Case Study

CONTROLLING CONVERTER BOTTOM BUILDUP IN SMS-1

Team Members (S/Shri)

Pig iron is converted into steel by oxidation of impurities in L D
converters lined with Mgo-C refractory bricks. Refining process in
J Anand Kumar
AGM(O) converter takes around 18 min where fluxes are added to facilitate
transport of impurities into slag. Excessive converter bottom build-
M V Ramnarayana Rao
AGM(O) up quite often to a level of 1.5m on an average is causing concern to
SMS because it is not only hampering productivity but also causing
K V M Nageswara Rao
DM(M) threat to the safety of the employees and to the equipment.

M Venkata Rao
DM(E) The case study is sharing the experience and learning while
E Purnachandar
implementing certain actions and modifying operating practices like
AM(O) converter positioning, methodology of addition of scrap and lime,
improvement in condition and availability of slag pot, increasing
periodicity of lance calibration and scanning of converter lining
conditions etc., to control the converter bottom build-up and
bringing it to a level below 0.4m.

STEEL MELT SHOP

 Controlling excessive bottom buildup in Converters
- Steel Melt Shop

Abstract :

Pig iron is converted into steel by oxidation of impurities in L D converters lined with Mgo-C refractory
bricks. Scrap& iron ore are added as primary and secondary coolants respectively. Refining process
takes around 18 min where fluxes are added to facilitate transport of impurities into slag. Of late
excessive converter bottom build up is causing concern to SMS because it is not only hampering
productivity but also causing threat to the safety of the employees and to the equipment.

This case study shares the learning and experience from the efforts made to control the excessive
converter bottom buildup by standardizing operating practices, increasing periodicity of converter
lining scanning, lance calibration etc.

Background:

Pig iron is converted into steel in L D converter by

oxidation of impurities. As the process operates at very
high temperatures, Mgo-C bricks are used as
refractory lining for the converters. Scrap is used as
primary coolant and iron ore is added as secondary
coolant. Refining process takes around 18 min where
fluxes are added to facilitate transport of impurities
into slag, after sampling and temperature is completed
the steel is tapped into the steel ladle. The slag left
over is splashed by N2 at 500Nm3/min for 2-3 min so
that a protective layer of slag is formed over the refractory lining which safeguards the lining during
blowing and the remaining slag is dumped into the slag pot.

After the previous heat is tapped and slag is drained, lining is inspected. Scrap and hot metal are
charged. Converter is tilted into the vertical position and the lance is lowered in the vessel to start the
blowing. Selection of the starting lance distance is such that the concentration of the force at the bath
level should not cause ejection of tiny iron particles (sparking) and at the same time maximum bath
surface area is covered by the oxygen jet. The starting lance distance (Xi) for specific oxygen blowing
rate Nm3/ (ton × min) can be calculated by
Xi = 0.541(db)1.04 where, db is bath diameter in meter.

Controlling Excessive Converter Bottom Buildup Page 1

 For 150 Tons converter, db=4.87m and Xi=2.8m,
when oxygen flow rate is approximately 460 to
480 Nm3 / min.
Initially oxygen is blown soft by keeping lance
distance higher to promote slag formation and
to avoid ejection of small particles, because hot
metal is not covered by slag. Lime is added in the
beginning of the blow in batches before 5 min of
the blow period. Oxygen is blown for nearly
15to18 minutes by progressively decreasing the
lance distance such that slag foaming remains
A typical view of Blowing under control and oxidation reactions occur
uninterruptedly. Slag and metal samples are
analyzed.
Physico-chemical interactions of molten bath with oxygen jet depends on the lance profile i.e. change
of lance height during the blow. The lance profile is specific to each converter and depends on
converter profile, hot metal composition, oxygen flow rate, hot metal chemistry and steel of desired
composition.

Nevertheless, in all converters initial lance distance is such as to promote iron oxidation so that
dissolution of CaO commences. The idea is to create a basic and limy slag at the early part of the blow
to onset de-phosphorization. Shallow jet penetration covers the larger bath surface and is favorable
more for iron and silicon oxidation. Small amount of carbon may be removed. Once slag is formed,
lance is lowered. Oxygen jet penetrates into the bath and carbon reaction favours because oxygen is
available now deep into the bath. At the same time, force of the oxygen jet creates metal droplets and
as a consequence three phase dispersion of gas/slag /metal droplets are formed which enhance the
rate of decarburization.

At higher lance distance, oxygen jet penetration into bath is shallow and slag formation occurs. As the
lance distance decreases, jet penetrates deep into the bath, carbon reaction commences, CO forms,
droplets are produced which together leads to the formation of a three phase dispersion consisting of
gas bubbles, slag, metal droplets. In this state of blow, both carbon and phosphorus removal occur at
a faster rate. Formation of three phase dispersion is a characteristic feature of the top blown
steelmaking. Three phase dispersion creates conditions for faster removal rates of C and P. Foaming
of slag has to be controlled to avoid expulsion of slag, which can be controlled by controlling Carbon
reaction with FeO in slag. Reaction between C and FeO in slag will not allow CO bubbles to grow.
Smaller size gas bubbles can be trapped easily in slag as compared to larger sizes. Slag may foam and
may be expelled from the converter. Thick viscous slag and adherence of the retained slag to the

Controlling Excessive Converter Bottom Buildup Page 2

bottom lining of the converter leads to excessive converter bottom buildup.

Excessive bottom built up in converter decreases the specific volume of the converter and also shift
the reaction zone of the converter to the top causing spillage of metal/slag, body jam formation and
track dozing, erosion of lip plates and also skull formation on the lance. Excessive bottom built up in
converter had directly reflected in productivity where converter -A had to be stopped due to skirt
movement problem for 241Hrs in the first campaign due to jam, later it was removed by O2 lancing
again this problem has repeated resulting declaring down for campaign repair. During the second
campaign also the same problem repeated resulting in a delay of 145Hrs.Apart from this, several other
problems faced are burning of SPTC & STC cables due to metal/slag overflow from mouth of the
converter, Lance tip failures, deformation of converter mouth, Umbrella plates deformation, Abnormal
change in blowing profile etc.,

1.8 Trend of Coverter Bottom Buildup

1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
21-Sep-…
30-Aug-…

11-Sep-…
13-Sep-…
15-Sep-…
17-Sep-…
19-Sep-…

23-Sep-…
25-Sep-…
27-Sep-…
29-Sep-…
22-Aug-…
24-Aug-…
26-Aug-…
28-Aug-…

1-Oct-15
3-Oct-15
5-Oct-15
7-Oct-15
9-Oct-15
11-Oct-15
13-Oct-15
15-Oct-15
17-Oct-15
19-Oct-15
21-Oct-15
23-Oct-15
25-Oct-15
27-Oct-15
29-Oct-15
31-Oct-15
1-Sep-15
3-Sep-15
5-Sep-15
7-Sep-15
9-Sep-15

In order to control the convertor bottom build up within the limits, a cross functional team has been
formed to study the above problem and to implement actions identified.

Implementation Methodology
Major Improvement Project

Team Members:
Sl.No. Name (S/Shri) Emp. No. Design. Dept.
1 J Anand Kumar 118874 AGM(O) SMS
2 M V Ramnarayana Rao 110805 AGM(O) SMS
3 K V M Nageswara Rao 111793 DM(M) SMS
4 M Venkata Rao 105536 DM(E) SMS
5 E Purnachandar 121783 AM(O) SMS

Controlling Excessive Converter Bottom Buildup Page 3

Details:
SIPOC (Supplier-Input-Process-Output-Customer) is made before proceeding the study of process map.

Supplier Input Process Out put Customer

SMS Slag Slag coated Converter
Utilities Nitrogen - (pre. converter lining
Slag Splashing
CRMP Calcined Dolo -
RMHP Sinter -
RMHP Coke -
Hot metal - (parameters:
BF/Mixers Converter
Converter with
SSD Steel Scrap - Light, heavy Charging load
CRMP Lime, Dolo -
RMHP Sinter -
Utilities Oxygen - Converter
(required
Blowing
Lime - Impurities free LS parameters:
Dolo -
Sinter -
Instrumentation Probes for temp. Report on LS Converter
Sampling
Converter Liquid Steel composition
Temperature

Sec. Metallurgy/
MM/CSD Ferro Alloys CCD
(required
Tapping
MM/CSD Petro Coke Liquid Steel parameters:
MM/CSD Aluminium

Then a detailed process map is made to study the process and to identify contributing factors and
existing controls to run the process within the permissible limits thereby to control excessive converter
bottom buildup.

Controlling Excessive Converter Bottom Buildup Page 4

 Steel
Scrap Tilt the
Converter to
charge Scrap

 High/ Low Si content in

HM.
 Lime quality Hotmetal Charging of
from BF/ metal into
mixer Converter

Existing Control: Fluxes Lance tip & height/ lance

Storing in Mixer for availability
homogenization. Lance
insertion &
Coordination with BF & blowing
CRMP
Existing Control:
Lance calibration in every
 Converter lining condition. Sampling & A-Shift
 Slag fluidity & Nitrogen Temparature
pressure. measurement

Slag pot, SPTC & STC

availability.
Existing Control:
Condition of Slag Pot.
Scanning once in every 300 Slag
Tapping
heats. Splashing

Existing Control:
Periodical maintenance &
planning
ARS

Parameters No
Ok

Yes

Casting

Controlling Excessive Converter Bottom Buildup Page 5

From the study using SIPOC and process map and through brain storming the following points were
identified as major contributing factors for converter bottom build up:
 Non availability of slag pot transfer car to dump slag after slag splashing due to electrical/
mechanical/operational problems.
 Non availability of clean slag pot to dump the slag completely.
 Hot metal Si % not in the range of 0.4 to 0.6
 Delay in slag dumping after splashing due to track jams/ non availability of transfer cars
 Addition of excessive dolomite during blowing and during splashing
 Long maintenance schedules
 Mouth inside jam formation restricting complete draining of slag
 Longer lance height calibration schedules.
 Bad flux analysis.
 Interruptions in blow resulting in excess lime addition to suppress the slopping

Data collection was carried out and from the data, most recurring factors among the above identified
contributing factors are further funnelled down and Pareto analysis has been carried out to identify
vital few factors those are contributing for excessive bottom build up. The Pareto Analysis is shown
below:
100.00

90.00

80.00

70.00

60.00

50.00

40.00

30.00

20.00
30.95 27.38 22.62 10.00
9.52 5.95 3.57 0.00
SPTC Non- Low reactivity in STC Non-
HM Si content Slag Pot jam Slag Yard Prob.
Availability lime Availability
% Contribution 30.95 27.38 22.62 9.52 5.95 3.57
Cum. % 30.95 58.33 80.95 90.48 96.43 100.00

Fig. Pareto Analysis – Identification of Major Contributing Factors

Further, various factors leading to the above are identified and a cause and effect diagram is made.
The cause and effect diagram is indicated below:

Controlling Excessive Converter Bottom Buildup Page 6

The causes identified were further analysed using Why-Why analysis to find out root causes. The why-
Why analysis is shown below:

Why-Why Analysis:
Process / Eqpt/ Failure/ Major reason Root Cause Analysis *
Sl.
Assembly/ undesired / Contributing
No Cause Sub-Cause-1 Sub-Cause-2 Sub cause-3 Sub-Cause-4 Sub-Cause-5
sub-assembly event factor
1 Steel Making/ Increase in Slag drying SPTC Non- Field fault
Converter Bottom Availability Cable Problem Cable cut Position
Buildup Stuck up Jam
Re-termination Cable cut Position
BF Throttling Material
Si in HM non-
availability
Slag Pot Jam Slag Drying Improper Slag fluidity Si Content BF Issue
dumping in HM
Delay in Crane
dumping problem
STC Non- Stucking up Jam Spills on Jammed slag
availability track pot
Cable Spillage of hot Jammed Slag
burning material pot
Field fault
Car De- Jam Spills on Jammed slag
railment track pot
Poor LOI variation CRMP issue
Flux
Quality &reactivity

In addition to the above analysis, risk prioritisation is also done using FMEA methodology. Then the
action plan is made to eliminate root causes and causes with higher risk priority number (RPN).

Controlling Excessive Converter Bottom Buildup Page 7

Controlling Excessive Converter Bottom Buildup Page 8
Action plan to eliminate or control the causes identified is shown in the table below:

Root Cause/ Cause to

Action Plan
Contributing eliminate
Sl.No.
Factor Resource
Ref.No. Description Ref.No. Activity Target Date
Required
1 Hot 1.1 Si Content low 1.1.1 Retention of Slag in Dec'16
Metal Converter onwards
1.1.2 Optimizing addition of Dec'16
steel scrap onwards
1.2 Si content 1.2.1 Intermediate de- Addl slag Continuous
high slagging pot
1.3 Non 1.3.1 Planning Continuous
availability/ maintenance/repairs
idle time
2 Lime 2.1 Low reactivity 2.1.1 Addition of lime in small Continuous
(< 250) batches,20% excess to
be added
3 Blowing 3.1 Lance height 3.1.1 Lance calibration in Dec'16
every shift. onwards
3.2 Lance 3.2.1 Keeping spare lance Addl. lance Dec'16
availability ready. onwards
4 Tapping 4.1 SPTC/STC non 4.1.1 Increasing inspection Dec'16
availability frequency. onwards
4.1.2 O.H cable SPTC, STC to Continuous
be used, Converter
positioning towards
charging or tapping
side.
4.2 Slag pot 4.2.1 50% of the pot to be Dec'16
jamming filled with dry slag onwards
before sending to
converter for slag
dumping.
4.2.2 Optimizing logistics to Crane direct u/process
completely dump slag. dumping with DNW

Solutions for Major factors contributing for bottom build up

1. Controlling Bottom Buildup during Slag pot/ SPTC non availability:

In case of non-availability of slag pot due to any failures, a practice of tilting the converter 900
towards the charge pad position or 900 towards the tap pad position has been introduced and
practiced so that the slag will stick to the charge pad area or tap pad area and not in the bottom.
In case the break down is contributing to more than 2-3 hrs, then it is practiced to empty slag by
dumping in a high life ladle and by not to allow the slag to dry by giving bottom lime to get
deposited in bottom. This practice has allowed in controlling excessive bottom build up and also
lining improvement in charge pad and tap pad area.

Controlling Excessive Converter Bottom Buildup Page 9

2. Addressing poor quality of flux:
For ascertaining quality of flux suitable for steel making, close monitoring of lime analysis report
by shift in charge/blower and discussing the issue with section in charges to pursue with CRMP
department. Even if poor quality of lime is observed with high LOI and low reactivity, then a
practice of charging 20% more than the designated lime in small batches continuously so that lime
will react with impurities to form good foamy slag, but not viscous slag. This practice of charging
lime in small batches improved the slag fluidity and hence resulted in controlling excess bottom
buildup.

3. Hot metal “Si” content:

Neither high nor low “Si” content is desirable in steel
making. The desired level shall be in the range of 0.4%
to 0.6%.
 In case if the “Si” content is less than 0.4%, then
following practices are introduced
 Blowing with small batches of steel scrap/fluxes
after hot metal charged into the converter as
scrap also contains “Si” content of 0.2% which
will further reduce the average “Si” content of
the hot metal.
 Retention of small amount of slag in the
converter while slag dumping into slag pot so as
to facilitate early slag formation.
 In case if the “Si” content is more than 0.6%, then
the volume of slag generated is more than slag pot
volume, it is practiced to plan intermediate de slagging process so that complete slag is drained
out of converter without production delay.

4. STC break down:

In case of any break down of STC after tapping practice of deploying a dozer for immediate clearing of
spilled material below the converter and giving priority for slag dumping are ensured.

5. Practice to counteract Jam slag pots:

Close monitoring to avoid circulation of jammed slag pots in Slag Yard when “SI” level is high in hot metal.
Even if jam slag pots are in circulation under un avoidable circumstances prevailed in Slag Yard, a prior
communication by slag yard to the converter in-charge Then it is practiced that removing maximum slag
during the period of recording the temperature and sending the slag pot to the slag yard for changing so
that by the time tapping and slag splashing is completed another slag pot is made available for slag dumping

Controlling Excessive Converter Bottom Buildup Page 10

 without any production delay and retention of excess slag inside the converter which ultimately result in
bottom buildup.

Fig. Slap pot – in good condition Fig. Slagpot in jammed condition

6. Slag yard problems:

In case of any major breakdowns in slag yard alternative method of slag dumping using high life ladles is
introduced. Also, at least one high life ladle is made available round the clock to cater any emergency break
down in slag yard.

Solutions for Minor Factors Contributing For Bottom Build Up

1. Viscous slag:
The tapping in-charge closely monitors the condition of slag in
every heat during tapping and inform the blower regarding the
same and instruct the blower for specific addition of dolomite for
slag conditioning before slag splashing. In case the slag is viscous
a practice of dumping slag completely without slag splashing is
introduced so as not to allow the viscous slag to adhere at the
converter bottom and leading to buildup.

2. Improper lance height: Fig. Complete Slag Dumping

The lance height plays a vital role in slag formation, Oxygen jet
penetration differs at varying heights. The present practice of calibrating the lance height in every “A” shift
(for 24 hrs)and the error is incorporated after calibration, but this error may vary depending upon several
conditions like ”SI” level in hot metal, amount of hot metal charged, blowing profile and several other
factors during the process. Hence lance calibration is recommended daily in every shift to avoid soft or
hard blows resulting in changes in converter bottom build up.

3. Slag retained after dumping:

In case of slag left over after slag dumping due to jam pots for any other reason, it is advised to wait for
another slag pot and dump the slag completely. If time does not permit to wait for another slag pot, rock

Controlling Excessive Converter Bottom Buildup Page 11

 the converter 900 towards the tapping side and 900towards the charging side if required small amount of
lime may be added. This will have minimum impact on bottom build up but also will help in buildup of
charging side and tapping side areas.
4. Excessive flux addition:
Correct amount of fluxes are to be added for transport of impurities into slag ,Excess fluxes not only
hampers the dissolution process causing hindrance to transport of impurities but also makes the slag more
viscous resulting in bottom buildup. Hence it is advised to start the blow after availability of hot metal
analysis to add correct amount of fluxes .Level -2 models are be used for flux addition to get the desired
benefits.

5. Poor productivity:
Any disruption in production causing idle time in Converter may lead to bottom buildup due to Lime added
in bottom will stick to the bottom and increase it. Hence whenever production clearance is withdrawn due
to machine closure .it is advised to keep the converter in nose down condition or inclined to 900 towards
charging side .Incase of minor maintenance schedules like mouth jam dropping, track dozing etc., bottom
lime should not be added.

Results

1) Converter bottom build up has been controlled through altering and ensuring certain operational
practices in the area of positioning converters, slag splashing and dumping, scrap and lime & other flux
materials charging practices, rescheduling/ increasing the periodicity of condition monitoring practices
etc.,

2) The bottom build up in all the three converters is controlled and kept below 0.5m level as targeted.
During Apr-May, 2017, the bottom buildup levels are varied below 0.4m.

Trend in Converter Bottom Buildup

1.8
Before Bottom Buildup
1.6
Target
1.4
1.2
1
0.8 After
0.6
0.4
0.2
0
10-Nov-16
20-Oct-15
10-Nov-15
27-Nov-15
10-Dec-15
26-Dec-15

20-Nov-16
25-Nov-16
30-Nov-16
31-Oct-16
5-Nov-16

15-Nov-16

5-Dec-16
10-Dec-16
15-Dec-16
20-Dec-16
25-Dec-16
30-Dec-16
4-Jan-17
9-Jan-17

5-Mar-17
16-Sep-15
30-Sep-15

15-Feb-16
26-Feb-16

13-Feb-17
18-Feb-17
23-Feb-17
28-Feb-17
22-Aug-15

3-Feb-17
8-Feb-17
10-Jan-16
26-Jan-16

14-Jan-17
19-Jan-17
24-Jan-17
29-Jan-17

10-Mar-17
15-Mar-17
20-Mar-17
25-Mar-17
30-Mar-17

Controlling Excessive Converter Bottom Buildup Page 12

 The bottom buildup results - converter wise for the period Apr-May, 2017 is shown below:

0.6 Trend of Converter Bottom Buildup

LD-1 LD-2 LD-3 Traget
0.5

0.4

0.3

0.2

0.1

The discontinuation of the trend during certain periods is due to campaign repairs of respective
converter during that period.

3) After implementation of various operational controls and continuing over a period of 6 months, the
FMEA is again carried out and indicated above. From the above FMEA it can be observed that there is
considerable reduction in RPN.

Failure Mode and Effect Analysis (FMEA) - Post Implementation

Before QIP Post Implementation
Process Potential Failure Sevi- Occu- Detect- Sev. Occ. Det. RPN
RPN Actions Implemented
Step Mode ority rance ability
(SxOxD)
(S) (O) (D)
Slag Slag composition 8 5 3 120 Intermediate deslagging 8 3 1 24
Splashing Slag dryness/ 8 6 3 144 Introduce practiece of No 8 4 1 32
fluidity scrap addition
Scrap Steel Scrap Quality 8 3 3 72 8 2 2 32
Charging
HM HM Composition 8 7 3 168 Practice of Slag retention in 8 4 1 32
Charging the vessel
HM Availability 8 4 3 96 Opportunity Maint. 8 2 1 16
Low HM Temp. 8 4 2 64 Practise No scrap addition 8 3 1 24
Flux Lime Reactivity 8 6 2 96 Batch optimisation 8 4 1 32
addition
Blowing Lance Avilability 8 5 2 80 Spare lance made available 8 3 1 24
Lance height 8 3 3 72 Calibrating lance in every 8 3 1 24
Lance calibration 8 5 3 120 shift
8 3 1 24

Controlling Excessive Converter Bottom Buildup Page 13

 Sevi- Occu- Detect- Post Implementation
Process Potential Failure RPN
ority rance ability Actions Implemented
Step Mode
(S) (O) (D)
(SxOxD) Sev. Occ. Det. RPN
Tapping Res idual s teel 8 3 2 48 Communi-cating ladle 8 1 1 8
condition.
Ladle availability 8 4 3 96 Pos itioning Converter in up 8 1 1 8
right
STC Stuck up 8 4 3 96 Over Head cable to all STCs 8 4 1 32
SPTC availability 8 4 3 96 Keeping Converter in Charge 8 4 2 64
pad/ tap pad angle.
CCM availability 8 4 3 96 Pos itioning Converter in 8 4 2 64
ups ide down condition/ mid
repiar.
Slag Slag yard Carnes 8 3 2 48 Practicing dumping of s lag 8 2 1 16
Dumping availability in down/old ladle.
Drying of s lag 8 4 2 64 Practics ing rocking of 8 3 1 24
converter on charge pad/tap
pad angle

Schedule of Work

Start Date : 01.08.2016

Completion Date : 31.05.2017

Conclusion

Several trials and studies have been conducted from the month of Aug-2016 to Mar-2017 to evaluate
root cause and the reasons for bottom build up were systematically screened. The solutions
implemented as described above yielded into controlling the converter bottom buildup below 0.4m
level from an average level of about 1.5m before taking up the project.

Learning & Insights gained

 Whenever converter is planned for maintenance bottom lime should not be added soon after
slag dumping, it should be added only before charging of hot metal. In earlier practices the
bottom lime added used to stick and resulted to in converter bottom build up.

 If slag is left over in the converter wait for another slag pot and dump the slag. During this waiting
period ensure converter is tilted towards charging side up to 900 or onto tapping side up to 900,
but should not be kept in in vertical position.

Controlling Excessive Converter Bottom Buildup Page 14

 During tapping, the condition of the slag is to be checked and incase if slag is viscous
blower/operator to dump the slag completely without slag splashing.

 In case of poor lime quality (high LOI and low reactivity) 20% more than required quantity of lime
is to be added but in small batches within 5 min.

 In case of low “Si” content <0.30 in hot metal, iron ore/sinter should be added as coolant in place
of steel scrap as addition of steel scrap further reduces the average “Si” content of the hot metal.

 In case of high “Si” content in hot metal>0.70 intermediate de-slagging should be done without
fail to avoid left over of slag in the converter even after slag dumping.

 Lance calibration in every shift has given good results.

 In case bottom build up is above 1.0 met the following procedure to be followed to reduce it to
below 0.5m within 24hrs which was implemented successfully in this project and kept as control
measures.
a) After completely dumping the slag charge 3-5 ton of hot metal in the converter.
b) Blow oxygen at a rate of 450nm3/min till cumulative oxygen reaches 2000 nm3
c) After blowing, keep the converter in vertical position for 30 min
d) After 30 min dump the entire slag completely in jam pots so that it will not damage the slag
pots
e) Do lance calibration there will be reduction in bottom and further reduction in bottom is also
noticed during subsequent heats.

Controlling Excessive Converter Bottom Buildup Page 15