STEAM GENERATION

AGENDA
 Introduction
 Description of the components that are part of Steam
Generation.
 Steam Improvement point checklist
 Reasons Steam Generation Could Not Reach Target.
 How could hit the Target
 Final tips & takeaways
INTRODUCTION

 Steam can refer to the gaseous state of water, which is

created when water molecules break free of their hydrogen
bonds and transition from a liquid to a gas at 212°F (100°C).
 This process is known as boiling, and it occurs when heat is
applied until the water reaches the enthalpy of
vaporization. Steam can also be created through evaporation.
 The major process of steam generation depends on Raw
materials like Dolomite, Coal & Pallets or Iron-ore which
pass lots of Heat from ABC(After Burning Chamber).
DESCRIPTION OF THE COMPONENTS THAT ARE PART OF
STEAM GENERATION.

1. Standard size of Raw material

2. Composition of raw material.
3. Detailing production capacity with Steam generation.
 1. Standard size of Raw material

Indicator Name Full Name Size Uses

Inlet Feed
1) I/O Iron Ore

2) F/C1 Feed Coal 1

8 to 20mm Inlet Feed

3) F/C2 Feed Coal 2

4) M/C1 Medium Coal 1

4 to 8mm

5) M/C2 Medium Coal 2

Outlet Feed

6) I/C Injection Coal 1

0 to 4mm

7) I/C2 Injection Coal 2

8) D/M Dolomite Inlet Feed

2. Composition of raw material.

Iron-Ore

• Fe: 62%
• Al2O3 + SiO2: < 5%
• Size: 5-18 mm
• Haematite Ore (Fe2O3) is preferred over Magnetite Ore (Fe3O4) because of its
greater reducibility due to 5 % more removal of oxygen
• During reduction hexagonal haematite changes its crystal structure to cubic
magnetite and wustite (FeO)
• During this transformation the volume of solid expand 25% more resulting
higher exposure of surface area for reduction.
• Whereas during transformation from Magnetite (Fe3O4) to wustite (FeO) the
volume expansion is very less so reducibility is poor.
 Gangue in Iron Ore

• Silicates (FeO, SiO2)

• Aluminates (nFeO, Al2O3)
• Carbonates (FeCO3)
• Hydrates (Fe(OH)2)

During reduction Gangue dissociates to:

FeCO3 ------ FeO + CO2
Fe(OH)2 ---- FeO + H2O

• These are endothermic reactions and lowers the temperature of process

• So Gangue should be less than 5% for 90% metallization
• Phosphorus in Iron-Ore varies from 0.03 to 0.035%.
 Sulphur in Iron Ore

• S is undesirable impurity present in Iron Ore

• Advisable to select Iron Ore having S content 0.015% max
• Sulphur Pick up in DRI is due to Sulphur present in Coal used
 Desired Specification of Coal

• FC – 45% (min)
• VM – 28-32% ( CH4, C2H6, Tar etc. Low VM will not produce adequate heat for
reduction)
• Ash – 25% (max). This is impurity and should be as low as possible.
Higher the ash content, higher the operating temperature
• Moisture – 10% (max). Should be as low as possible
 South African Vs Indian Coal

Parameters South African Coal Indian Coal

Fixed Carbon % 55 40
Volatile Matter % 25-30 30
Ash Content % 20 30
 DOLOMITE

• It is a composition of Calcium Carbonate and Magnesium Carbonate

• Used in the process of Desulphurization
• Sulphur is converted to SO2 which combines with moisture to form sulphurous
acid
• Since acidic gases are harmful, the desulphurization is made in the form of
sulphites of calcium and magnesium
• CaO + SO2 ----- CaSO3
• MgO + SO2 ----- MgSO3
3. Detailing production capacity with Steam generation.

South Africa
Yield
RB3 RB2

FC 49 52

0.48-0.50 95 100

0.501-0.52 97 104
Production

Iron-Ore
0.521-0.55 100 108

0.55+ve 104 115

Pellets 0.7 110 125

0.48-0.50 5.80 6.20

0.501-0.52 5.90 6.40

Iron-Ore
Steam

0.521-0.55 6.00 6.70

0.55+ve 6.50 7.00

Pellets 0.7 7.00 8.00

 Steam Improvement point checklist

Steam Improvement Point Check List Steam Improvement Point Check List
S.No Name of Activity Observation / Inspection Remark
Kiln-1,2,3 & 4. NEW OSM SYSTEM
S.No Name of Activity Observation / Inspection Remark 1 OSM DUCT LINE CLEANING
1 Kiln Inlet Segments Bag-Filter should not run during DD-Fan
3
running
2 Kiln Outlet Segments OLD OSM SYSTEM
1 I-BIN Bag Filter Suction Pipe
3 Wet Scrappers
2
4 DSC Junction House Bag Filter Suction Pipe
3 Bag Filter Solenoid Valve Punching
5 RALF System
6 CD-Belt Area 4 Bag Filter Cleanning
Pulveriser
7 Cooler Inlet 1 Pulveriser Running
8 Cooler Outlet 2 Pulveriser Hammer Replacing
 Reasons Steam Generation Could Not Reach Target.

 According to one-week analysis Some details are found which obstruct to hit the
target of steam generation.
 Other mechanical Machines like Bag-Filter, Pulveriser, and DD-fan only help to
boost steam generation, it’s not part of the target of steam generation.
 When coal-feeding is properly given then steam automatically reaches the target
level.
 Some time Heat level reaches at between 920 0C to 980 0C then steam generation
increased.

One week Steam generation record mentioning in below:-

 Steam Generation TPH
Date Kiln No. Type of Coal Used
Target Actual
K-1 7.81 4.15 RB2(65%) + RB3(35%)
K-2 7.81 7.66 RB2(65%) + RB3(35%)
04-04-2024
K-3 8 7.53 RB2(100%)
K-4 0 0 0
K-1 0 0 0
K-2 7.81 7.58 RB2(84%) + RB3(16%)
05-04-2024
K-3 8 7.39 RB2(100%)
K-4 0 0 0
K-1 0 0
K-2 7.5 7.01 RB2(84%) + RB3(16%)
06-04-2024
K-3 8 6.73 RB2(100%)
K-4 0 0
K-1 0 0
K-2 7.55 7.57 RB2(84%) + RB3(16%)
07-04-2024
K-3 8 7.37 RB2(100%)
K-4 0 0
K-1 0 0
K-2 7.55 7.55 RB2(84%) + RB3(16%)
08-04-2024
K-3 8 7.25 RB2(100%)
K-4 0 0
K-1 0 0
K-2 7.55 7.55 RB2(84%) + RB3(16%)
09-04-2024
K-3 8 7.22 RB2(100%)
K-4 0 0
K-1 - 2.85 RB2(80%) + RB3(20%)
K-2 7.31 7.36 RB2(90%) + RB3(10%)
10-04-2024
K-3 7.85 7.66 RB2(100%)
K-4 - 4.3 RB2(100%)
 How could hit the target

 Need to find & calculate exact actual consumption & production details.
 Need to improve feeding coal Quantity.
 The checklist needs to be followed in detail on a daily basis.
 17

ENGAGING THE MEMBER

• During running condition, all mechanical persons should thoroughly verify that
leakage should not occur in any section.
• Try to resolve in a short time which part can be changeable which obstructs to
increase of steam.
THANK
YOU