15 days Industrial Training Report File

On Blast Furnace 1 & 2 Plant (25/03/2017-08/04/2017)

Submitted To Submitted By

Mr. Nadeem Khan Shani Kumar Singh

General Manager/HOD Roll No-1344948

Blast Furnace 1 & 2 Branch-Mechanical

Jindal Steel and Power Ltd, Raigarh Semester-8th

College-CGC-COE, Mohali

Signature-

1|P a g e
 Acknowledgement
It is matter of great pleasure and privilege for me to present this report of 15 da ys
industrial training in “BF 1 & 2”.Though this report, I would like to thank numerous people
whose consistent support and guidance is standing pillar in architecture of this report.

To begin with, my sincere thanks to Ateet Namdeo, AGM-HR & ES of Jindal Steel and
Power Ltd for providing me an opportunity to get acquainted with various activities
different Plant. I express thanks to Mr. Nadeem Khan, General Manager of Blast Furnace 1 &
2 for extending co-operation to enable me to get acquainted with the various activities of
their department.

I would like to express my sincere gratitude to my guide Mr. Gunjan Jha. I was
privileged to experience a sustained enthusiastic and involved interest from his side

I would like to express my sincere thanks towards members of Maintenance, Operation

and Stock house department for making me a deep knowledge about various activities of
Blast Furnace.

Shani Kumar Singh

2|P a g e
 INDEX

1. Introduction of Jindal Steel & Power Limited

2. Facilities at Raigarh Plant Include
3. Introduction of Blast Furnace
4. Process & Layout of Blast Furnace
5. Major Equipments or Station of Blast Furnace
 Stock House
 Blast Furnace
 Stoves
 Slag Granulation Plant
 Gas Cleaning Plant
 Pulverised Coal Injection
 Pig Casting Machine

3|P a g e
 Introduction of Jindal Steel & Power Limited

 JSPL is an industrial powerhouse with a dominant presence in steel, power, mining

and infrastructure sectors.
 Turnover of approx. US$ 3.3 billion, JSPL is a part of about US$18 billion diversified
Jindal Group conglomerate.
 In terms of tonnage, it is the third largest steel producer in India.
 The company manufactures and sells sponge iron, mild steel slabs, Ferro chrome,
iron ore, mild steel, structural, hot rolled plates and coils.
 JSPL operates the largest coal-based sponge iron plant in the world and has an
installed capacity of 3 MTPA (million tons per annum) of steel at Raigarh in
Chhattisgarh.
 JSPL has been rated as the second highest value creator in the world by the Boston
Consulting Group.
 The 11th fastest growing company in India by Business World and has figured in the
Forbes Asia list of Fab 50 Companies.
 In Oman (Middle East), the company has set up a US $ 500 million,1.5 MTPA gas -
based hot briquetted Iron(HBI) plant. It has now added a 2MTPA integrated Steel
Plant.
 Alongside contributing to India’s growth story the company is driving an ambitious
global expansion plan in Africa, Australia and Indonesia.
 It deploys its resources to improve infrastructure, education, health, water,
sanitation, environment and so on in the areas it operates in. It has won several
awards for its innovative business and social practices .

4|P a g e
 Facilities at Raigarh Plant Include

 DRI Plant-4nos. of 500TPD (0.72 Million TPA) and 6nos. of 300TPD rotary kilns (0.72
Million TPA)
 DRI Plant-4nos. of 500TPD (0.72 million TPA) and 6nos. of 300TPD rotary kilns (0.72
million TPA)
 0.8 million TPA Coke Oven Plant
 2.5 million TPA sinter Plant
 1.25 million TPA and 0.42 million TPA Blast Furnace
 2.0 million TPA and 1.25 million TPA steel melting shop
 2 Vacuum degassing Unit
 RH degassing Unit
 1 No. Single strand slab Caster
 1 No. of 6-strand billet-cum-round Caster and 1 No. 6 Strand billet caster
 2 No of 4-strand combi-caster
 Rail and Universal beam Mill(RUBM) (0.75 million TPA)
 Plate-cum-coil MILL(1.0 million TPA)
 Submerged arc furnace(SAF)(0.03 million TPA)
 Oxygen Plant 37683 Nm^3 per hour
 Lime and Dolomite Calcination Plants(0.4165 million TPA)
 358 MW Captive Power Plant(CPP)
 0.7 million TPA medium and light structure mill

5|P a g e
 Introduction of Blast Furnace

“The Blast Furnace is a counter current reactor to chemically reduce and physically
convert iron oxides into liquid iron called "hot metal". It is a huge, steel stack lined with
refractory brick, where iron ore, sinter, coke and fluxes are charged from top, and
preheated air (i.e. Hot Blast) is blown through the tuyeres at the bottom. The raw materials
require 6 to 8 hours to descend at the hearth of the furnace where they become the final
product of liquid metal and slag. These liquid products are drained from the furnace at
regular intervals through taphole. The gases generated into the furnace ascends to the top
in 6 to 8 seconds after going through numerous chemical reactions”.

The purpose of a blast furnace is to chemically reduce and physically convert iron oxides
into liquid iron called "hot metal". The blast furnace is a huge, steel stack lined with
refractory brick, where iron ore, coke and limestone are dumped into the top, and
preheated air is blown into the bottom. The raw materials require 6 to 8 hours to descend
to the bottom of the furnace where they become the final product of liquid slag and liquid
iron. These liquid products are drained from the furnace at regular intervals. The hot air that
was blown into the bottom of the furnace ascends to the top in 6 to 8 seconds after going
through numerous chemical reactions. Once a blast furnace is started it will continuously
run for four to ten years with only short stops to perform planned maintenance .

Blast Furnace

6|P a g e
 Process & Layout of Blast Furnace

Modern furnaces are equipped with an array of supporting facilities to increase efficiency,
such as ore storage yards where barges are unloaded. The raw materials are transferred to
the stock house complex by ore bridges, or rail hoppers and ore transfer cars. Rail-mounted
scale cars or computer controlled weight hoppers weigh out the various raw materials to
yield the desired hot metal and slag chemistry. The raw materials are brought to the top of
the blast furnace via a skip car powered by winches or conveyor belts.

There are different ways in which the raw materials are charged into the blast furnace.
Some blast furnaces use a "double bell" system where two "bells" are used to control the
entry of raw material into the blast furnace. The purpose of the two bells is to minimize the
loss of hot gases in the blast furnace. First, the raw materials are emptied into the upper or
small bell which then opens to empty the charge into the large bell. The small bell then
closes, to seal the blast furnace, while the large bell rotates to provide specific distribution
of materials before dispensing the charge into the blast furnace. A more recent design is to
use a "bell-less" system. These systems use multiple hoppers to contain each raw material,
which is then discharged into the blast furnace through valves. These valves are more
accurate at controlling how much of each constituent is added, as compared to the skip or
conveyor system, thereby increasing the efficiency of the furnace. Some of these bell -less
systems also implement a discharge chute in the throat of the furnace (as with the Paul
Wurth top) in order to precisely control where the charge is placed.

The iron making blast furnace itself is built in the form of a tall structure, lined
with refractory brick, and profiled to allow for expansion of the charged materials as they
heat during their descent, and subsequent reduction in size as melting starts to occur.
Coke, limestone flux, and iron ore (iron oxide) are charged into the top of the furnace in a
precise filling order which helps control gas flow and the chemical reactions inside the
furnace. Four "uptakes" allow the hot, dirty gas high in carbon monoxide content to exit the
furnace throat, while "bleeder valves" protect the top of the furnace from sudden gas
pressure surges. The coarse particles in the exhaust gas settle in the "dust catcher" and are
dumped into a railroad car or truck for disposal, while the gas itself flows through a venturi
scrubber and/or electrostatic precipitators and a gas cooler to reduce the temperature of
the cleaned gas.

The "cast house" at the bottom half of the furnace contains the bustle pipe, water cooled
copper tuyeres and the equipment for casting the liquid iron and slag. Once a "tap hole" is
drilled through the refractory clay plug, liquid iron and slag flow down a trough through a
"skimmer" opening, separating the iron and slag. Modern, larger blast furnaces may have as
many as four tap holes and two cast houses. Once the pig iron and slag has been tapped,
the tap hole is again plugged with refractory clay. Tuyeres of Blast Furnace at Gerdau, India

7|P a g e
The tuyeres are used to implement a hot blast, which is used to increase the efficiency of
the blast furnace. The hot blast is directed into the furnace through water-cooled copper
nozzles called tuyeres near the base. The hot blast temperature can be from 900 °C to
1300 °C (1600 °F to 2300 °F) depending on the stove design and condition. The
temperatures they deal with may be 2000 °C to 2300 °C (3600 °F to 4200 °F). Oil, tar, natural
gas, powdered coal and oxygen can also be injected into the furnace at tuyere level to
combine with the coke to release additional energy and increase the percentage of reducing
gases present which is necessary to increase productivity.

Reaction in Iron Making

 C + O2  CO2 - ΔH
 CO2 + C  2CO + ΔH
 3Fe2O3 + CO  2Fe3O4 + CO2 - ΔH
 Fe3O4 + CO  3FeO + CO2 - ΔH
 FeO + CO  Fe + CO2 - ΔH
 FeO + C  Fe + CO + ΔH
 SiO2 + 2C  Si + 2CO + ΔH
 MnO + C  Mn + CO + ΔH
 P2O5 + 5C  2P + 5CO + ΔH
 FeS + CaO + C  CaS + Fe + CO + ΔH
 H2O + C  CO + H2 + ΔH

8|P a g e
Stock House

A blast furnace (BF) needs for the production of hot metal (HM) (i) iron bearing raw
materials like sinter, pellet, and calibrated lump ore also known as sized iron ore, (ii) fuels
and reductant like BF coke, nut coke and pulverized coal, (iii) fluxing materials like lime
stone, dolomite, and quartzite, and (iv) miscellaneous materials (also known as ‘additives’)
like manganese ore, and titani-ferrous iron ore etc. All these materials except the pulverized
coal which is injected in the blast furnace at the tuyere level are charged in the furnace at
the top and are handled through a stock house .

The blast furnace charging system consists of two main areas, the stock house system and
the top charging equipment. The purpose of the blast furnace charging system is to enable
the raw materials to be placed inside the furnace accurately and consistently in a
predictable and controlled way. At the stock house system, the weighing, batching of the
raw materials is carried out for their delivery to the top charging equipment. The top
charging equipment serves the function of delivering blast furnace raw materials to the
furnace top and distributing these materials into the furnace. The purpose of the stock
house is to deliver the correct quantities of coke, iron bearing materials, fluxing materials
and additives to the furnace as expeditiously as possible to keep the blast furnace at top
operating performance.

Iron Ore : 2 Bunkers

Sinter : 6 Bunkers

Coke : 6 Bunkers

Fluxes : 6 Bunkers (One each)

Raw Material Finished Products

 Iron Ore  Hot metal analysis
Fe : 63-64 % C : 3.8 – 4.2 %
SiO2 : 2-3% Si : 0.6 – 0.8 %
Al2O3 : 2-3% S : ~0.07 %
 Sinter P : 0.05 – 0.06 %
Fe : 53-55% Temp. : 1450 – 1460°C
SiO2 : 4.5-5%  Slag analysis
CaO : 9.5-10% SiO2 : 34 – 35 %
MgO : 2-2.5% CaO : 33 – 34 %
Al2O3 : 2.5-3% Al2O3 : 18 – 19 %
 Coke MgO : 8–9%
Carbon : 85% FeO : ~0.8 %
Ash : 12% Basicity: 0.96 – 1.0
S : 0.6%  Top Gas analysis
 Lime Stone CO : 22-24%
CaO : 45-50% CO2 : 18-20%

9|P a g e
 MgO : 2.5-3% H2 : ~2.5%
SiO2 : 5-5.5% N2 : ~55%
Al2O3 : 1.5-2%
 Dolomite
CaO : 28-30%
MgO : 19-20%
SiO2 : 3-4%
Al2O3 : 0.5-1%
 Quartz
SiO2 : 98%

Furnace

The purpose of a blast furnace is to chemically reduce and physically convert iron oxides
into liquid iron called "hot metal". The blast furnace is a huge, steel stack lined with
refractory brick, where iron ore, coke and limestone are dumped into the top, and
preheated air is blown into the bottom. The raw materials require 6 to 8 hours to descend
to the bottom of the furnace where they become the final product of liquid slag and liquid
iron. These liquid products are drained from the furnace at regular intervals. The hot air that
was blown into the bottom of the furnace ascends to the top in 6 to 8 seconds after going
through numerous chemical reactions. Once a blast furnace is started it will continuously
run for four to ten years with only short stops to perform planned maintenance. Blast
Furnace consist of reciveing Hopper, Transfering Hopper, Bellless Distributor, Stack, Belly,
Bosh, Hearth.

Furnace Specification
 Total Volume : 1681 m3
 Working Volume : 1462 m3
 Throat Diameter : 6.73 m
 Belly Diameter : 10.0 m
 Hearth Diameter : 8.40 m
 Stack angle : 85.2.
 Bosh angle : 81.0.
 Throat volume : 89 m3
 Stack volume : 901 m3
 Belly volume : 172 m3
 Bosh volume : 210 m3
 Hearth volume : 219 m3

10 | P a g e
Stoves

The hot blast air is produced by passing cold blast air through preheated chambers or
‘stoves’, and heating the air to above 1000°C.

The stove is first heated up by burning gas and combustion air within the chamber and
allowing the heat to be absorbed into the brickwork, or ‘chequerwork’. This mode is
calledon-gas. When sufficient heat has been absorbed, the stove is put on-blast. In this
mode, no combustion takes place, but cold blast air is forced through the stove and absorbs
the heat to become hot blast. This is then mixed with cold blast to bring it to the right
temperature, and is then forced into the blast furnace via the tuyeres near its base, as
shown in Figure 2.

It is quite common to have three or four stoves, so that at any time one stove is on-blast
while the others are on-gas or boxed. A boxed stove has been heated up to temperature
and sealed, so that it is ready to go on-blast. If one stove is down for repair, it is possible to
run on just two stoves.

Stove changeover

Figure shows the layout of a typical stove system. The procedure for changing over from one
stove to another is as follows:

 assume stove 2 is on-blast and stove 1 is heated up and boxed ready for use

 valve 1 of stove 1 is opened first, allowing cold blast into the stove to pressurize it

 valve 2 of stove 1 is opened, so that stoves 1 and 2 are now on blast

 stove 2 now comes off blast by shutting valves 1 and 2 of stove 2

11 | P a g e
Stove 2 is now put on-gas, to heat up again, now that its stored energy has been used.
Valves 3 and 4 of stove 2 are opened during this stage, allowing gas and air to enter the
stove, and the waste gases to leave once the gas has been burned. When the stove is up to
temperature these valves are closed again, leaving the stove boxed.

Slag Granulation Plant

The process of slag granulation involves pouring the molten slag through a high pressure
water spray in a granulation head, located in close proximity to the blast furnace.
Granulation process is the controlled quenching of the slag in cold water which does not
give time for crystalline growth to take place. Large volume of water is required (10 parts of
water to 1 part of molten slag being optimum). During this process of quenching, the molten
slag undergoes accelerated cooling under controlled water flow condition and gets
converted into glassy sand with 97 % of the solid granulated slag particles less than 3 mm
and an average size of around 1 mm. The impact point of the molten slag and the high
pressure water is dependent on the slag flow, its temperature and slope and shape of the
hot runner. It is necessary the exchange of heat between the molten slag and high pressure
water to take place in a very short time. The high pressure water jet breaks the molten slag
stream into molten slat lamellae which initially convert into filaments and then into
droplets. Maximum heat transfer takes place when the contact surface between the molten
slag and the water for granulation is maximum ie. When the molten slag has been converted
into droplets and is fully enclosed with water. The time of the solidification is dependent on
the size of the slag droplets, the difference of temperature between the molten slag and
high pressure water and the contact environment between water and the slag.

12 | P a g e
Gas Cleaning Plant

Dry separation of dust particles in the blast furnace top gas before wet scrubbing is
traditionally done by a gravity dust catcher and most recently by cyclones. The recycled dust
must be low in zinc to satisfy the limits of the blast furnace zinc balance. Primary gas
cleaning is based on the gravity separation principle and is used for the removal of large
particles of the dust. It is the dry separation of dust particles in the blast furnace top gas
before wet scrubbing and is commonly done by a gravity dust catcher or most recently by
large diameter cyclones. In this stage all the coarser particles are removed. The objective is
to remove as much dust as possible in a dry condition for reuse and recycling. The recycled
dust must also be low in Zinc and lead to satisfy the limits of the blast furnace zinc balance .

BF gas after primary cleaning in the dust catcher, where the majority of heavy particles are
removed, moves towards the secondary gas cleaning stage (scrubbers) which is the wet
cleaning system. In this stage, BF gas is cleaned in contact with water and almos t all the
suspended particles are separated (more than 99 %). In some plant this gas is further taken
into electrostatics precipitators. Treated gas after secondary gas cleaning stage is taken into
BF gas network of the plant and is used also for BF stoves heating. Polluted water from the
system at the same time contains high concentrations of suspended particles in the range of
and 500-10,000 mg/l and as such is sent to settling ponds/ clarifier-thickener where the dust
settles down and the clear water from the top is pumped for reuse. Scrubbers are available
in a wide range of designs, sizes, and performance capabilities. They are to be designed
primarily for collection of particles.

Pulverised Coal Injection

Pulverized Coal Injection (PCI) is a process that involves injecting large volumes of fine coal
particles into the raceway of a blast furnace (BF). This provides not only a supplemental
carbon source but also speeds up the production of liquid iron besides reducing the need for
metallurgical coke for reactions in the blast furnace. The desire to move away from the

13 | P a g e
production of the metallurgical coke with its inherent environmental problems has
motivated the use of pulverized coal injection in blast furnace.

The process description is as follows.

1. Raw coal is screened and processed to remove tramp materials and is stored in raw
coal bins
2. Raw coal is pulverized, dried and then pneumatically conveyed to filters in a once
through system. Coal is dried thoroughly to prevent saltation and compaction.
3. The pulverized coal is deposited in a single reservoir bin and stored under inert
conditions.
4. Pulverized coal is gravity fed from the reservoir bin to the feed tanks which are then
pressurized with inert gas as part of a batch process in which the feed tanks are
filling, feeding, venting or holding in order to provide a continuous flow pulverized
coal into the furnace.
5. The flow rate of the pulverized coal is regulated by inert gas pressure as a function of
feed tank weight change.
6. The single stream of dense phase coal from a feed tank is combined with transport
gas (nitrogen) at the mixing tee.
7. A single transport pipe carries the coal/gas mixture to a coal distributor located at
the blast furnace (Fig 1). At the distributor the single stream of coal/gas mixture is
divided automatically into multiple equal streams and conveyed by a pipe into each
tuyere for injection into the blast furnace.
8. A block detector system guards against tuyere blockage.

14 | P a g e
Pig Casting Machine

Pig Casting Machine has a special purpose of installation in Blast Furnace. It is seen that
some times supply of molten metal produced in blast furnace is disconnected due any
reason. In that condition it is alternate to avoid any type of losses or for continous operation
of blast furnace.

The Pig Casting Machine (PCM) is basically an inclined chain conveyor having a set of
overlapping moulds fixed between a pair of chain which moves over a set of stationary
rollers. There is a set of sprockets on either side of the PCM one of which is driven (idle) and
the other is driving sprocket. The drive unit consists of an AC or DC motor coupled to a
multistage helical reduction gear box, the output shaft of which is connected through’
coupling to the driving sprocket shaft supported at the ends by bearing.

15 | P a g e