You are on page 1of 50

PRESENTED BYDEEPAK DWIVEDI DEPT.

OF METALLURGY OPJIT, RAIGARH (CG)

Steel Melt Shop
A Journey Towards Excellence

STEEL MELT SHOP II

MAJOR FACILITIES
ANNUAL CAPACITY
PRODUCTION 2009-10
(UPTO 31/01/10)

2.0 MT
65000 T

ELECTRIC ARC FURNACE
LADLE REFINING FURNACE

02 NO.
03 NO.

VACUUM DEGASSER
CONTINUOUS CASTER

01 NO.
03 NO.
STEEL MELT SHOP II

MAJOR MILE STONES OF SMS-II sms -2 have been produced 73 heats in a day since April. (world’s second largest )

STEEL MELT SHOP II

PRODUCTS STEEL MELT SHOP II .

STEEL MELT SHOP II .

NALWA. STEEL MELT SHOP II . JSL. BHEL.KEY CUSTOMERS • RUBM (ROLLING AND UNIVERSAL BEAM MILL) • SEMI’S—MSL.

STEEL MELT SHOP .II .

STEEL MELT SHOP II .

SCHEMATIC DIAGRAM OF EAF STEEL MELT SHOP II .

ELECTRIC ARC FURNACE SALIENT FEATURES • • • • • • • MAKE CAPACITY TRANSFORMER RATING ELECTRODE DIA. NO OF OXYGEN LANCE FURNACE LINING BRICKS TAP HOLE : : : : : : : Sms demag 100 MT 100 MVA 24"(600 MM) 4 MAGNESIA CARBON BRICKS EBT TYPE STEEL MELT SHOP II .

Decarburisation. 3.FUNCTIONS OF EAF Functions of EAF: 1. Raising the temperature of the melt to ≈16200C for tapping. STEEL MELT SHOP II . 2. Slag free and compact stream tapping. Dephosphorisation. 5. Melting of inputs and homogenization of steel bath. 4.

2% %Si : 0.8 to 4.5 Scrap : 1 to 5% (optional) INPUTS FOR EAF  FLUX: • • Lime from LDP (Lime and Dololime Plant) Burned dolomite from LDP  OTHER INPUTS: • • Oxygen from Oxygen plant.0 % %P : 0. CPC (Calcined petroleum coke) STEEL MELT SHOP II .1 max %Fe(met) : 81 min %SiO2 : 3.ELECTRIC ARC FURNACE  METALIC INPUTS: • • • • • • • • • • Hot metal from blast furnace : 30 to 70% %C : 3.13 max Temperature : 1280 deg min DRI (Lumps +Fines) from DRI Plant : 40 to 49% %C : 0.3 TO 1.

010 % Other elements : Trace Tapping Temperature : 1620°C STEEL MELT SHOP II .ELECTRIC ARC FURNACE HEAT CYCLE: Charging Hot metal pouring Melting& Blowing Tapping Tap to tap time : 53 min EBT filling time : 3 min Slag pot changing/ pit cleaning time: 13 min Hot metal pouring time : 5 min HEAT Arc time : 29 min CYCLE Tapping time : 3 min CONTROL PARAMETERS: Power in put : 70 to 75 MW Oxygen input : 120 Nm3/min Tap Chemistry %C : 0.05 %P : 0.

• DRI-0-55% • Hot metal.Melting process in eaf • EAF shift incharge insure the charge mix preparation as per the instruction of incharge.0-40% • (scrap+skull+DRI+pig iron) .0-80% • Bucket charge.

• Calculate oxygen blown in furnace through VLB .• Best charge mix combination always try to • Aim for optimum output is mentioned below which depends upon availability of raw material and power • Power.50-72 MW • Hot metal.40.48% • Bucket charge – 0-2% • EAF is switched on and operating on low power depending on scrap.50-58% • DRI.

Temp. of melt should not less than 1600c .• If the carbon content is high in that condition the extra oxygen will be supplied for the reduction of carbon in the form of Carbon dioxide Furnace helper takes the temperature of the melt in EAF .

• During tapping addition of ferroalloys .• TAPPING • Shift incharge instructs the PIT side supervisor to get the ladle below the tapping hole of the EAF .before tapping it is ensured that the purging is in open condition . fluxes and deoxidizer are done. • Then transfer towards ladle. .

Thermocouple circuit of EAF .

50.FUME EXTRACTON SYSTEM EAF No of ID fan : Flow value of each fan : Total bag area : Air to cloth ratio (PEAK) : Pressure drop across bag filter house : Dust content at outlet of bag house : 3 nos (2W+1S) FES 7.862 m2 100 Nm3/m2/hr (approx) 16 mbar (approx) 20 mg/Nm3 STEEL MELT SHOP II .000 Nm3/hr 14.

FES LINE DIAGRAM .

STATUTORY NORMS STEEL MELT SHOP II .

1 LRF-2x3 EAF 1&2 RMH bag house NORMS 50mg/m 3 (Max) 50mg/m 3 (Max) 50mg/m 3 (Max) 50 mg/m3 (Max) STEEL MELT SHOP II . AMBIENT NOISE LEVEL . RESPIRABLE PARTICULATE MATTER SO2 NOx CO 120 µg/m3 (Max) 120 µg/m 3 (Max) 5000 µg/m3(Max) 4.NORMS Normal Work zone 6AM to 9PM 9PM to 6AM (Day) (Night) 75 dB 70 dB 85 dB 85 dB 2. STANDARD PARTICULATE MATTER AT GUEST HOUSE STATUTORY SPM 500 µg/m3 (Max) NORMS 3. STACK EMISSSIONS MONITORING SMS LRF.1.

2%.2-1.calculations • At eaf• Dri-0-55% • Hot metal (si-.temp. 1100-1380c)-080% • Bucket charge (scrap+skull+dri+pig iron)-040% • Power: 50-72 mw .

total hot metal will consist 360 kg of si.4 For maintaining 2 bassisity -410.8 cao is required. 100-kg---------. • Then= si +o2 = sio2 • • • • • Sio2 = 360x1.Example• If we want hot metal consist 60kg si then according to the capacity of eaf (60mth/m.2x2=820.85kg pure cao 820.2 kg -----. But pure lime consist approx 85% pure so.114=410.85/100 x 820.8 .

• When it had achieved 73 heat then tap to tap • Time will =39.45 min. tat to tap time is 32 min.example • Silica load x 50% = req. . Mgo • The capacity of eaf 65 ton. if furnace run at 1 MW . . 70 x 30 = 2100kg. in jspl 70 Mw furnace run • So.

will raise 5c And we know that furnace temp.1530c Supply temp. raise=5c . is. raise = 69c 1 min temp. So total temp.is 1599 c.Super heat • Lrf ---80c-----slab –20c----tundish –40c --casting –30c----So super heat is= 20+40+30=90c Let us assume after 1 min. temp.

. drop. • So total running of furnace can calculated as =14+7+5=26 min. We are adding 1. Through fafa.so furnace will have to run 7 min.• so furnace will run for around 14 min.5 ton of sub. • Due to this super heat furnace wikll run for extra 14 min. but ladle takes time because• 1-addition of substances • 2-cooling of ladle • 1% addition of any substance results 20-25c temp.

• They have a transfarmer of 12 mva at power factor of 0. 60 min power consumption is =9600w • 26 min ----------4160w • That means power req. for 1 ton is 4160 watt • Cost of power for 1 ton melting can also calculated if 1 watt’s cost is g • Thencost=4160 x g .8so total power consume=9600w • We are running furnace for 26 min. • So.

Paper is called as eloxide paper . • It is supplied by shreeram industry.(spectrolab) • to start Spectrometer we have to press f2 botton . . • Sample must be polished . • For picking sample sample lancing is used . • Before that loly pop sample have taken from lrf as well as eaf also. For that purposedisc polisher and automatic polisher is available. • It consist of ab 60 grit paper. • Automatic polishing machine have been supplied from germeny.height of sample lancing is 5 ft.• Quality control dept.

• Simn-60%mn. 13-15%si • Fe-si – 70% si • Hcmn – 70%Mn .• Lequous temp. of steel-= • 1537-(.8% c • Al wire – 96% Al .65x %c+8x%si +5% Mn) • Wheet powder is a good insulator and it wilkl drop 1-2c. 4.

alloy addition = pointed to be need x tonnege of material x100%/%efficiency .• So.

.

STEEL MELT SHOP II .

STEEL MELT SHOP II .

of LRF Make Capacity : : : 03 Sms demag 100T 18 MVA Transformer rating : STEEL MELT SHOP II .Ladle Refining Furnace(LRF) Salient Features No.

Raising desired temperature for casting.Thermal and Chemical Homogenization.Refining of steel 2. STEEL MELT SHOP II .Achieving desired chemistry.Desulphurisation 3.FUNCTIONS OF LRF 1. 3. 4.

000 Nm3/hr Connected to Secondary (Canopy Duct) of Main Fume Exhaust system.FES FOR LRF : No of Booster Fan Capacity : : 1 no. 1.00. STEEL MELT SHOP II .

STEEL MELT SHOP II .

VACUUM DEGASSER LADLE STEEL MELT SHOP II .

Continuous 16 Nm3/hrs max Argon Stirring : STEEL MELT SHOP II .italy 350 Kg/hr at 0.5 torr 5 minutes to 0.5 torr 9 Steam ejectors 3 +1condensers works on successive compression of off-gas in a series of steam ejectors. Engg and Supply Suction Capacity Pump down time Vacuum System : : : : danieli.Vacuum Degasser Salient Features Design.

Removal of sulphur by slag-metal reactions promoted by Argon purging.VACUUM DEGASSER Functions of VD: 1.Removal of entrapped gases 2. STEEL MELT SHOP II .

STEEL MELT SHOP II .

BILLET CASTER (UNDER PROJECT) COMBI CASTER STEEL MELT SHOP II .

Combi Caster :        • •             No. of strands Machine Type Supplier Radius Mode of straightening Strand Center distance Machine speed Speed range Restranding speed : Length from meniscus in mould to torch cutter Casting mode Mould length Metallurgical length Ladle accommodation Dummy bar system EMS Mould level control : Type of mould Oscillation Cutting Device Cut length : : : : : : : : : : : : : : : : : : 04 Combination caster with curved mould vai 12000 mm Continuous 1800 mm 0 to 2.0 m/min 32. Hydraulic mould oscillator (Dynaflex) GEGA Torch cutting machine 4.5 m/min ≈ 3.5 to 12 mtrs STEEL MELT SHOP II .5 mtrs Ladle turret (Butterfly type) Chain type dummy bar (Bottom feeding) Electromagnetic mould stirrer Cs 137 source with stopper rod control. Curved mould with Cu plates for beam blank and Blooms.5 mtrs Powder casting with stopper rod system and mould EMS system 800 mm 20.Continuous Casting Machine 1. Cu tube for rounds.

305 mm Rnd. 255.1. 355x280x90 mm Beam blank. 285x390mm 250x250 mm Bloom. 220. STEEL MELT SHOP II . Combi Caster Products 420x480x120mm. 200.

1 mtrs Butterfly type Ladle turret Rigid type dummy bar (Bottom feeding) Electromagnetic mould stirrer Co60 source with stopper rod control. Billet Caster (Under project):                    No.Continuous Casting Machine 2. Curved tublar Cu mould Electro mechanical ALBA Torch cutting machine 9 to 12 mtrs STEEL MELT SHOP II .5 m/min 27. of strands Machine Type Supplier Radius Mode of straightening Strand Center distance Machine speed Speed range Restranding speed Length from meniscus in mould to torch cutter Casting mode Mould length Rounds Squares Metallurgical length Ladle accommodation Dummy bar system EMS Mould level control Type of mould Oscillation Cutting Device Cut length : : : : : : : : : : : : : : : : : : : : : 06 Curved heavy duty Type CONCAST 9000 mm Continuous 1200 mm 0 to 5 m/min ≈ 3.1 mtrs Powder casting with stopper rod system and mould EMS system 800 mm 1000 mm 27.

165x165mm 200x200 mm STEEL MELT SHOP II . Billet Caster (Under Project) : Products : 130x130mm.Continuous Casting Machine 2. 150x150mm.

17.5 to 9m.3m • Hydrulic • 3. of strands: Machine type: Supplier: Mould length: Metallurgical length: • Oscillation: • Cut length • • • • • 01 Curved mould Sms demag 700mm.Slab caster • • • • • No. .