© DANIELI CORUS DC Document No. 2B0422G1-J100-8004 Jindal DocumentNo. Rev. 0 | JINDAL - GREEN FIELD B/F RAIGARH & TORANAGALLU, INDIA | New Blast Furnace No.2 - 2005 Blast Furnace Process BLAST FURNACE MASS & ENERGY BALANCE FINAL 23 JUL 2004 (@ DANIEL! CORUS TAI Rohs TeSeived, confidential, This document 6 prepared by Daniel Conus BV ontaling valuable Knowhow owned by Oaniel Corus BV and is supped only for the spectic use as authorized by written agreement. This document shal nt be disciosed, used reproduced elther wholy or in part except in connection with such aulnorized use and then only wih the prior witlen consent of Daniol Corus BV. This document must not be used unt signed as checked and approved by Daniel Gonys BV. (©2008 Daniel Conus BV if a a AR LoD Ze Rev. Date Description Prepared by | Checked foved ‘ani -anrepneset Pope -B°ABO220 Inga New 8P02-Enaewna@’ | Jindal Project No. Trage tof 2 Eres Posen CC: careenser toro aietre | OC Praed No wom |© DANIELI CORUS REVISION SHEET Rev Date Section | Page Description Jindal, Groon Field B/E Page 2 of 12 July 14, 2008 Document No.: 25042261-J100-B001 shia© DANIELI CORUS Table of Contents REVISION SHEET. 2 1 INTRODUCTION...... 4 2 SUMMARY OF RESULTS... 4 3. CALCULATION METHOD a 4, BASE CASE 5 44 Production 5 42 Dimensions. 5 43 SOREN taste atte attest tteeiatitteteatatet 5 44 Blast 6 45 PCI Coal... 6 46 COKE ose 6 aT Burden 7 5. SENARIOS (CASES)... 7 5A Maximum top gas rate (A)... 7 52 Rich top gas (B) 7 53 Lean top gas (C)..... a8 54 Maximum hot blast pressure (D)... 9 55 Maximum top gas moisture content (E).. : et 9 56 Maximum coke rate (F) 10 6. PROCESS DATA SHEET... Se ie vot Jindal, Green Fie BF Page Sof 2 suiy 14,2008 Docurment No,: 28042261-1100-001 Rev. 0@ DANIEL! CORUS 4. INTRODUCTION This document is a summary of the Blast Furnace Mass and Energy Balances undertaken with for the Jindal Green Field Blast Furnace project. The summary consists of a Base Case scenario which is then used as a basis to calculate various parameters required by other unit operations. For example, the top gas composition for the hot blast stoves, the maximum coke rate for the burdening system and the top gas rate for the gas cleaning. ‘The Blast Furnace Mass and Energy Balance is calculated with a two stage Blast Fumace model developed by Corus. The calculations are based on steady state blast furnace operation. Special situation such as blow down or blow in will have different process results which can be different than these calculations, 2. | SUMMARY OF RESULTS Table 1 below shows a summary of the major results from the process calculations. For a more detailed description of the cases see the following sections. _Table 1: Summary of results. Case _| Description MIN. NORM. (Base) MAX. A Max. top gas rate : 3941 Nm*/min 4306 Nm*/min B Rich top gas - 3786 ku/ Nm® (dry) | 4303 kJ/ Nm? (dry) Cc Lean top gas 3347 kJ/ Nm? (dry) | 3786 kd/ Nm* (dry) | - D Max. blast pressure | - 270 kPa (g) 320 kPa (g) E _| Max. top gas moisture | - 4.9 % 9.6 % F Max. coke rate : 374 kg/THM 491 kg/THM (85%C) | 3. CALCULATION METHOD ‘The boundary conditions for the mass & energy balance calculation are based on values stated in the contract and the performance guarantees. For all calculations the following parameters are set as input values, Production rate Furnace dimensions Slag rate Hot blast temperature an composition Cooling losses Jindal, Green Field BF Page 4 of 12 Document No.: 25042261~J100-8001 Ore burden oxidation degree (O/Fe) and additives July 14,2004© DANIEL! CORUS Carbon Monoxide utilisation at the FeO level Hydrogen utilisation Burden resistance index Hot metal quality Coal quality and injection rate Coke quality ‘Top gas pressure Given these input values the following are calculated Blast rate and pressure Coke rate ‘Top gas composition, rate and temperature Adiabatic flame temperature vvvy The maximum blast rate is 2660 Nm3/min. This the design rate for the hot blast stoves, which is based on the proposal/contract value, and checked with the mass & energy balance calculations The maximum oxygen enrichment is 5% as specified in the contract/proposal The general calculation method (depending on the other inputs) is to vary the hot blast oxygen enrichment between 0 and 5%, to keep the following operational parameters in the ranges stated below, * Top gas temperature 120 - 275°C * Adiabatic flame temperature 2050 - 2300°C + Blast rate < 2660 Nm3ih * Burden pressure drop < 200 kPa 4. BASE CASE All cases are calculated relative to a standard base case. The input values for this case are described below, together with a short description of the variation of the variables where applicable. 4.1 Production Maximum production is taken as 3625 THM/d. Note actual guaranteed value is 3605 THM/d (3425 THM/d with an availability of 95%) 4.2 Dimensions The blast furnace dimensions are from the Blast Furnace Proper layout drawing, 280422G1-M100- coot 4.3 Operation The CO utilization at the wusite (FeO) level in the BF has been assumed to be 22%. This is as expected based on DC experience given the BF operation and raw materials in India. For further calculations the utilization is varied between approximately 20 and 24%, for less efficient and more Jindal, Green Field B/E Page 5 of 12 July 14, 2008 ‘Document No,: 28042261-100-8001 Rev 0© DANIELI CORUS effi ;nt operation respectively. ‘The burden temperature at the FeO level in the furnace is assumed to be 900°C (Corus standard/coke reactivity). This is kept constant for all calculations. The hydrogen utlization at the FeO level is assumed to be 35%. This is varied to a maximum of 40%. This value is from operating experience. Note; the overall hydrogen utilization is assumed to be 40%. Top pressures is taken as 150 kPa (g), as specified in the contract. The slag rate is assumed to be 300 kg/THM. This is the maximum slag rate in the performance guarantee, and is the basis for the cast house calculations. The burden resistance index is assumed to be 440. This is based on DC experience with furnaces with a similar hearth diameter. This is varied to a maximum of 500. A higher burden resistance index corresponds to a higher pressure difference across the burden. The hot metal quality is taken as the average of data provided by JINDAL. The cooling losses are assumed to be 40 GJ/h (265 MJ/THM). This value is the expected rate from ‘experience with similar blast furnaces. 70% of the cooling losses are assumed to occur in the lower furnace. 44° Blast For the calculations the moisture in the blast is assumed to be 20 gr/Nm3. The range used in the calculation is between 2.5 and 60 gr/Nm3. This is based on data from JINDAL. The blast temperature is taken as 1250 °C as specified in the contract. The oxygen percentage in the blast is 4%, as stated in the contract. 4.5 PCI Coal The PC! coal data is taken as the SBW/Ensham mix provided by JINDAL. This is a relatively standard coal. It is still unclear exactly which coal will be injected, however this is a sound basis. ‘An extremely high ash coal (26%), "Washed Coal” is also used in the high coke rate calculations. ‘The cracking heat of the coal was not provided in the analysis, the value is approximated from a correlation. The coal rate is 150 kg/THM as specified in the Performance Guarantees. 46 Coke The coke is taken to be “Standard” Corus [Jmuiden coke with 87.5% Carbon. The minimum coke carbon content provided by JINDAL is quoted as 85%. This can be corrected to JINDAL coke with the following formula, Coke rate (85% C) = 87.5/85 x Coke rate (87.5% C). The coke moisture is assumed to be 5%. This is varied to a maximum of 10%, as specified by Jindal, Greon Fold BF Page 6 of 12 July 14, 2008 Document No,: 280422G11100-8001 Rev 0© DANIEL! CORUS JINDAL. 4.7 Burden ‘The burden is assumed to be self fluxing. Thus no addition of limestone or dolomite is considered. This is not specified in the contract, however was discussed in the kick-off meeting, The oxidation degree of the burden is assumed to be 1.453 (O/Fe). This is relatively low. This is based on 70% sinter operation with a FeO content of 10%. The ore burden moisture is assumed to be 1%. This corresponds to a high sinter burden (70%). This is varied to a maximum of approx. 3% for a high ‘wet' pellet burden (30%) SENARIOS (CASES) 5.1 Maximum top gas rate (A) The maximum top gas rate is required for the sizing of the gas cleaning system and the overall plant gas balance. ‘The maximum top gas rate occurs for a relatively inefficient furnace with the maximum blast rate, and the maximum energy demand in the lower fumace. In this case the following deviations from the base case inputs were made; CO utilisation at the FeO level was reduced from 22 to 20% Hot blast moisture was increased to maximum from 20 to 60 gr/Nm3. Cooling losses were increased from 40 to 50 Gu/hr (265 to 331 MJ/THM) ‘Oxygen enrichment increased from 4 to 4.38% to achieve the maximum blast rate of 2660 Nm*/min. No changes to the hot metal quality or burden were made for simplicity. This results in a relatively inefficient process with a low CO utilisation (40%), and a high coke rate (419 kg/THM), and a high specific oxygen demand (273 Nm°/THM). The resulting maximum top gas rate is 4306 Nm3/min (1711 Nm3/THM). 5.2 Rich top gas (B) The richest top gas is required for the sizing of the hot blast stoves. The maximum top gas calorific value occurs with a high CO and H2 concentration, and a low nitrogen concentration. This occurs with a relatively inefficient process, with maximum hydrogen addition and maximum oxygen enrichment. In this case the following deviations from the base case inputs were mad Jindal, Goon Felé BF Page T of 12 uly 14, 2008 Document No.: 2804726 1~)100-8001 Rev 0© DANIELI CORUS * CO utilisation at the FeO level was reduced from 22 to 20% + Hot blast moisture was increased to maximum from 20 to 60 gr/Nm3. + Oxygen enrichment increased to maximum from 4 to 5%. This results in a relatively inefficient process with a low CO utilisation (40.3 %), and a high coke rate (416 kg/THM), and a high specific oxygen demand (270 Nm3/THM). The resulting maximum top calorific value is 4303 kJ/Nm3 (dry). The resulting top gas composition (dry) is 28.7 % CO, 19.3% CO2, 6.4% H2 and 45.6% N2. 5.3 Lean top gas (C) The leanest top gas is required for the sizing of the hot blast stoves, and the pre-heating heat ‘exchanger. The minimum top gas calorific value occurs with a low CO and H2 concentration, and a high nitrogen concentration. This occurs with an efficient process, with minimum hydrogen addition and minimum oxygen enrichment. For simplicity the changes in the PCI coal were not considered. In this case the following deviations from the base case inputs were made; * CO utilisation at the FeO level was increased from 22 to 23% + Hot blast moisture was decreased to maximum from 20 to 2.5 gr/Nm3. «Oxygen enrichment decreased to from 4 to 1.51% to reach the maximum blast rate 2660 Nm3/min. This results in an efficient process with a reasonable CO utilisation (47 %), and a low coke rate (350 kg/THM), and a low specific oxygen demand (242 Nm3/THM). The resulting maximum top calorific value is 3347 kJ/Nm3 (dry). The resulting top gas composition (dry) is 23.4 % CO, 20.7% CO2, 3.7% H2 and 52.2% N2. Jindal, Groon Field BF Page Bo 12 Jy 14, 2004 Document No.: 28042261-J100-8001 Rev: 0© DANIEL! CORUS 5.4 Maximum hot blast pressure (D) ‘The maximum hot blast pressure is required for the sizing of the cold blast and hot blast systems, and the tuyere diameters. ‘The maximum blast pressure occurs at the maximum blast and top gas rate, and the maximum burden resistance. For this case the maximum top gas rate case was taken (A) and the burden resistance index increased from 440 to 500. From DC experience this is the maximum resistance expected. The resulting maximum blast pressure is 320 kPa (g). The burden resistance index is defined by the correlation below. {Gun 0a) Py at Asserts X10" Vepase Where, R Resistance index 2 Pros Blast pressure bar(a) Pry Top pressure bar(a) Voorcas Volume top gas Nevimin Aveartn Hearth cross sectional area mi? The maximum allowable burden pressure difference for regular burden decent is 200 kPa (based ‘on experience at Corus Jmuiden). Above this pressure difference irregular burden decent can ‘occur due to the high upward impulse of the blast furnace gas. Ata top pressure of 150 kPa (g) and a maximum blast pressure of 320 kPa (g) the burden pressure difference is 170 kPa (g). This is 30 kPa below the maximum allowable limit, thus there is more process room available. This process room can be used to increase production and productivity in the future by increasing the blast rate or top pressure. 5.5 Maximum top gas moisture content (E) The maximum top gas moisture content is required sizing the gas cleaning system. The maximum top gas moisture content occurs with maximum moisture addition and maximum hydrogen utilization. In this case the following deviations from the base case inputs were made; + Hot blast moisture was increased to maximum from 20 to 60 gr/Nm3. * Coke moisture was increased to a maximum, from 5 to 10%. * Ore burden moisture was increased to maximum, from 1 to 3%. Jindal, Groon Field BF Page 9 of 12 uly 14, 2004 Document No.: 2804726'-J100-8001 Rev 0© DANIELI CORUS ‘+ PCI coal moisture was increased from 1.3 to 2%. «Hydrogen utilisation was increased to maximum from 35 to 40% The resulting moisture content in the top gas is 9.6%. 5.6 Maximum coke rate (F) ‘The maximum coke rate is required for sizing the burdening system. ‘The maximum coke rate occurs with the most inefficient process, with maximum oxygen enrichment and with a PCI coal with the lowest replacement ratio. In this case the following deviations from the base case inputs were made; CO utilisation at the FeO level was reduced from 22 to 20% Hot blast moisture was increased to maximum from 20 to 60 gr/Nm3. Cooling losses were increased from 40 to 50 Guhr (265 to 331 MJ/THM) Oxygen enrichment increased to from 4 to 4.6% to get maximum blast rate. The injection coal was changed to “Washed Coal” from JINDAL. “Washed Coal” has extremely high ash (24.4%), and low carbon content (50.4%). The theoretical replacement ratio is approximately 37 (extremely low). This is a very bad coal which we would not recommend to inject, however will produce the highest coke rate. This results in a relatively inefficient process with a low CO utilisation (39.8 %), and a high specific oxygen demand (277 Nm°/THM). The resulting maximum coke rate is 477 kg/THM. Note this rate is for Corus standard coke with a carbon content of 87.5%. Given that the minimum carbon content of the JINDAL coke is 85% the resulting coke rate has to be corrected as follows. Maximum coke rate (85% C) = 87.5/85 x 477 = 491 kg/THM, Jindal, Green Field BF Page 100f 12 Document No,: 28042261 -J100-8001 sly 14, 2008 Rov: 0© DANIELI CORUS 6. PROCESS DATA SHEET MASS & ENERGY BALANCES JINDAL | 2804220 CASE BASE A B c D E Variable Units Hearth diameter | m a4. 64. 64 64 64 84 84] Working vol m3 | 1462«1462=«1462~=« 1482 146214621482 Tuyeres - 20 20 2m 0 20 2 2 Production ve 3625 3625-3525 ©3625 «3625 «36253625 Productivity umsizane | 2479 2479 2479 2479 2479-2479 2.479 BURDEN Oxidation - 1453 14531453 «1453-1.453 1.453 1.453, Limestone kot 0 ° o 0 0 o ° Dolomite | kot ° o ° ° ° ° 0 Slag rate kglt 300 300» 300» 300 «300» 300300 Ore moisture % 1 1 1 1 1 3 1 HOT BLAST 7 Prossure KPa(o) 273-201-286 27S GBA Rate Nmaimin | 2525.1 2660 2571.8 2660 2660 2575 2660 Temp. °c 1250 1250 1250 «1250 «1280» 12601250 Moisture | griNm3 2 6 6 25 6 6 60 Oxygen % 4 438 5 151 438 4 48 ‘OPERATION Cooling losses Gainer 4 9 4 9 6 4 80] Cooling losses Mut 2648 331-2648 «198.6 «= 3312688331 Fraction lower BF | - o7 07 «oF «oF 60? a? | EtaCO, FeO % 2 202 mM 228 %w 2 2 EtaH2 6/100 035 035 «(035 «035 «(03504 (0.88 Direct reduction | % 334 904 308 349 304 2771 3058 ‘Ad.Fieme temp. | °C 2245 2091 «211222112081 20482158 Burden Res. : 440 440««440,= 440. 500440440 2th Nm3it 255 2732702273 28027 Jindal, Gro Field FE Page 11 of 12 uy 14,2008 Docuthent No: 2808226 1-00-8001 Revs 0© DANIELI CORUS CASE BASE A PCI Pe : | Rate kg 150 150150 150, 150150150 c % 7% 78 «978 | 787878 H2 % 440 444A 4A 4 8D ° % 54 BAA SATS N2 % 174d 47 A ash % 10 861001 H20 | % 130°0°«41380«18 1318 2 4 Cracking heat cult 05 05 08 05 0S 0S 1045 COKE Moisture % 5 5 5 8 5 10 5 | Rate (87.5%C) kat a4 N91 350419 4A 2 % 025 025 «025 «026 «025 028 028] N2 % 125128125128 1.25 125 1.25 HOT METAL si % o7 07 «07 OF 07 «07 OF | xn % 04 of Ot ttt P % O11 041 Off Ot O44 Ott Ot Tt | % 0.075 0.075 0.075 0.075 0.075 0.075 0.075 s % 004 004-004 0.04 0.04 0.04004 % 446 446-446 445445485 4.48 Fo % 9451 9451 9451 94.51 94.51 94.51 94.51 Temp. °c 1480 1480 148014801480 14801480 TOP GAS He % | 46 88 64 37 63 60 88 co % 21 23 27 234 283 26 208 coz % 209 189 193 27 189 22 191) Etaco % 445 401 403 «469 «401-432-308 Temp. °c 126 162185148 162101135 Pressure kPa (g) 150 160150 180, 180 180180. Rate Nmaimin | 3641 49306 4208-9973 430641254316 | Cal value (én kumms | 3706 4248 4303 3347 424840014267 Jinél, Gren Fee Page 1201 12 uly 44,2008 Bocument No! 7804226'~1100.6001 Rew 0