11.

5 WORK INSTRUCTION FOR HEAT PROCESSING AT EAF

1. Responsibility :- 1.1. EAF& RMHS I/C

1.2. EAF Melter
2. Tools & Equipment:- EOT crane, Earth moving Vehicles, Lifter, Shovel, Transfer Ladle and
Slag pot.
3. PPEs :- Helmet, Gloves, Ear Plug, Fire retardant jacket & Safety Shoes, Melter goggles,
Face shield, nose mask
Record Reference:
1. EAF Shift Register - JSLO/RG/SMS-O-EAF/01
2. EAF material receiving register - JSLO/RG/SMS-O-EAF/02
3. EAF Log Sheet - JSLO/F/SMS-O-EAF/01
4. Method :-
4.1Start of Heat:-
4.1.1 Ensure all the interlocks for Furnace Start up are in healthy condition.
4.1.2Allocation of Heat No.
4.1.2.1 XYYZZZZZ
4.1.2.2 ‘X’- Denotes the Furnace EAF1/2 – In this case X-2.
4.1.2.3 ‘YY’- Denotes last two digits of the current running year. Example:- As the
current running year is 2012, YY-12.
4.1.2.4 ‘ZZZZZ’ – This figure denotes the Serial Number of Heat processed in SMS .
4.1.2.5 Example:- If Heat No. of the first heat in SMS is 21200001.
4.1.3 Time noted in EAF Log Sheet Doc
4.1.4 Previous heat tapping time to be noted in the EAF2 Log sheet.
4.2Scrap Charging in EAF.
4.2.1 Power Off.(Refer to Clause:- 4.11)
4.2.2 Ensure Furnace Tilting Lock is done.
4.2.3 Electrode Raise.
4.2.4 Roof Raise & Swivel out.
4.2.5 Centering of Charging Bucket by EOT Crane.
4.2.6 Open the bucket – along with communication with crane operator and EAF
Operator. After the scrap charging ensure the charge dressing.
4.2.7 Bucket out and Roof Swivel in and down.
4.2.8 Furnace Tilting Unlock if charge is complete.
4.3 Power On:-
4.3.1Isolator in 1 Position
4.3.2 Vacuum Circuit Breaker in Closed Position.
4.4Arcing :-
4.4.1Selection of Tap.
4.4.1.1 Power Availability – To be confirmed from Shift In-Charge SMS.
4.4.1.2 Refer to TABLE No.1.
4.4.1.3 Feeding the Tap and Curve setting to HMI.
4.4.2.Initial Arcing for Melting of Scrap.
4.4.2.1.Electrode Lowered and left in auto mode.
4.4.2.2.Electrical Energy = 350KWH/Mt of Charge added (approx).
4.4.2.3.Semi Molten:- After application of the above calculated power
and visual inspection that ensuring 60-70% of the
added scarp is melt, the heat is said to be in semi
molten state.
4.4.2.4. Ensure Low Tap Low current in the initial stage of melting.
4.4.3. Arcing for attainment of tapping Temperature.
4.4.3.1. Selection of Tap. (Refer to Clause No. 4.4.1)
4.4.3.2. Power On. (Refer to Clause No. 4.3)
4.4.3.3. Ensure Low Tap High Current.
4.4.3.4. Oxygen Injection to be started by BSE Lance at approximately 30-35 MWH and
quantity to be determined with respect to input charge mix.
4.4.3.5. Coke injection to be started along with oxygen injection
4.5.Addition Calculation and Planning.
4.5.1 Addition Calculation.
4.5.1.1 Aim Chemistry of Grades received from WI 11.7, clause 4.2
4.5.1.2 Total weight of charge received from Charging Log sheet.
4.5.1.3 After checking the total addition from Charging log Sheet
Ferro-alloy/ metallics addition is done as per the formula below.
4.5.1.4 Formula to Calculate Ferro-Alloy/Pure Metal Addition.
%of Alloy* Expected Liquid Metal
Addition of Ferro-Alloy /Pure Metal(PM) = ----------------------------------------------
(In KG) Efficiency of Ferro-Alloy/PM * Recovery

4.5.1.5 Flux addition is carried out as per Basicity requirement of 1.2-1.5.

CaO + MgO
Basicity = -------------------------------------------------------
SiO2
  To reduce energy consumption - :-
o Reduction in amount of flux addition:-
 Flux addition changes with every individual heat based on input charge
material, which leads to decrease in flux addition per heat at EAF. We are
saving electric energy which is required to melt these fluxes in EAF basis
the below calculator.

Typical Flux Calculator:-

Si Calulator is programmed

Raw material chemistry Bucket Required Si% opening 0.4

Charge O2 required for Si
  C Si wt.(T) Si load opening(after liq FeCr) 812
Ni PI 4 70 0 0
If no Liq FeCr is added, enter gas in
FeNi 2.2 1.8 4.67 0.0841 2nd box
CI slag pot 2.2 0.5 0 0 O2 blown b4 liq FeCr 0
SS 0.3 0.2 97.18 0.1944 O2 blown after liq FeCr 700
Solid FeCr 8 3.5 18.75 0.6563
SAF 3.5 4 0 0 Yield 94
Charge wt W/O liq FeCr 140.16 0.9347 LM 140
Liq FeCr 8 4.3 9 0.387
Charge wt with liq FeCr 149.16 FeSi to be added 0
Series 300 Required Flux  
Lime 1.60
Dolo 1.67
4.5.2 Planning.
4.5.2.1 Decision taken for addition of fluxes or raw material through MHS or by
EOT Crane as per their feasibility of addition.
4.6 Batching & Conveying.
4.6.1 The amount Ferro-Alloy/Pure Metal / flux calculated in Clause 4.5 are being fed in to
Batch Table which collects the material from the day bins, convey the material to
weighing hopper with the help of conveyor for weighing ,which further been
conveyed to Charging Chute and finally discharged to EAF.
4.6.2Material Added are reported in the EAF Log Sheet.
4.7Addition by EOT Crane:-
4.7.1 The material to be added are either arranged in a basket charge or lifted individually
(bags, coil or hook jam) depending on feasibility of addition.
4.7.2 Power Off.(Refer to Clause:- 4.11 )
4.7.3 Ensure Furnace Tilting Lock is done.
4.7.4 Electrode Raise.
4.7.5 Roof Raise & Swivel out.
4.7.6 Centering of charging chute by EOT Crane.
4.7.7 Communication with EOT Crane Operator.
4.7.8 Addition.
4.7.9 Bucket out and Roof Swivel in and down.
4.7.10 Furnace Tilting Unlock.
4.7.11 If liquid Ferro Chrome is available then plan to pour it into the furnace as per instruction
4.8. Temperature Measurement:-
4.8.1 Temperature Measurement with temperature lance.
4.8.2 Temperature Displayed in Electronic Display Board is noted down in EAF Log
Sheet.
4.9. Reduction
4.9.1 Addition of Al mix through chute after roof out.
4.9.2 Addition of FeSi through MHS
4.9.3 All additions to be noted in EAF Log Sheet.
4.10. Sample Analysis Report Check:-
4.10.1 Sample Taken from ladle after tapping and sent to QC lab through pneumatic sample
conveyor.
4.10.2 Reception of Sample Analysis report from QC Laboratory.
4.10.3 Noting down the analysis report in EAF Log Sheet.
4.10.4 Checking of received sample chemistry with that mentioned in Section 11.7, Clause
4.2
4.11. Power Off.
4.11.1 Circuit breaker must be in open condition.
4.11.2 Isolator must be in 0 position.
4.12Pre-Tapping Checks
4.12.1 Transfer ladle received and placed in Ladle Car.
4.12.2 If required, transfer ladle to be cleaned by TML before tapping
4.12.3 Transfer ladle to be centered.
4.12.4 Additions to be done during tapping must be kept nearer to work place for timely
execution.
4.13Tapping.
4.13.1 Ensure metal strikes at the base of the ladle and not at the wall.
4.13.2 Move the ladle forward and backward in the initial stages of tapping, so that metal
penetration at a single point in the ladle bottom does not happen
4.14 End of Heat.
4.14.1. Plan for basket charging for the next heat.
4.14.2 Heat end time is noted in EAF Log sheet.
4.14.3 Total Power consumed must be noted in EAF Log Sheet.
4.14.4 Tap to Tap time must be noted in EAF Log sheet.
4.14.5 Check for information to be noted down to EAF Log sheet before beginning of new
heat.
4.15 Addition of Liquid Ferro Chrome:-
4.15.1. Power Off (as referred in 4.11)
4.15.2. Follow the instruction as per 4.7.2-4.7.5.
4.15.3. Ensure centering of ladle/slag pot by EOT Crane.
4.15.4. Follow the instruction 4.7.8-4.7.10.
4.16. Special Precaution for Melt Down Heats:-
 One wash heat is taken with the same scrap as of meltdown before processing of
meltdown heats and the complete wash of metal from the furnace to be ensured.
 Tapping temp. 1570 – 1590 Deg C to be maintained, so that energy is not wasted by
unnecessarily heating the liquid metal by arcing thereby ensuring reduction in electrical
energy consumption.
 Oxygen injection to be done primarily for scrap cutting.
4.17 Slag door cleaning
4.17.1 Slag door cleaning to be done after taking first charge
4.17.2 Forklift and boom to be used to poke the slag jam at the slag door
4.17.3 Slag to be dropped on stationary slag pot below

4.18 Instructions for first heat after shell change/bottom repair

4.18.1 Clearance to be taken from refractory shift I/C and mechanical shift I/C before heat start
4.18.2 The three DPPs are to be kept covered
4.18.3 1 MT of CPC to be spread on bottom and bank
4.18.4 1 MT of dololime to be spread on top of the coke
4.18.5 Metal sheets to be spread on top of the dololime
4.18.6 First charge should have maximum loose shredded scrap
4.18.7 Furnace power on as per clause 4.3, start arcing as per clause 4.4 till first charge is half
molten and then furnace power off as per clause 4.11
4.18.8 Second charge to be taken and soaking to be done for 45 minutes. Soaking is the activity
in which the heat generated from melting will be utilized for hardening of the powder refractory
at the bottom. Prerequisites for this are the temperature and time.
4.18.9 During this interval no oxygen lancing to be done
4.18.9 Liquid FeCr not to be taken in this heat
4.18.10 Furnace power on as per 4.3, start arcing as per clause 4.4 till charge is three-fourth
molten and then furnace power off as per 4.11
4.18.11 soaking to be done for 20 minutes
4.18.12 Furnace power on as per clause 4.3, start arcing as per clause 4.4. Only 300 Nm3 of
oxygen lancing be done in this heat. Lance not to be aimed at the bottom and to be started after
complete liquid pool is achieved.
4.18.13 Temperature to be taken as per clause 4.8. Tapping temperature should be below 1600
deg C. If necessary temperature has been achieved, then add reduction mixture as per clause 4.9
or continue arcing as per clause 4.4.
4.18.14 Hold the furnace for 5 minutes for soaking before tapping
4.18.15 Tapping to be done as per clause 4.13

4.19 EAF refractory hot repair

4.19.1 Gunning
4.19.1.1 Check the EAF for gunning requirement
4.19.1.2 Check if the gunning hopper has the refractory material. If no, then fill up the refractory
material by using crane.
4.19.1.3 Check if the air pipe is clear or not and then fit the pipe
4.19.1.4 Check if the water hose is running or not and then fit the hose
4.19.1.5 Insert pipe inside the furnace and open the air hose
4.19.1.6 Once the refractory material starts coming out of the pipe, start water hose also
4.19.1.7 Once gunning is done, turn off the water hose and stop the air pipe line
4.19.1.8 Take out the gunning pipe.

4.19.2 Fettling
4.19.2.1 Check if refractory material present in hopper. If no, then fill the material using crane
4.19.2.2 Check if air hose is clear before fitting it to the machine4.19.2.3 Put the machine inside
the furnace by using crane
4.19.2.4 Close slag door if fettling machine is spinning, else not
4.19.2.5 Open the airline and move the fettling machine using the manual controller
After fettling is done, take the machine out and open the hose pipe.