PRESENTED BYDEEPAK DWIVEDI DEPT.

OF METALLURGY OPJIT, RAIGARH (CG)

Steel Melt Shop

A Journey Towards Excellence

STEEL MELT SHOP II

MAJOR FACILITIES
ANNUAL CAPACITY
PRODUCTION 2009-10
(UPTO 31/01/10)

2.0 MT
65000 T

ELECTRIC ARC FURNACE

LADLE REFINING FURNACE

02 NO.
03 NO.

VACUUM DEGASSER
CONTINUOUS CASTER

01 NO.
03 NO.
STEEL MELT SHOP II

MAJOR MILE STONES OF SMS-II sms -2 have been produced 73 heats in a day since April. (worlds second largest )

STEEL MELT SHOP II

PRODUCTS

STEEL MELT SHOP II

STEEL MELT SHOP II

KEY CUSTOMERS
RUBM (ROLLING AND UNIVERSAL BEAM MILL) SEMISMSL, JSL, NALWA, BHEL.

STEEL MELT SHOP II

STEEL MELT SHOP - II

STEEL MELT SHOP II

SCHEMATIC DIAGRAM OF EAF

STEEL MELT SHOP II

ELECTRIC ARC FURNACE

SALIENT FEATURES
MAKE CAPACITY TRANSFORMER RATING ELECTRODE DIA. NO OF OXYGEN LANCE FURNACE LINING BRICKS TAP HOLE : : : : : : : Sms demag 100 MT 100 MVA 24"(600 MM) 4 MAGNESIA CARBON BRICKS EBT TYPE

STEEL MELT SHOP II

FUNCTIONS OF EAF

Functions of EAF:

1. Melting of inputs and homogenization of steel bath. 2. Raising the temperature of the melt to 16200C for tapping. 3. Decarburisation. 4. Dephosphorisation. 5. Slag free and compact stream tapping.

STEEL MELT SHOP II

ELECTRIC ARC FURNACE

METALIC INPUTS:
Hot metal from blast furnace : 30 to 70% %C : 3.8 to 4.2% %Si : 0.3 TO 1.0 % %P : 0.13 max Temperature : 1280 deg min DRI (Lumps +Fines) from DRI Plant : 40 to 49% %C : 0.1 max %Fe(met) : 81 min %SiO2 : 3.5 Scrap : 1 to 5% (optional)

INPUTS FOR EAF

FLUX:
Lime from LDP (Lime and Dololime Plant) Burned dolomite from LDP

OTHER INPUTS:
Oxygen from Oxygen plant. CPC (Calcined petroleum coke)

STEEL MELT SHOP II

ELECTRIC ARC FURNACE

HEAT CYCLE: Charging Hot metal pouring Melting& Blowing Tapping Tap to tap time : 53 min EBT filling time : 3 min Slag pot changing/ pit cleaning time: 13 min Hot metal pouring time : 5 min HEAT Arc time : 29 min CYCLE Tapping time : 3 min CONTROL PARAMETERS: Power in put : 70 to 75 MW Oxygen input : 120 Nm3/min Tap Chemistry %C : 0.05 %P : 0.010 % Other elements : Trace Tapping Temperature : 1620C
STEEL MELT SHOP II

Melting process in eaf

EAF shift incharge insure the charge mix preparation as per the instruction of incharge. DRI-0-55% Hot metal- 0-80% Bucket charge- 0-40% (scrap+skull+DRI+pig iron)

 Best charge mix combination always try to Aim for optimum output is mentioned below which depends upon availability of raw material and power Power- 50-72 MW Hot metal- 50-58% DRI- 40- 48% Bucket charge 0-2% EAF is switched on and operating on low power depending on scrap. Calculate oxygen blown in furnace through VLB

 If the carbon content is high in that condition the extra oxygen will be supplied for the reduction of carbon in the form of Carbon dioxide Furnace helper takes the temperature of the melt in EAF . Temp. of melt should not less than 1600c

 TAPPING Shift incharge instructs the PIT side supervisor to get the ladle below the tapping hole of the EAF .before tapping it is ensured that the purging is in open condition . During tapping addition of ferroalloys , fluxes and deoxidizer are done. Then transfer towards ladle.

Thermocouple circuit of EAF

FUME EXTRACTON SYSTEM EAF

No of ID fan : Flow value of each fan : Total bag area : Air to cloth ratio (PEAK) : Pressure drop across bag filter house : Dust content at outlet of bag house : 3 nos (2W+1S) FES 7,50,000 Nm3/hr 14,862 m2 100 Nm3/m2/hr (approx) 16 mbar (approx) 20 mg/Nm3

STEEL MELT SHOP II

FES LINE DIAGRAM

STATUTORY NORMS

STEEL MELT SHOP II

1. AMBIENT NOISE LEVEL - NORMS

Normal Work zone 6AM to 9PM 9PM to 6AM (Day) (Night) 75 dB 70 dB 85 dB 85 dB

2. STANDARD PARTICULATE MATTER AT GUEST HOUSE STATUTORY

SPM 500 g/m3 (Max)

NORMS

3. RESPIRABLE PARTICULATE MATTER

SO2 NOx CO 120 g/m3 (Max) 120 g/m 3 (Max) 5000 g/m3(Max)

4. STACK EMISSSIONS MONITORING

SMS LRF- 1 LRF-2x3 EAF 1&2 RMH bag house NORMS 50mg/m 3 (Max) 50mg/m 3 (Max) 50mg/m 3 (Max) 50 mg/m3 (Max)

STEEL MELT SHOP II

calculations
At eaf Dri-0-55% Hot metal (si-.2-1.2%,temp. 1100-1380c)-080% Bucket charge (scrap+skull+dri+pig iron)-040% Power: 50-72 mw

Example If we want hot metal consist 60kg si then according to the capacity of eaf (60mth/m, total hot metal will consist 360 kg of si, Then= si +o2 = sio2
Sio2 = 360x1.114=410.4 For maintaining 2 bassisity -410.2x2=820.8 cao is required. But pure lime consist approx 85% pure so, 100-kg---------- 85kg pure cao 820.2 kg ------ 85/100 x 820.8

example
Silica load x 50% = req. Mgo The capacity of eaf 65 ton, if furnace run at 1 MW , tat to tap time is 32 min. , in jspl 70 Mw furnace run So, 70 x 30 = 2100kg. When it had achieved 73 heat then tap to tap Time will =39.45 min.

Super heat
Lrf ---80c-----slab 20c----tundish 40c --casting 30c----So super heat is= 20+40+30=90c Let us assume after 1 min. temp. will raise 5c And we know that furnace temp. is- 1530c Supply temp.is 1599 c. So total temp. raise = 69c
1 min temp. raise=5c

 so furnace will run for around 14 min. Due to this super heat furnace wikll run for extra 14 min. but ladle takes time because 1-addition of substances 2-cooling of ladle 1% addition of any substance results 20-25c temp. drop. We are adding 1.5 ton of sub. Through fafa.so furnace will have to run 7 min. So total running of furnace can calculated as =14+7+5=26 min.

 They have a transfarmer of 12 mva at power factor of 0.8so total power consume=9600w We are running furnace for 26 min. So, 60 min power consumption is =9600w 26 min ----------4160w That means power req. for 1 ton is 4160 watt Cost of power for 1 ton melting can also calculated if 1 watts cost is g Thencost=4160 x g

 Quality control dept.(spectrolab) to start Spectrometer we have to press f2 botton . Before that loly pop sample have taken from lrf as well as eaf also. Sample must be polished . For that purposedisc polisher and automatic polisher is available. Automatic polishing machine have been supplied from germeny. It consist of ab 60 grit paper. Paper is called as eloxide paper . For picking sample sample lancing is used .height of sample lancing is 5 ft. It is supplied by shreeram industry.

 Lequous temp. of steel-= 1537-(.65x %c+8x%si +5% Mn) Wheet powder is a good insulator and it wilkl drop 1-2c. Simn-60%mn, 13-15%si Fe-si 70% si Hcmn 70%Mn , 4.8% c Al wire 96% Al

 So, alloy addition = pointed to be need x tonnege of material x100%/%efficiency

STEEL MELT SHOP II

STEEL MELT SHOP II

Ladle Refining Furnace(LRF)

Salient Features
No. of LRF Make Capacity : : : 03 Sms demag 100T 18 MVA

Transformer rating :

STEEL MELT SHOP II

FUNCTIONS OF LRF

1.Refining of steel

2.Achieving desired chemistry.

3.Desulphurisation 3.Thermal and Chemical Homogenization. 4.Raising desired temperature for casting.
STEEL MELT SHOP II

FES FOR LRF :

No of Booster Fan Capacity : : 1 no. 1,00,000 Nm3/hr

Connected to Secondary (Canopy Duct) of Main Fume Exhaust system.

STEEL MELT SHOP II

STEEL MELT SHOP II

VACUUM DEGASSER

LADLE

STEEL MELT SHOP II

Vacuum Degasser
Salient Features
Design, Engg and Supply Suction Capacity Pump down time Vacuum System : : : : danieli,italy 350 Kg/hr at 0.5 torr 5 minutes to 0.5 torr 9 Steam ejectors 3 +1condensers works on successive compression of off-gas in a series of steam ejectors. Continuous 16 Nm3/hrs max

Argon Stirring

STEEL MELT SHOP II

VACUUM DEGASSER

Functions of VD:
1.Removal of entrapped gases
2.Removal of sulphur by slag-metal reactions promoted by Argon purging.

STEEL MELT SHOP II

STEEL MELT SHOP II

BILLET CASTER (UNDER PROJECT)

COMBI CASTER

STEEL MELT SHOP II

Continuous Casting Machine

1.Combi Caster :
No. of strands Machine Type Supplier Radius Mode of straightening Strand Center distance Machine speed Speed range Restranding speed : Length from meniscus in mould to torch cutter Casting mode Mould length Metallurgical length Ladle accommodation Dummy bar system EMS Mould level control : Type of mould Oscillation Cutting Device Cut length : : : : : : : : : : : : : : : : : : 04 Combination caster with curved mould vai 12000 mm Continuous 1800 mm 0 to 2.5 m/min 3.0 m/min 32.5 mtrs Powder casting with stopper rod system and mould EMS system 800 mm 20.5 mtrs Ladle turret (Butterfly type) Chain type dummy bar (Bottom feeding) Electromagnetic mould stirrer Cs 137 source with stopper rod control. Curved mould with Cu plates for beam blank and Blooms, Cu tube for rounds. Hydraulic mould oscillator (Dynaflex) GEGA Torch cutting machine 4.5 to 12 mtrs

STEEL MELT SHOP II

1. Combi Caster Products

420x480x120mm, 355x280x90 mm Beam blank, 285x390mm 250x250 mm Bloom, 200, 255, 220, 305 mm Rnd.

STEEL MELT SHOP II

Continuous Casting Machine

2. Billet Caster (Under project):
No. of strands Machine Type Supplier Radius Mode of straightening Strand Center distance Machine speed Speed range Restranding speed Length from meniscus in mould to torch cutter Casting mode Mould length Rounds Squares Metallurgical length Ladle accommodation Dummy bar system EMS Mould level control Type of mould Oscillation Cutting Device Cut length : : : : : : : : : : : : : : : : : : : : : 06 Curved heavy duty Type CONCAST 9000 mm Continuous 1200 mm 0 to 5 m/min 3.5 m/min 27.1 mtrs Powder casting with stopper rod system and mould EMS system 800 mm 1000 mm 27.1 mtrs Butterfly type Ladle turret Rigid type dummy bar (Bottom feeding) Electromagnetic mould stirrer Co60 source with stopper rod control. Curved tublar Cu mould Electro mechanical ALBA Torch cutting machine 9 to 12 mtrs STEEL MELT SHOP II

Continuous Casting Machine

2. Billet Caster (Under Project) : Products
: 130x130mm, 150x150mm, 165x165mm 200x200 mm

STEEL MELT SHOP II

Slab caster
No. of strands: Machine type: Supplier: Mould length: Metallurgical length: Oscillation: Cut length 01 Curved mould Sms demag 700mm. 17.3m

Hydrulic 3.5 to 9m.