PROJECT REPORT

BLOWING PRACTICE IN 130T CONVERTERS AT SMSII IN BHILAI STEEL PLANT

SUBMITTED BY

CHETAN JAIN P.NO: 402224

STEEL AUTHORITY OF INDIA LIMITED BHILAI STEEL PLANT

CERTIFICATE

This is to certify that the project work entitled BLOWING PRACTICE IN 130T CONVERTERS AT SMSII IN BHILAI STEEL PLANT, being submitted by Mr. Chetan Jain (Personnel No. : 402224) has been completed under my guidance for the partial fulfillment of training of duration 1 year at Bhilai Steel Plant. It is expected that it will fulfill the purpose for which it is submitted. Wish him all the best.

Mr. N. V Joshi DGM, Converter Shop (operations) SMS-II Date: August 19, 2010

ACKNOWLEDGEMENT

I would like to take this opportunity to extend my gratitude to my project felicitator, Mr. N.V. Joshi for his guidance, keen interest and his valuable time and help without which this project work would not have been possible. I also wish to thank Mr. Diwakar Sirmour, Mr. Tarun Swarnkar and Mr. Rajesh Bombeswar for giving me valuable guidelines for making this project in a professional way. My thanks to all the employees of the converter shop for their active support over the building up of the project. I would like to thank my friends and colleagues who were a constant help to me during the making of this project and also provided me with assistance as and when required. Chetan Jain

CONTENTS
1.0 INTRODUCTION 2.0 SAFETY 3.0 INTERLOCKING 4.0. AIM VALUES FOR PROCESS 5.0. AIM VALUES FOR PRODUCT 6.0. PROCESS AUTOMATION 7.0. CALIBRATION OF LANCE 8.0. BLOWING REGIME 8.1. COMPUTER MODE 8.2. MANNUAL MODE 9.0. FLUX & FLUIDISER 10.0. TERMINATION OF BLOW 10.1. INTERMEDIATE STOP 10.2. FLAT BLOW 11.0. TEMPERATURE CORRECTION 12.0. FERRO ALLOY ADDITION 13.0. ACTION PLAN FOR IMPROVEMENT 13.1. Action plan to reduce carbon Diversion 13.2. Action plan to reduce Phosphorous Diversion 13.3. Action plan to reduce Sulphur Diversion 14.0. CONCLUSION 15.0. BIBLIOGRAPHY

1.0. INTRODUCTION:
To blow hot metal and scrap with oxygen and bulk material to achieve turndown temperature and chemistry required for tapping the desired grade of steel. The main objective at end point: 1. [C] Preferably > 0.15 % (0.12 0.18%) 2. [P], [S] as per the grade of the steel 3. Temperature : 16500C for Secondary Heats 16800C for Normal Heats Blowing will continue if lance and Converter condition are maintained healthy and tapping will continue if the tracks (alley) remain clear. To achieve this lance is to be checked after every heat for suitability for next blowing. Experience suggests that nine out of ten lances stuck up in thimble due to build up skulls in the 8.0 9.0 m level. If build up remains in the upper part of the lance it should be out of process and changed as per convenience. During splashing, nitrogen is blown from lance and it is lowered to such a height so that uniform droplets of fluid slag coats lining of the converter. During blowing care should be taken not to produce excess slag which is not only detrimental to converter lining but also increases the probability of slopping. It is a practice to keep half tonne of calcined dolomite and half tonne lime in the intermediate bunkers to take care of the excess slag and to avoid slopping. Slopping is a phenomenon in which excess slag that is formed in converter is thrown out of it. It jams the tracks and can be fatal as well for people working near converter.

2.0. SAFETY:
Most important part of any operational plant is safety and same is the case with the converter shop. Many equipments (lance, skirt, etc.) in the converter shop use water for cooling which flows at high pressure inside these equipments, there is every possibility of water leakage due to variety of reasons. Combination of water and hot metal is extremely dangerous and can cause explosion. Therefore, lance with heavy water leakage is never used for blowing. During blowing if water goes into the converter, it is practiced to lock the converter in vertical position from MCP. Tilting of the converter is stopped till complete water is evaporated; it is ensured through lance thimble. Utmost care is taken to prevent water logging around Converter area. Dumping of skull and sand is done in the periphery of the alley to prevent entry of rain water. When Caterpillar/ Dozer are working at zero meters for cleaning, charging and blowing activities are stopped as slag droplets formed during blowing goes at zero meter level and person on which it may fall may get burned. Lance skulls to be visually assessed for entering into lance thimble after every heat. If lance is stuck up, entire slag is dumped in the thimble before taking the job of lance cleaning. If lance movement is stopped during/after blowing at a height of blowing (about which we will talk later) it is customary to inform Shift Incharge (Mechanical /Electrical) & reduce O2 flow gradually to the minimum level i.e. 80 - 100 Nm3/Min (approx.) with intermittent addition of lime in small doses to control bath temperature and slag formation. After the lance is lifted stand by lance is used. If the same lance is to be used for blowing again, thorough inspection of the nozzles is done for any clogging.

In case of chain slack during lowering of lance, Shift Incharge electrical is informed to reset the supply. After the supply is restored, first the lance is lifted by approx. 1.5-2.0 m and then lowered to required position. This is done to assure that counter weight do not fall with an impulse. In case chain slack again takes place, lance is checked from lance thimble platform for any obstruction in lance movement before asking electrical maintenance for further resetting. Even if lance slack persists, the same lance is not used for blowing. The gas recovery system is of suppressed combustion principle (air factor 0.1) i.e. gases rich in CO are not allowed to come in contact with the atmospheric oxygen. Skirt should be lowered, 30 second after ignition. If nitrogen pressure drops, converter is kept in vertical position & locked. In case ID Fan is tripped, converter is tilted towards charging side, away from the hood so that quencher water does not fall in to the converter. In some cases when there is excess puffing (flames coming out of skirt) slag formation should be done cautiously and GCP group must be informed suddenly and if comtinue puffing is there blow should be stopped.

3.0. INTERLOCKING:
1. Lance movement downward is possible when G.C.P. is ready, Converter is vertical, Lance cooling water temperature, flow and pressure are normal, Oxygen Pressure is normal, Lance is coaxial with converter. 2. Emergency lift of lance in any of the following conditions: Lance cooling water temperature, pressure and flow below normal, Oxygen pressure is low, Blow stop condition from GCP, nitrogen pressure is below marked parameters. 3. Converter tilting is possible only when lance is out of converter mouth. 4. Safety shut off valve will open if following conditions are satisfied a. Lance control selection switch is in Manual - Remote or Auto - Remote or Computer - Remote position. b. Isolation and concerned blowing valve fully open. c. SSV control selection switch in "Auto" position. d. Lance cooling water temp, press and flow are normal. e. Lance is coaxial with converter. f. Oxygen pressure normal g. GCP Ready

4.0. AIM VALUES FOR PROCESS:

a. Blowing duration: 16-20 minutes (In return heat blowing duration will vary with amount of hot metal charged, as a thumb rule it is estimated as 60Nm3 per tonne of Hot Metal charged) b. Tapping time: more than 04 minutes c. Blowing oxygen pressure: Line pressure: > 11.5 kg /cm2 d. Lance cooling water: Flow: 110 20 M3/ hr Pressure: 10 2 kg/cm2 Temp. Difference (outlet-Inlet): 50 5 e. Nitrogen pressure: > 6.0 kg/cm2

f. Lime: Cao + MgO: 80.0 % Min. Reactivity: 280 Min.

5.0. AIM VALUES FOR PRODUCT

a. Turndown temperature: 1650 C for Secondary Route, 16800 C for Normal heats b. Slag basicity: 2.8 min Total Fe: < 20 % c. Bath analysis: Carbon: 0.12 0.18 %, Sulphur: 0.025 % Max Phosphorus: 0.020 to 0.040% as per the requirement of the grade.

6.0. PROCESS AUTOMATION:

The role of process automation is to optimize steelmaking operation due to its ability to predict various inputs used in process with the help of Mathematical Models. Following models are used for this purpose: 1. Process Aim Calculation: It is a feasibility check. It reads grades and re-blow pattern. The model predicts aim Carbon percentage and the temperature at end point based upon expected ladle history and condition (Empty time, Skull mass, preheating duration, ladle life etc.). It also calculates expected Ferroalloy additions as per the requirement of the particular grade of steel. It also incorporates Converter information regarding tapping duration, additional losses etc.) 2. Hot Metal and Scrap ordering calculation (First Charge): Hot metal, scrap or iron ore can be fixed in the next heat based upon aim temperature at end point calculated in the last step and prevailing hot metal temperature and composition. Bulk materials are calculated. It also downloads order to mixer and scrap yard. Slag basicity can be adjusted as per the requirement of the particular grade of steel. 3. Main Blow calculation (Second Charge): Done after start of heat. Actual hot metal mass and temperatures are given as input to the model and the model advices oxygen amount to be blown (1st blow). It also outputs expected steel composition at endpoint and slag weight. 4. Second Blow/ Reblow calculation: After taking sample and temperature during first blow, this calculation can be done model advices oxygen amount and bulk material additions/coolants expected end values Re-blow is necessary if percentage of Carbon is too high, and slag is too viscous.

5. Ladle alloying calculation: Before the start of tapping this model calculates ladle addition based upon analysis at the end point (Actual / calculated). It advices three different combinations of alloys and amount of C, Si-Mn, Fe-Si, Fe-Mn are calculated. 6. Feedback calculation: Calculates closing items and model standards based upon heat and mass balance.

7.0. CALIBRATION OF LANCE:

Converter is charged with Hot Metal. About 1.5 m long steel pipe is inserted in one of the nozzles of Lance. Lance is lowered below 1.0 m from (h2) reading of Encoder without opening the safety shut off valve. The lance is kept at that position for about half a minute. Lance is lifted to the upper most position in lowest speed. Pipe is removed from the lance and the length of Pipe not dipped in metal (h1) is measured. Now, h3 = h1 - h2 + 80 mm/10 T of scrap Working height = Encoder Reading + h3.

8.0. BLOWING REGIME:

At the start of blowing the quantity of hot metal & scrap charged and their composition & temperature is fed to the computer model (If not available, analysis of previous heat is fed). Blowing is controlled by Using three predefined Blowing patterns (Addition Scheme and Variation of lance height and oxygen flow rate at different moment). Monitoring waste gas flow rate and composition. Visual observation of flame and ejections at the converter mouth.

The blowing regime is decided as per with Si content of the hot metal and the hot metal temperature. If % Si in the Hot metal is 0.80 %, slag will form very easily and metal temperature rise will be very fast. Again in case of return heat or heat with retained slag inside the converter blowing is started at the working height. Otherwise in normal cases when HM % Si is within 0.60 0.75% blowing is started 0.6m above the working height. Blowing is started with a oxygen flow rate of 450 Nm3/min. Skirt is lowered after 30 seconds of confirmed ignition. Static models are used for determining flux additions and oxygen to be blown. Due to very fast oxidation of the metalloids especially of Si, metal temperature rises to a level so that slag formation starts. A very reactive slag is formed with high FeO content is detrimental to the converter lining. An initial dose of one tonne Calcined Dolomite is preferred as flux. It will raise the activity of MgO in the slag phase and will minimize lining erosion. As lance is still above the working height, oxygen jet will preferably oxidize iron, formation of slag will continue. Ejections from the converter mouth confirm slag formation. Flow of oxygen is lowered down to 400 Nm3/min at

about 800 oxygen moment and first dose of lime is discharged from the intermediate bunker. As planning changes even after the start of blow, it is preferable to add nearly sixty to seventy percent of the calculated bulk material before the violent decarburization period and comes to the working height. For an example, at the start of blowing, blower is informed to blow for a bloom heat, but the plan changes after 06 08 minutes and it is planned for a normal heat. In this situation as turndown temperature is higher by thirty degrees material addition is to be lowered accordingly. It also helps in another way. It keeps bath temperature always in the higher side which helps slag formation in the de-phosphorising period. Adding excessive flux material in the earlier phase of the blow not only delays formation of fluid slag but also responsible for rising bath level. Remaining thirty-forty percent material is kept in IBs and Dosators in divided doses to be added as per requirement in the later part of the blow.

Choosing proper working height is very important in blowing. Previous heat data is always the criteria for selecting working height. As blowing continues, ejection pattern changes and sparks are coming out from the converter mouth and the blow proceeds towards a dry phase. At a particular working height if the bath goes dry at about 3000 200 oxygen moment, working height is considered to be correct. If it appears earlier it is to be understood that bath level is raised. Rising of bath level is also indicated by the excessive hood jam at the present working height and normal skirt pressure. As the bath remains violent during the maximum decarburization period (oxygen moment approx. 2500 4500) addition of bulk materials is not done during this period. Stony ejections are appeared from the mouth during this period and flow is lowered to about 350 Nm3/min at about 3500 oxygen

moment to restrict its occurrence. If no such ejections are found lowering of the oxygen pressure extends decarburization period and delays dephosphorisation phase.

After the violent de-carburization phase is over at about 4500 oxygen moment with a thick and dry slag, attention is paid to make a fluid slag either by adding a small dose of iron ore or by raising the lance height to about 0.60 m from the working height. After ensuring slag a dose of lime is added as per with process requirement. A fluid basic slag ensures bath P to the desired level. Flow of oxygen is then increased to about 400 Nm3/min and lance is lowered to the working level again. Increasing oxygen flow allows more metal droplets in the fluid slag phase so that bath is de-phosphorised to a maximum level. At least 500 600 oxygen is blown with 450 Nm3/min to allow sufficient slag-metal reactions before termination or intermediate stop. In the manual mode of blowing, almost every aspects of blowing is decided form the ejections from the converter mouth. If at the moment of termination of blow, sufficient quantity of fluid slag is not visible in the converter, it is not necessary that we should finish the blow at the working level or at oxygen flow rate of 450 Nm3 /min. It must be adjusted as per our requirement.

Skirt is raised and flame is observed through the converter mouth to ensure carbon drop. When carbon level drops below 0.20%, flame stops flickering and blow is terminated for sampling and temperature. If slag at turndown is viscous/ insufficient, additional lime is given & Oxygen is blown to achieve the desired S & P level in bath before tapping.

2.6 m 2.2 m

1.8m 1.6m 450 2 400 4 5 400 9 350 13 400 17 450

Time from blow start, min

Steps involved in the converter process Charging : First blow: Sample / temperature Measurement Second blow: Reblow: Tapping: Deslagging/splashing/lining inspection 07 minutes 16 18 minutes 05 minutes 02 minutes 01 minutes 06 minutes 05 minutes

BLOWING REGIME: Time from blow start (sec) 0 120 240 300 540 780 1020 Lance working height (m) 2.6 2.2 1.8 1.6 1.6 1.6 1.6 Oxygen flow rate (Nm3/min) 450 400 400 400 350 400 450

Lance working height is the height of lance from charged surface.

8.1. COMPUTER MODE: a. Lance control selection switch should be in Remote position in computer. b. Bath correction is fed in computer. c. Suitable blowing regime is selected from computer. d. Command to start the blow is given. Computer mode blowing is not practiced here in BSP. 8.2. MANNUAL MODE: a. Lance control selection switch should be in Remote position in computer. b. Lance is operated manually. Usually Ignition takes place within 30 seconds (indicated by luminous flame at converter mouth). If ignition does not take place within 30 seconds lance is lifted to top most position. Rocking the converter is done for 2-3 times. Again blow is started. After about 30 seconds after ignition the skirt is lowered. Blowing is continued as per blowing regime.

9.0. FLUX & FLUIDISER

Amount of bulk materials required for blowing is decided as per computer model. If reactivity of lime is less than specified then slag formation is ensured by lance manipulation. Hot Metal Si Lime Calcined Dolomite 0.50 4.25 2.7 0.60 5.0 3.2 0.70 5.8 3.8 0.80 6.6 4.4 0.90 8.0 4.5

If charge pad material is prepared for the converter/ tap hole is repaired entire slag is drained out from the tap hole/mouth. Converter gets cooled as no slag cover remains inside it. As no slag is retained, next heat for the converter should be blown with lime only 1 tonne Calcined dolomite depending on the slag condition. Blowing should be done with a higher lance height and always fluid slag should be maintained, going dry-phase is avoided. At the end of tapping of a heat, tapping in-charge informs blower about the condition of the converter, whether any metal is retained or not. Sometimes he also predicts the amount of metal retained inside the converter. It is practiced that in the next heat charge quantity is reduced equivalent to the amount of steel retained. In case when amount of scrap reduced (scrap acts as a coolant), bulk material should be kept at the same level to achieve the equivalent turndown temperature. When HM quantity is reduced amount of bulk material should also be reduced to achieve the same. It should also be kept in mind that whenever HM quantity is reduced, amount of Oxygen to be blown is also reduced.

Quantity of Oxygen required: Previous heat blowing data is the most reliable guide for the next heat oxygen amount. Prediction can also be made from the

other converter data on the oxygen amount. As a thumb rule 60Nm3 is required for a tonne of HM charged. If the previous heat ends at 6500 Nm3 oxygen, this heat will also be terminated at about 6500 200 Nm3 oxygen moment.

A few important considerations: The ignition problem: In many cases blown steel is retained inside the converter after tapping and that amount varying up to 15 T. In such cases the next heat is planned with a small addition of scrap i.e. 8- 10 / charge instead of 16- 18 T. Immediately after nitrogen splashing and deslagging, scrap is charged and it is practiced to add nearly 1.5 T 2.0 T lime at the bottom of the converter after scrap charging. Igniting the charge for the next blow is a big problem. In such cases blow is started with a higher flow rate 480Nm3/min and at 40-60 cm above the previous heat working height. If the steel is not ignited within 15-20 seconds the lance is moved down word with a frequent step of 10 cm / 5 cm for 3-4 seconds and flow is raised simultaneously up to 520 Nm3/min. A huge quantity ferruginous slag is formed and blower prepares to come to the working height or even lower by 10 cm to ignite the bath and control the slag foaming. A dose of lime (1.0 1.5 T ) is immediately added to take care of the foamy slag. Immediately after ignition flow is reduced to the level of 400 Nm3/min and lance height is adjusted as per with the blowing conditions. Free fall material is never used for bottom additions. If added at the bottom it causes ignition problem,

 Calculating the amount of lime /CD to be charged with a few tonnes of HM is retained during charging: Considering for 120 T HM charge nearly 6500 Nm3 is consumed so that 1 THM consumes 60 Nm3 oxygen. If 5 T of HM is retained for the charge it is supposed that (300 Nm3 oxygen) blow will complete early and oxygen consumption will be less by 300 Nm3. Per 100Nm3 blowing at the working height at the near end blow raises nearly 80 C. 1 T Lime 300C 1T CD 200C 1 T Fe Ore 300C For 300 Nm3 lowering of oxygen consumption will require T lime 150C, T CD 100C less to make up the turndown temperature. Amount of carbon retained in the converter is judged by seeing the flame by seeing out the flame coming out of the converter mouth by raising the skirt up and allowing open combustion for a while. In open combustion rise in temperature is 1.5 times higher than the normal cases and sometimes in normal heats (without secondary heating) it is practiced to blow the metal with a lower working height and allowing open combustion. If it is found that carbon is retained in the steel even after completion of predicted amount of blow (shown in the following table) it is practiced to add 0.5 T lime / 0.5 T CD or both to restrict the temperature according to the amount of oxygen blown

Si in Hot Metal, % 0.45 0.60 0.65 0.70 0.75 0.80 .

Predicted oxygen amount, Nm3 6300 6500 6700 6800 7000

Material free fall: Calcined dolomite is a powdery material often falls free from service bunkers to Dosators. Amount of material (free fall) = Gross wt tare wt While shifting materials from Dosators to Intermediate Bunkers (I/Bs) amount of free fall material must be taken into account and such amount of CD must be added to the bulk material during blowing .

10.0. TERMINATION OF BLOW:

10.1. INTERMEDIATE STOP: Blow is stopped when about 400 m3 of Oxygen is balance from predicated amount. Bath temperature & sample is taken. Finish blow as per predicted oxygen or as per instruction of Tapping In charge. 10.2. FLAT BLOW: Termination of blow is decided jointly or singularly from following conditions: After blowing about 400 M3 of oxygen after drop of flame through the tap-hole. Drop in skirt pressure from 15 Pascal to 10 Pascal. By fall in CO level in flue gases to 40 % (as per gas analysis recorder). Lance is lifted only after half a minute of lifting skirt.

11.0. TEMPERATURE CORRECTION

Temperature correction is carried out by re-blowing oxygen at a rate of 100 m3 per 8 deg C rise in temperature. Higher turndown temperature correction is carried out by lime/ iron ore addition as per instruction of Tapping I/c (Temp. Drop will be about 15 deg C/T of Lime and 25 deg/T of Iron ore ). Intimate Shift Manager for charge balance correction, if required, for proper turndown temperature.

12.0. FERRO ALLOY ADDITION

During tapping Ferro alloys are added from service bunkers as per requirement depending upon the grade of steel and instruction of Tapping I/c.

13.0. ACTION PLAN FOR IMPROVEMENT:

13.1.Action plan to reduce carbon Diversion: Bath analysis is checked before tapping. By avoiding over oxidation at turn down (bath C is kept within 0.10 0.20). During tapping Coke is added in the ladle along with Si-Mn for better recovery. 13.2.Action plan to reduce Phosphorous Diversion: Aiming turn down temperature less than 16800C. Sufficient quantity of lime is added during blow. Avoiding short tapping i.e. minimum tap hole duration (run) should be 04 minutes. 13.3.Action plan to reduce Sulphur Diversion: One tonne extra lime added during blow. Treatment given with lime at turn down. One container lime added in the ladle after tapping of special/ bloom heats. Sufficient quantity of synthetic slag is added during tapping.

14.0. CONCLUSION:
Blowing is practiced in SMS II in Bhilai Steel Plant is in the Manual Mode. Computerized mode blowing was not satisfactory due to failure in static model as only there are only three blowing patterns to meet so many variables. It is said that one thing is constant in steel making i.e. variable. Keeping all the input parameters within certain limits requires many extra precautions which is otherwise causing many operational difficulties. It is therefore recognized that blowing in the manual mode is highest level skilled job.

Over the years productivity of the shop is increasing at a consistent rate with many value added steel grades are being put into stream. SMS II, Converter Shop faced almost every problem faced by steelmaker, but it overcomes all the hurdles with zeal, by taking challenges, implementing innovative ideas into practice and above all with commanding management practices.

15. BIBLIOGRAPHY:
1. Sri Ajay Kumar Shukla, S. Rai End Point Control in BOF Steelmaking at Durgapur Steel Plant, presented in National Metallurgist

Day2003,Kolkata, organised by Indian Institute of Metals. 2. Gateway An introduction guide to Bhilai Steel Plant, BSP,Bhilai. 3. Sri R.K.Rathi, Unpublished class notes/ MTT training /SMS II Bhilai. 4. Sri R. H. Tupkary and V. R. Tupkary Modern Steel Making. 5. E.T. Turkdogan, Fundamentals of Steelmaking. 6. Kudrin, V, Steel Making. 7. Work Instructions for blowing practices /ISO Manual/TQM/BSP, Bhilai.