technologies for reducing water consumption in steel plants to ensure zero discharge of water.
J.5.1. Utilize tailings for building materials, ceramics, foamy bricks, waste water treatments, high value
chemicals and phytoremidiation, for growth of specific plants and removal of harmful components leading to zero
waste concept.
J.3.1. Study of Geochemical analyses of bottom sediment from rivers, major destinations for effluent and waste
discharge
J.10.1. Study of various water recycling technologies like coagulation, flocculation, flotation, reverse osmosis etc.
J.9.1. Study of technological enhancements in rainwater harvesting techniques.

K.1. Differences between casting and forging techniques, application, process of forging and welding
K.2. High energy rate forging, precision forging, carried out manually or using automated softwares?
K.3. Science and mechanics behind forging, casting, forming, welding
K.4. Types of welding techniques (arc, gas, resistance energy beam, thermo-chemcal, radiant energy, solid state, manual or
automated in plant? any application software used? selection of welding techniques
K.5. Types of welded joints, welding symbols, application and techniques
K.6. Technological Innovation
K.7. Primary inputs, outputs, source and destination
K.8. Automation techniques, equipment, capacity, breakdown and shutdown analysis, preventive maintenance procedures

K.8.1. Automating the preparation of pattern for creating moulds, optimizing risers/runners using software based
tool.
K.3.1. Operator training on welding techniques using software. Suggested study--Lincoln software
K.3.2. Development and characterization of spot welding techniques for coated steels.
K.5.1. Fatigue behavior analysis to enhance the performance of welded high strength steels.
K.1.1. A Comparative study of Open Die, Impression Die, Rolled Ring and Cold Forging Processes
K.5.2. Study of parameters assessing the quality and performance of welding
K.6.1. Analytical and mathematical analysis of various welding techniques.
K.6.2. Residual Life Assessment of welding structures.

L.1. Understanding the role and responsibilities of each department

L.2. Government acts, rules and regulations
L.3. Measures taken to reduce and optimize the waste and pollution management, measures taken towards energy
efficiency achievement
L.4. Use of automation, telecommunication etc.technology aids in various departments
L. Services and Utilities (Energy,
L.5. water footprinting
Environmental, Safety, Waste Security
L.6. security and safety measures, management
management)
L.7. Communication techniques
L.8. Technological Innovations
L.9. GICS (global industry classification standard) implementation

L.3.1. Cost optimization for coal/coke plant. Optimizing coal blending process.
L.3.2. Energy Conservation techniques for Power Plant. Efficient utilization of gas/coal.
L.6.1. Performance analysis measures of safety, speed cameras, CCTV automation.
L.3.3. Analysis of Slag utilization measures for its effective consumption/recycle/distribution. eg. For ash bricks,
agriculture, metal separation/recycle etc
L.3.4. pollution control by minimizing green house effect
L.3.5. To develop/adopt technologies/practices which have an impact in reducing energy consumption and reduce
carbon dioxide emission.
L.8.1. Development of technology/practices for the 100% recycling/utilization of LD/EAF slag
L.5.1. Study of water footprinting techniques

M. Electrical and Power

M.1. Power generation, transmission and distribution, non conventional sources of energy, important components of
substation, earthing and grounding techniques
M.2. Equipment and machinery identification, purpose, capacity for power generation and generation
M.3. Instrument selection criteria, AC.DC, VFD drives, PLC, SCADA, DCS,
M.4. Automation techniques, equipment, capacity, breakdown and shutdown analysis, fault analysis,
preventive,failure,block, operationa, corrective maintenance procedures
M.5. Technological Innovations
M.6. Tool kits, training kits and lab facilities, telecommunication techniques
M.7. handles maintenenace and safety of all major units of the Industry
M.8. Environmental, health and safety regulations

M.1.1. Analysis and survey of short circuit faults and relay coordination. Study of interlocks and suggest
techniques to minimize the down time.
M.4.1. Study of automation systems--PLC, DCS, SCADA, in Plate Mill and preparing concise documentation for
usage and creating database for breakdown reports.
M.2.1. Study of Crane management systems operated using variable frequency drives, slipring motors, AC drives
M.6.1. Efficient usage and hands on practice on Trainer kits (PLC, drives, sensors, PCB repairing) and formalize
experiments and documentation for efficient training sessions.
M.4.1. Temperature monitoring systems using robotic arms in hazardous areas
M.6.2 Set up wireless communication network between captive dam and main plant unit. Automating water level
monitoring/control using cameras and sensors
M.5.1. Study and suggest ways to improve static voltage capacitive error voltages in high tension lines.

N.1. Identify major thrust research areas, mainly in the field of iron making, refining and casting
N.2. Major facilities available, in terms of equipment, chemicals etc.
N.3. Parameters for quality assessment
N.4. Secondary metallurgical techniques, if applicable in plant
N.5. Technological innovations
N.6. Funding

N.1.1. Improvement methods for hot metal and smelter metal desulfurization
N.5.1. Reducing Nozzle clogging
N.5.2. Inclusion formation and removal from liquid steel
N.5.3. Scaling of steel and stainless steel strip during processing
N.2.1. Sequencing the sample processing in the steel plant laboratory
N.5.4. Innovative Coil Coating Technologies
N.5.5. RH/RH-OB process, CAS-OB process, LF/AOD/VOD/VAD/VD for secondary refiing processes
N.5.6. Use of 'wire feeders' to reduce variation of steel alooy elements
N.3.1. Development of Mathematical modeling and simulation in process Metallurgy (e.g., modeling of continuous
annealing operation for IF steel strip (microstructure and texture control), integrated optimization of refining,
rolling, heat treatment for enhancing properties and productivity through simulation and modeling)
N.6.1. Government initiatives to promote R & D services in steel industry

O.1. Infrastructure, skills, data centers, cloud compting, various softwares, operating systems
O.2. Data and information sources, safety and backup, security, network channels,
O.3. routers, switches, information flow, data mining and analysis
O.4. e-business, e-transactions, e-procurement, e-marketplace
O.5. online facilities, drivers and barriers
O.6. enterprise resource planning, SAP
O.7. computer aided manufacturing, product lifecycle management
O.8. customer oriented systems

O.1.1. Mapping of shop and maintenance activities in ERP plant maintenance module
O.3.1. Data mining techniques to analyse large sets of data
O.7.1. Discrete particle simulation for the analysis and optimisation of the granular flows during steelmaking
O.1.2. To assess the impact of ICT on enterprises, industries and the economy in general, particularly with regard
to productivity, employment and workforce composition, innovation, market structure and value chains.
O.4.1. RFID implementation and plans for automated collection of data about a certain object or person, including
localisation

P.1. Department structure, hierarchy, activities

P.2. Code of conduct, customer relationship maagement, total quality management
P.3. Cross functional competencies
P.4. In-house executive development programmes
P.5. SWOT analysis
P.6. Action oriented leadership programs
P.7. Appraisal management system, recruitment policies
P.8. Training and development, employee welfare, retirement schemes, grievance redressal, cultural and recreational
activities, social gatherings, health, educational related activities
P.9. Community development
P.10. Strategic alliances

P.7.1. Establishing a model showing linkage between HRD practices, HRD Climate and outcome .
P.3.1. Understanding the causal relationship with the help of correlation coefficient between various independent
variables and dependent variables e.g. training-labor productivity, training-lost time, labor productivityproduction, labor productivity-profit.
P.3.2. Understanding the nature of relation between the independent and dependent variables using multiple
regressions to study the impact of independent variables manpower, training, labor productivity on dependent
variables profit and production
P.2.1. Review of relation between HRD practices and firm performance
P.8.1. Review of continuous improvement methods in morale, motivation and employee satisfaction through
innovative approach

N. Research and Quality Control

O. Information Technology
(Computerisation)

P. Human Resource Development

#REF!