1

Gunniting
experiences at JSW
Steel Ltd.

T K Naha
Sr, Vice President
JSW Steel Ltd.

2
 Background

In Both the COREX modules refractories over stave row 5 to 8 got
dislodged within three years of operation.

There was frequent rise in MG shell temperature and even hot spot
formation which lead to drastic decrease in hot metal production rate.

It was found essential to take some immediate measures to protect the
MG staves till the capital repair and continue operation with a reasonable
melting rate.

Gunniting over the staves was decided to be an ideal solution for the
same.

3
Preparation for Shutdown and Restart for Gunniting

Visited Saldanha for sharing the experience

Brainstorming

Preparation of detailed procedure for stop and restart of furnace

Tracking of char bed level during Blowing down and restart

4
 Preparation for gunning

Blowing down of COREX melter gasifier

Gunniting

Restart of COREX

5
 Blowing Down

Use of various innovative measures to track the

char bed level during blow down

Use of wet coal

Use of mill scale

Water addition

On-line mathematical model

Shell temperature measurement

6
Blowing down of MG

LRO 1602 (21.40 m)

LRO 1603 (20.25 m)
LRO 1604 (19.65 m)
LRO 1605 (18.35 m)

TARGET (16.1 m)

TUYERE (14.12 m)

7
 Lowering of char bed, during Gunniting in Mod-I

Actual tap start MR Coke rate Remark

Time before
time during last Tap start O2 stop
gunitting T/hr % Level at the time of tap start.
9th last
32 hrs
(Normal Operation) 32 hrs 90 20 LRO-1602 - 100%
(200 tons)
( 10/10/03 22:00 )
29 hrs 8th last
29 hrs 90 23 LRO-1602 - 50%, LRO 1603 - 100%
(205 tons) ( 11/10/03 01:00 )
26 hrs 7th last
26 hrs 85 25 LRO-1602 - 0%, LRO 1603 - 100%
(200 tons) ( 11/10/03 04:00 )
23 hrs 6th last
23 hrs 80 27 LRO-1602 - 0%, LRO 1603 - 100%
(202 tons) ( 11/10/03 07:00 )
20 hrs 5th last
20 hrs 60 30 LRO-1602 - 0%, LRO 1603 - 100%
(193 tons) ( 11/10/03 10:00 )
16 hrs 4th last
16 hrs 55 32 LRO-1602 - 0%, LRO 1603 - 100%
(200 tons) ( 11/10/03 14:00 )
12 hrs 3rd last
12 hrs 50 35 LRO-1603 - 0%, LRO 1604 - 75%
(57 tons) ( 11/10/03 18:00 )
8 hrs 2nd last
8 hrs 40 40 LRO-1604 - 0%, LRO 1605 - 100%
(235 tons) ( 11/10/03 22:00 )
2 hrs Last Tap
2 hrs 40 50 LRO 1605 - 0 %
(277 tons) ( 12/10/03 04:00 )

8
 Lowering of char bed, Melting rate and Tapping details
during Gunitting

Time before O2 MR Coke rate Remark Cast House /

Tap start REMARK
stop T/hr % Level at the time of tap start.
7th last
(Normal Operation) 25 hrs 90 20 LRO-1602 - 100% B
( 21/05/05 05:00 )
6th last
( 21/05/05 08:00 )
22 hrs 80 23 LRO-1602 - 0%, LRO 1603 - 100% B
5th last
( 21/05/05 11:00 )
19 hrs 60 27 LRO-1602 - 0%, LRO 1603 - 100% A
4th last B (Open
( 21/05/05 15:00 )
15 hrs 55 32 LRO-1602 - 0%, LRO 1603 - 100%
Periwall)
3rd last A (Open
( 21/05/05 19:00 )
11 hrs 50 35 LRO-1603 - 0%, LRO 1604 - 75%
Periwall)
2nd last B (Open
( 21/05/05 23:00 )
7 hrs 40 40 LRO-1604 - 0%, LRO 1605 - 100%
Periwall)
Last Tap 30% CRE, A ( Open
( 22/05/05 04:00 )
2 hrs 40 LRO 1605 - 0 %
70% Coke Periwall) *

Note: * after oxygen stop open cast house B as well

9
Mod – I Char Bed Level

10
Mod – I Stave Diff Temperature – Before Gunniting

11
 Prediction of Char Bed Level

TABLE

TIME , hrs MG Angle 00 MG Angle 900 MG Angle 1800 MG Angle 2700

1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9

MG Height
(mts)

21 140

20 140

19 135

18 130

17 80

16 60

12
Preparation for MG Gunniting
COAL
GUIDE CHAINS IN LINER
FROM DRI DROP
BOX CHAINS
MANHOLE FLANGE

27 mts
MAN HOLE

NORMAL OPERATING LEVEL

LRO 1602 (21.4mts)
PIO1212 VOLUME = 110.9 m3
(20.5mts) LRO 1603 (20.25mts)
VOLUME = 53.4 m3
LRO 1604 (19.65.4mts)
VOLUME = 105.7 m3
PIO1211
(18.35mts) LRO 1605 (18.35mts)

VOLUME = 159.2 m3
GUN
PIO1210 LRO 1606 (16.55mts)
(16.5mts)
TARGET LEVEL (16.12 mts)

3
VOLUME = 110 m

TUYERE (14.12mts)

TAP HOLE (10.01mts)

13
Melter Gasifier View Before Gunniting Mod-I

14
 Melter Gasifier View After Gunniting Mod-I

After completion

Gunning Process under Progress

15
 Restart of COREX after Gunniting

DRI, COKE, CRE,

LD SLAG, FLURO
LRO 1605
SPAR (160 m3)

CRE, LD SLAG,
FLURO SPAR (40 m3) TARGET

TUYERE (14.12 m)

16
 Restart after Gunniting

TABLE
Remarks
No. of Total tuyere Plant
Time after oxygen start Melting rate
tuyeres oxygen pressure

0 hrs 3 3 6000 2.5 Tuyeres were

opened
2 hrs 8 4 7200 3.5 alternately
towards 90° and
3 hrs 10 5 9000 3.5 270°.

4 hrs 12 6 10800 3.5

5 hrs 14 7 12600 3.5

6 hrs 16 8 14400 3.5

7 hrs 18 9 16200 3.5

8 hrs 25 10 18000 3.5

17
Results of COREX® Gunniting

18
Results of COREX® Gunniting

19
 Details of Gunitting of COREX®
Parameters COREX - I COREX - I COREX - II COREX - I
Date of Gunniting Dec 5 - 9, 2002 Oct 12 - 15, 2003 May 10 - 14, 2004 May 22 - 25, 2005
Shut down duration 89 hr 35 min 66 hr 13 min 63 hrs 71 hrs 3 min
Gunning mass
consumed, Tons
108 136 135 113
Gunning thickness,
mm
150 - 200 200 -230 200 - 230 150 - 160

DRI consumed, Tons 1646 1680 1975 2130

CRE consumed, Tons 103 139 173 167

LD slag consumed,
Tons
555 555 859 848

Coke consumed, Tons 1131 2000 1714 1914

Flourspar, Tons 13 14 9 19

70 % SBW & 30% 50 % Metropolitan 70 % SBW & 30 %

Coal blend 100 % SBW
Ensham & 50 % Ensham Ensham
Stave condition
Lower part of stave Partial naked and Partial naked and
Skull formation at stave
Stave row 5 row # 5 was covered lower part was lower part was covered
row # 5
with skull covered with skull with skull
Partialy Skull
formation at stave row
Stave row 6 - 7 Naked Naked Naked
# 6 & stave row # 7
was naked
Lower part of stave Lower part of stave Lower part of stave row Lower part of stave row
Stave row 8 row # 8 was naked row # 8 was naked # 8 was naked # 8 was naked
20
Details of Gunitting of COREX®

21
 Hot Metal Production [t]

0
1,000,000
2,000,000
3,000,000
4,000,000
5,000,000
6,000,000
7,000,000
8,000,000
9,000,000

08/08/1999

08/02/2000

08/08/2000

08/02/2001

08/08/2001

08/02/2002

08/08/2002

08/02/2003

08/08/2003

08/02/2004

08/08/2004

08/02/2005

08/08/2005

08/02/2006

08/08/2006

08/02/2007

08/08/2007

08/02/2008
Accumulated

08/08/2008
Hot metal throughput and gunniting of COREX- I

HM Production:
7. 7 Million tons

08/02/2009

08/08/2009
22
 Hot Metal Production [t]

0
1,000,000
2,000,000
3,000,000
4,000,000
5,000,000
6,000,000
7,000,000

16/04/2001
16/08/2001
16/12/2001
16/04/2002
16/08/2002
16/12/2002
16/04/2003
16/08/2003
16/12/2003
16/04/2004
16/08/2004
16/12/2004
16/04/2005
16/08/2005
16/12/2005
16/04/2006
16/08/2006
16/12/2006
16/04/2007
16/08/2007
16/12/2007
16/04/2008
Accumulated

16/08/2008
HM Production:

16/12/2008
6 .7 Million tons

16/04/2009
Hot metal throughput and gunniting of COREX- II

16/08/2009
23
24
 25 Production rate, T/hr
/0
5/
20
05
6:

0
10
20
30
40
50
60
70
80
90
100
110

25 14
/0
5/
20
05
11
:0
25 2
/0
5/
20
05
15
:5
25 0
/0
5/
20
05
20
:3
26 8
/0
5/
20
05
1:
26
26
/0
5/
20
05
6:
26 14
/0
5/
20
05
11
:0
26 2
/0
5/
20
05
15
:5
26 0
/0
5/
20
05
20
:3
27 8
/0
5/
20
05
GUNNITING RESULTS: Module-I May 2005

1:
26
Achieved 100 t/h

12 hrs after restart

Melting rate within

25
 GUNNITING RESULTS: Module-I May 2005

Tap No 1 2 3 4 5 6
Temperature, °C 1568 1580 1484 1515 1497 1525
Silicon, % 6.09 3.89 1.52 1.22 2.20 1.87
Sulphur, % 0.008 0.013 0.079 0.039 0.040 0.024
Hot metal, Tons 61 190 188 267 225 176
Slag, Tons 20 90 102 147 62 103

26
 90
C1-TIO1560.08: Shell Temperature_16mts_90° (°C)
80 C1-TIO1560.23: Shell Temperature_16mts_270° (°C)
C1-TIO1560.10: Shell Temperature_16.5mts_90° (°C)
C1-TIO1560.22: Shell Temperature_16.5mts_270° (°C)
70 C1-TIO1560.16: Shell Temperature_17.5mts_90° (°C)
C1-TIO1560.26: Shell Temperature_17.5mts_270° (°C)
C1-TIO1560.12: Shell Temperature_18mts_90° (°C)
60
C1-TIO1560.30: Shell Temperature_18mts_270° (°C)
MG surface temp., Deg.C

50

40

30

20

10

0
27
 140
C1-TIO1560.15: Shell Temperature_18.5mts_90° (°C)
C1-TIO1560.28: Shell Temperature_18.5mts_270° (°C)
C1-TIO1560.32: Shell Temperature_19mts_270° (°C)
120
C1-TIO1560.18: Shell Temperature_19.5mts_270° (°C)
C1-TIO1560.03: Shell Temperature_20mts_90° (°C)
C1-TIO1560.21: Shell Temperature_20mts_270° (°C)
100
MG Shell temperature, Deg.C

80

60

40

20

0
28
 Lowering of char bed, Melting rate and Tapping details
during Gunitting in May-04 - Mod-II

Time before O2 MR Coke rate Remark Cast House /

Tap start REMARK
stop T/hr % Level at the time of tap start.
7th last
(Normal Operation) 25 hrs 90 20 LRO-1602 - 100% D
( 09/05/04 13:00 )
6th last
( 09/05/04 16:00 )
22 hrs 80 23 LRO-1602 - 0%, LRO 1603 - 100% D
5th last
( 09/05/04 19:00 )
19 hrs 60 27 LRO-1602 - 0%, LRO 1603 - 100% C
4th last D (Open
( 09/05/04 23:00 )
15 hrs 55 32 LRO-1602 - 0%, LRO 1603 - 100%
Periwall)
3rd last C (Open
( 10/05/04 03:00 )
11 hrs 50 35 LRO-1603 - 0%, LRO 1604 - 75%
Periwall)
2nd last D (Open
( 10/05/04 07:00 )
7 hrs 40 40 LRO-1604 - 0%, LRO 1605 - 100%
Periwall)
Last Tap 30% CRE, C ( Open
( 10/05/04 12:00 )
2 hrs 40 LRO 1605 - 0 %
70% Coke Periwall) *

Note: * after oxygen stop open cast house D as well

29
30
31
Melter Gasifier View during Gunitting in May-05 – Mod-I

Stave row - 8

Stave row - 7

Row - 6 (skull)

32
Melter Gasifier View Before Gunitting during Dec-02 - Mod-I

Lower part of
stave row # 8 8

33

Two stage process: Reduction and smelting

Non-coking coal directly to Melter gasifier
Lump Ore / Pellets
Export gas 48% CO, 20% H2
/Additives

Coal Scrubber
Top Gas Export Gas

Red uction
Shaft
Scrubber
Reduction Gas

Hot Gas
Cycl on e
Compressor

Cooling Gas
Melter
Gasifier Dust

Oxygen
Settling Pond

Slag and
Hot metal

34
 UNIQUE FEATURES OF COREX®

Uses non-coking coal

Direct use of iron ore fines

Very good quality hot metal

The gas generated from the process finds wide range of application

Easy correction of hot metal & slag analysis possible within few hours

Easy shut down and restart of the plant, greater flexibility

Environmental friendly process

35
PERFORMANCE OF SHAFT

Metallization degree of the DRI and the Calcination of the additives are strongly
dependent on the following parameters.

Amount of the reduction gas flow

Quality of the reduction gas

Temperature of the reduction gas

Reducibility of the iron carrier

Grain size of the solids charged

IDEAL CONDITION FOR SHAFT OPERATION

Low pressure drop

Uniform gas distribution

High degree of metallisation

Low dust load

36
PERFORMANCE OF MELTER GASIFIER

The melter gasifier can largely be divided into three reaction zones as the following

Gaseous free board zone (Upper part or dome)

Char bed (Middle part above oxygen tuyeres)

Hearth zone (Lower part below oxygen tuyeres)

Fluidized bed in the transition area between the char bed and the free board zone.

The following factors affect the performance of melter gasifier

Coal Quality
i. Proximate analysis
ii. Size analysis (mean particle size)
iii. High temperature properties
iv. CSR, CRI and Free Swelling Index

Coke rate

Oxygen distribution through tuyere and dust burner

Dome temperature control

Metallisation percentage of DRI
37
 TYPICAL ANALYSIS OF IRON BEARING MATERIALS
ANALYSIS PELLET - I PELLET - II LUMP ORE -1 LUMP ORE-II
SIZE (mm) 8 - 20 8 - 20 10 - 30 10 - 30
Fe (T)% 65.78 64.2 66.6 65.2
FeO % 0.41 0.6 0.37 0.39
CaO % 1.20 1.60 0.06 0.09
MgO % 0.14 0.38 0.02 0.01
SiO2 % 2.98 2.84 1.41 2.48
Al2O3 % 1.47 2.35 1.25 2.26
P% 0.030 0.044 0.06 0.05
S% 0.003 0.005 0.004 0.004
REDUCIBILITY
(%O2/min) 0.42 - 0.56 0.42 - 0.56 0.42 0.42
DISINTEGRATION
INDEX % (-6.3 mm) 6.4 9.3 19.5 29.9
ABRATION INDEX %
(-0.5 mm) 1.8 2.8 2.3 4.9

38
 TYPICAL ANALYSIS OF VARIOUS COALS AND COKE
ANALYSIS COAL - I COAL - II COAL - III COAL - IV COAL - V COKE
FIXED CARBON % 69.2 63.0 58.3 55.3 53.4 87.5
VOLATILE % 20.4 27.3 27.5 32.7 34.4 1.3
ASH % 10.4 9.7 14.2 12.0 12.2 11.2
SULPHUR % 0.38 0.45 0.77 0.48 0.71 0.7
PHOSPHOROUS % 0.05 0.04 0.12 0.05 0.04 0.01
CALORIFIC VALUE
Kcal/kg 7520 7400 6900 7280 7010 7000
CRI % 23.5 33.5 32.5 33.0 40.0 22.8
CSR % 60.1 43.6 39.6 44.0 35.0 68.9
FREE SWELLING
INDEX 2 1.5 1.0 - 1.5 1 1 -

39
 TYPICAL ANALYSIS OF ADDITIVES
ANALYSIS LIMESTONE DOLOMITE QUARTZ LD SLAG DUNITE BHQ Mn Ore
CaO % 46.79 27.98 0.14 50.00 0.84 0.32 -
MgO % 3.83 19.84 - 9.20 44.35 0.10 -
SiO2 % 5.2 6.01 97.88 16.00 34.90 39.54 7.00
Al2O3 % 1.16 0.53 0.9 0.80 0.82 0.62 5.00
Fe2O3 % 0.96 0.49 0.62 18 (FeO) 7.20 57.70 22 - Fe(T)
P2O5 % 0.04 0.01 0.01 0.96 - - -
SO3 % 0.01 0.01 0.01 0.11 - - -
Mn % 0.008 0.008 0.070 0.59 - - 30.0
LOI, % 41.32 43.70 0.13 - 10.80 0.71

40
 ®
TYPICAL ANALYSIS OF COREX HOT METAL , SLAG AND SLUDGE

ANALYSIS
C Si S P Ti CaO MgO SiO2 Al2O3 FeO Fe2O3 TiO2
(%)

HOT 4.5 0.80 0.06 0.15 0.06

METAL

SLAG 0.60 0.26 34.5 14.5 31.7 15.1 0.50

30.61
SLUDGE 35.6 0.81 0.25 7.94 3.20 9.18 4.38 0.29

41
 COREX - ECONOMICES OF PRODUCTION

Use of non-coking coal instead of coke

Use of lump ore

Pellet plant

Oxygen

COREX gas credit
®

Energy consumption in COREX

Location

Power Surplus

High level of automation and low man power

Independence of Petro-products

42