DOLVI BF2 : HIGH

PRODUCTIVITY OPERATION
WITH HIGH PELLET
IMRAN AHMED &
Presenter name : RANGAPPA
Plant location : JSW DOLVI
Logo :

64th OCM – BF & SINTER

 Dolvi Process Flow Diagram @10 MTPA
RAW MATERIAL
Iron ore HANDLING SYSTEM
Sea Fluxes Coal
fines
Creek

PP-II PP-I 1 MTPA 3 MTPA AGGLOMERATION

2.35 2.55
MTPA MTPA
8 MTPA 4 MTPA SP-I SP-II COP-I COP-II

LCP1234
1800 TPD
Billet Caster
1.6 3.5 Bar Mill
MTPA MTPA
SIP BF-I HSM-I
Conarc LHF
Thin Slab Caster
5 MTPA
LCP 567 1800 TPD

BF-II HSM-II

Converter LHF Twin Stand Caster

IRON MAKING 2 2
STEEL MAKING
2 MILLS
 HIGH PELLET OPERATION : THE NEED

2.5 DRI 1.5 MTPA

1.5  WITH COMMISSIONING OF
PP1 4 MTPA DRI PLANT - SALAV
BF2, IBRM REQUIREMENTS
IBRM REQ (NET)
INCREASED TO 14 MTPA
SP1 2.35  AFTER IBRM BALANCING,
BF1 3.5 MTPA SINTER 2.0 MTPA
PELLET WAS THE
MTPA PELLET 3.8 MTPA
AVAILABLE MATERIAL
2.5
SINTER 2.7 MTPA WHICH COULD CATER TO
PP2 8 MTPA 5.5 BF2 4.5 MTPA BOTH BFs
PELLET 5.0 MTPA
 HENCE BOTH BFs
SP2 2.55 SWITCHED OVER TO HIGH
MTPA PELLET OPERATION, AFTER
COMMISSIONING OF BF2

PDQC 3
 DOLVI BF2 : FACTS AND FIGURES
VOLUME OF THE FURNACE
WORKING VOLUME 4521m3
• FASTEST RAMPUP TO RATED PRODUCTION
INNER VOLUME 5358m3 150 DAYS
– 12500 TPD
TOTAL VOLUME 6055m3

WORKING VOLUME
VOLUME BREAKUP 125 DAYS • FASTEST RAMPUP TO PCI – 200 KG/THM
HEARTH VOLUME 941m3 INNER VOLUME
TOTAL VOLUME

BOSH VOLUME 856m3 70% OF • HIGHEST PRODUCTION IN FIRST YEAR OF

BELLY VOLUME 540.4m3 RATED COMMISSIONING
SHAFT VOLUME 2780m3
THROAT VOLUME 237.5m3 70 % PELLET • HIGH PELLET OPERATION – STABILISED
BELOW TAPHOLE 697m3
VOLUME • ACHIEVED 13000 TPD LANDMARK
176 DAYS
OPERATING CONDITIONS PRODUCTION
TOP PRESSURE 2.94
• ACHIEVED 14000 TPD LANDMARK
COLD BLAST VOLUME 8290Nm3/min 1.5 YEARS
PRODUCTION
O2 ENRICHMENT 60300Nm3/hr

BLAST TEMPERATURE 1250deg • ACHIEVED 14500 TPD LANDMARK

2 YEARS
HOT BLAST HUMIDITY 40gm/Nm3 PRODUCTION
PRODUCTION CAPACITY 12100-12600
T/Day
4
 BF2 HIGH PELLET JOURNEY
14000 1 2 3 4 5 6 7
PRODUCTION

9000
NOTABLE HIGH LIGHTS
4000

Th. slag rate kg/thm Raw flux rate

210
1. JAN 22 –
400
160 • CHANGEOVER TO HIGH PELLET
SLAG & FLUX

RAW FLUX
SLAGRATE

350
110
2. FEB 22 –
• PP2 TI > 92%
300 60
• BD CHANGES – STORAGE MODE
250 10 3. MARCH 22
Fuel rate kg/thm
250 600 • ACHIEVED RATED PRODUCTION
200 580 4. MAY – JUL 22
FUEL & PCI

FUEL RATE
PCI RATE

150 560 • DISTURBED PHASE, LOW

100 540 PRODUCTION TARGET
50 520
5. AUG 22
0 500
Sinter Lump ore PELLET • LOW SILICA IN PP2 – INCREASED B2,
80 LOW FLUX AT BF
60 6. NOV 22
CENTRE COKE CHARGING
IBRM

40 •
20 • 13500 PRODUCTION
0
80.0 7. MARCH 23
60.0 • LOW SILICA IN PP2 – INCREASED B2,
HEAT LOSS

40.0 LOW FLUX AT BF

20.0 • 14000 TPD ACHIEVED
0.0
1-Jan 1-Feb 1-Mar 1-Apr 1-May 1-Jun 1-Jul 1-Aug 1-Sep 1-Oct 5
1-Nov 1-Dec 1-Jan 1-Feb 1-Mar
 CHALLENGES – ACTION TAKEN
S NO CHALLENGES IMPACT ON BF ACTION
1 PELLET ROLLING INSIDE FURNACE OPTIMISATION OF BURDEN DISTRIBUTION
• PELLET ROLLS TOWARDS WALL INCREASED HEAT LOSS -> STORAGE MODE
• PELLET ROLLS TOWARDS CENTRE -> CENTRE COKE CHARGING
2 PELLET HANDLING OUTSIDE FURNACE
• ROLLING ON CHARGING CONVEYERS PELLET SPILLAGE -> BELT MATERIAL DISTRIBUTION
• MICROFINES HANDLING OUTSIDE CONVEYERS -> BUNKER INTERCHANGE
3 PELLET BEHAVIOUR IN LOWER PART OF BF PELLET CHEMISTRY CHANGE : AS PER BF
• SWELLING INCREASED HEATLOSS ->PELLET B2 INCREASED GRADUALLY FROM
• IMPACTS SOFTENING MELTING ZONE 0.35 TO 0.65
4 HIGH FLUX INPUT ZERO FLUX CONCEPT
• HIGH PELLET WITH LOW PELLET B2 INCREASED HEATLOSS ->MAXIMISE FLUXING AT SINTER & PELLET
• RAW FLUX CHARGED UPTO 60 KG/THM INCREASED FUEL RATE -> SOP REVISED
5 TAPPING DELAYS
• SLAG HOLDUPS INCREASED HEAT LOSS ->LOW GUTKO OPERATION
• RESULTING CHANNELLING

CHALLENGE IMPACT ON BF

UNCONTROLLED PELLET BEHAVIOUR HIGH HEATLOAD

HIGH PELLET INCREASED FR WEAR OF STAVES
DISTRIBUTION INSIDE IN BF
6
 OPTIMISATION OF BURDEN DISTRIBUTION
MODIFICATION DONE : TILTING ANGLE CHANGED MODIFICATION DONE : TILTING ANGLE CHANGED
FURNACE TRAJECTORY WITH HIGH PELLET – ANALYSED IN MODEL MATERIAL FLOW RATE WITH HIGH PELLET– ANALYSED IN MODEL
FINDING : MATERIAL FOUND HITTING THROAT ARMOUR FINDING : HIGH FLOW RATE AT START OF DISCHARGE/WALLS

RESULT : RESULT :
OUTER RING ANGLE CHANGED FROM 52 DEG TO 47 DEG UNIFORM FLOW RATE ACHIEVED THROUGHOUT THE
DITRIBUTION RINGS

7
 OPTIMISATION OF BURDEN DISTRIBUTION
IMPACT ANALYSIS: MODIFICATION DONE : CENTER COKE CHARGING
AFTER DOING THE ABOVE BURDEN DISTRIBUTION CHANGES, IT INCREASE OF CHARGING CAPACITY WITH CCcO PATTERN
WAS OBSERVED:
1. PRODUCTION TARGETS UPTO 13000 TPD WAS ACHIEVED
2. HEATLOSS GOT AGGRAVATED, IN CASE OF
A. HIGH SILICA INPUT IN SINTER/PELLET – INCREASED
SLAG VOLUME/FLUX RATE CCcO PATTERN – ORIGINAL CCcO PATTERN – ORIGINAL
B. PELLET QUALITY DISTURBANCE ACHIEVED PRODUCTION – 11500 T ACHIEVED PRODUCTION – 13500 T
C. IN CASE OF ANY TAPPING DELY CENTRE COKE QTY – 6T CENTRE COKE QTY – 6T
D. IN CASE OF CDQ BREAKDOWN DISCHARGE RATE - 200 TPH DISCHARGE RATE - 750 TPH
E. IN CASE OF STARTUPS TIME TAKEN - 2.5 MIN TIME TAKEN - 30 SECS
DISCHARGE GATE - BELT DISCHARGE GATE - DISCH
3. FUEL RATE GOT INCREASED IN DISTURBANCES WEIGHER GATE

SOLUTION PROPOSED : CENTER COKE EXECUTION PLAN

CENTRE COKE CHARGING TO BE STARTED • TECHNOLOGY USED – BURDEN DISTRIBUTION MODEL + PROFILOMETER + TOP
CAMERA
FINDING : SYSTEM INCAPABLE OF CATERING TO HIGH • CO PATTERN – CENTER ROTATION 7 ( Cc27% BY WT)
PRODUCTION LEVELS • COCOCc PATTERN ADOPTED WITH SAME WT OF Cc
• COCCcO PATTERN ADOPTED WITH SAME WT OF Cc CONSIDERING COKE PUSH EFFECT
• OPTIMISATION OF CENTRE COKE QUANTITY – 23%

8
 OPTIMISATION OF BURDEN DISTRIBUTION
CO PATTERN BURDEN DIST MODEL 3D TOP SCAN TOP CAMERA

• LOW O/C AT WALLS, ORE APPROACHING CENTRE, WIDE CENTRE

COCOCc PATTERN
COCO
COCCcO
COCOCc
EARLY STABLE
AREA

• INC O/C AT WALLS, ORE REACHING CENTRE, WIDE CENTRE

COCCcO PATTERN

• LOW O/C AT WALLS, ORE FREE CENTRE, NARROW CENTRE

• CENTRE COKE BLOCKS THE ORE
PDQC 9
 OPTIMISATION OF BURDEN DISTRIBUTION
UPTAKE 1
Uptakes Temperature degC
Center coke implemented
degC

100

ABP-1 Temperature degC ABP1_T2 ABP1_T3 ABP1_T4 ABP1_T5

degC

50
ETA CO
55 Gas Utilisation
52
49
%

46
43
40 JSW_DLV_BF2_TE_439 JSW_DLV_BF2_TE_440
200 Stave Temperatures B3 JSW_DLV_BF2_TE_441 JSW_DLV_BF2_TE_442
degC

0
JSW_DLV_BF2_TE_510 JSW_DLV_BF2_TE_511
• CENTRE COKE CHARGING IMPACT
200 Stave Temperatures S5 • A CLEAR PRODUCTION INCREASE IN BOTH
CASES IS OBSERVED BY 500 T
degC

• FUEL RATE SAVINGS OF 4 KG/THM

0
21:00
1:00
5:00
9:00
13:00
17:00
21:00
1:00
5:00
9:00
13:00
17:00
21:00
1:00
5:00
9:00
13:00
17:00
21:00
1:00
5:00
9:00
13:00
17:00
21:00
1:00
5:00
9:00
13:00
17:00
21:00
1:00
5:00
9:00
13:00
17:00
21:00
1:00
5:00
9:00
13:00
17:00
21:00
1:00
5:00
9:00
13:00
17:00
21:00
1:00
5:00
9:00
13:00
17:00
21:00
1:00
10
5:00
9:00
13:00
17:00
21:00
1:00
5:00
9:00
13:00
17:00
21:00
1:00
5:00
9:00
13:00
17:00
21:00
1:00
5:00
9:00
13:00
17:00
21:00
1:00
5:00
9:00
13:00
17:00
4-Nov 5-Nov 6-Nov 7-Nov 8-Nov 9-Nov 10-Nov 11-Nov 12-Nov 13-Nov 14-Nov 15-Nov 16-Nov 17-Nov
 PELLET HANDLING : OUTSIDE FURNACE

MODIFICATION DONE : BELT DISTRIBUTION & BUNKER

PELLET LINE
CHANGEOVER
SINTER LINE
PELLET GETTING ACCUMULATED AT TAIL END OF MCC
FINES HANDLING BECOMING DIFFICULT PELLET
SINTER
FINDING : PELLET ROLLING BACK AT 10 DEG INCLINATION
PELLET MICROFINES SLIDING IN BUNKER

SOLUTION: SINTER DISCHARGE SPEED FURTHER SLOWED

PELLET DELAY INCREASED, BUT SPEED MAXIMISED AD 01 PELLET LINE

PELLET 7 CHANGED TO SINTER, ADDITIVE 1 MADE PELLET

SINTER LINE

RESULT :
PELLET ROLLING ELIMINATED PELLET
SINTER
FINES TRANSPORT VIA CONVEYER – 100%

11
 PELLET CHEMISTRY : AS PER BF
PARAMETERS ACID PELLET BASIC PELLET

MIDDLE DP
REAL TIME IMPACT
FLUIDITY INDEX 1.206 POISE 0.307 POISE ON BF2
RESISTANCE 255 27 • INCREASE IN
SILICA
START OF PRIMARY SLAG 1217 1250 • PELLET B2
END OF PRIMARY SLAG 1460 1403 DROPS

HEATLOSS
• HEATLOSS
SWELLING 20.5/23.8 8.5
INCREASES
REDUCIBILTIY % 59 74 • VARIATION IN
RUL % 34 1 MIDDLE

PELLET SiO
REQUIREMENTS HIGH PELLET OPERATION IN BF
• BASIC PELLET – 0.6 & ABOVE
• CCS >220 KG
• TI > 94
CHALLENGES

PELLET B2
• LOW SILICA FEED AT PELLET
• INCREASE OF B2 , CCS DROPS
• INCREASED MICROFINES GENERATION
12
 IMPROVEMENT AT PP2 : B2 INCREASED
BF2 PRODUCTION
14000
CONCEPT :
12000
 PELLET B2 TO 0.6 AND ABOVE
 BF SLAG & FLUX RATE DECREASE 10000

 IMPROVED PERMEABILITY
8000
METHODOLOGY AT PP2: 18-Jan 18-Feb 18-Mar 18-Apr 18-May 18-Jun 18-Jul 18-Aug 18-Sep 18-Oct 18-Nov 18-Dec 18-Jan 18-Feb 18-Mar 18-Apr 18-May

• TARGET CaO TO 3.0% AND ABOVE SLAG RATE

400
• REDUCE LOI, BY USING LOW SILICA
FEED IRON ORE 350

• PROCESS PARAMETERS ADJUSTED TO

300
MAINTAIN CCS >220
IMPACT : 250 PELLET CaO
4.00
• GRADUAL INCREASE OF PELLET B2 3.50
FROM 0.4 TO 0.6% 3.00

• CONSEQUENT DROP IN BF2 SLAG RATE 2.50

– RESULT IN PRODUCTION INCR 2.00

• CONSEQUENT DROP IN FLUX RATE- 1.50

PELLET CCS
OPTIMISED FUEL RATE AT BF
• PERMEABILITY IMPROVED AT CCS>200 280.00

230.00

180.00
13
 IMPROVEMENT AT PP2 : TI IMPROVEMENT

CONCEPT :
 REDUCE FINES GENERATION AT BF END
 IMPROVEMENT IN TI
METHODOLOGY:
• +150 MICRON OF FILTER CAKE DOWN
TO 15% BY INCREASING BALL MILL
LOAD CAPACITY
• IMPROVED FLUX GRINDING
• MPS OF PELLET REDUCED FROM 11.5
TO 11.0 - GAPS BETWEEN SDRS
REDUCE FROM 17 TO 15MM
• BTT MAINTAINED AT 400 DEG
IMPACT :
• TI INCREASED UPTO 93.5%
• IMPROVED PERMEABILITY
• RETURN FINES AT BF DROPPED TO 7-
8%
• DUST GENERATION REDUCED TO 30 PP02 pellet fines generation (%)
KG/THM 15.00%

• IMPROVED DRY GCP EFFICENCY 10.00%

5.00%

0.00%
1-Jan 1-Feb1-Mar 14
1-Apr 1-May 1-Jun 1-Jul 1-Aug 1-Sep 1-Oct 1-Nov 1-Dec 1-Jan 1-Feb 1-Mar 1-Apr 1-May 1-Jun 1-Jul 1-Aug 1-Sep 1-Oct
 ZERO FLUX CONCEPT
FLUX RATE KG/T
CONCEPT : 60

 REDUCE FLUX AT BF END TO LESS THAN 10 40

 IMPACT : FLUX (-10KG/THM = -2.5 KG/THM)
20

METHODOLOGY: PELLET B2
• PELLET B2 – 0.6 AND ABOVE 0.80

• LOW SILICA FEED AT PP2 0.60

• SINTER B2 – 2.5 AND ABOVE 0.40

• HIGH SILICA FEED AT SP 0.20
• INCREASE IN SINTER CaO TO 15% AND ABOVE 0.00
SINTER CaO
• ADJUSTMENT OF SINTER +/- 5% TO MINIMISE 16.00

RAW FLUX 15.00

14.00

13.00

IMPACT : 12.00
SINTER B2
• FUEL RATE OPTIMISED 4.00
• HEAT LOSS FURTHER STABILISED
3.00

2.00

1.00
15
 HEARTH DRAINAGE : STRINGENT TAPPING

CONCEPT :

PERMEABILITY
PERMEABILITY DETERIORATED

 AT HIGH PELLET OPERATION, LIQUID HOLD UPS,

IMMEDIATELY TRIGGERS HEATLOSS
 IMMEDIATE IMPACT SEEN IN THE BOSH TCs IN CASE OF
DELAYS
 IF DRAINAGE IS VERY POOR, SLIP OBSERVED

TAPPING
METHODOLOGY:
• HEARTH TO BE KEPT DRAINED AT ANY MOMENT OF TIME
• FOUR TAPHOLE OPERATION : IN CASE OF ABNORMALITY
• GUTKO TIME REDUCED TO 10 MINS
PROD GUTKO GUTKO T/H IN DRILL DIA
LEVEL (EARLIER) (NOW) SERVICE
Short tapings and no slag time. HEAT LOSS SPIKES

HEATLOSS
13000 40 30 4 55
13500 30 20 4 60
14000+ 15 10 4 62

IMPACT :
• HEAT LOSS SPIKES REDUCED

PDQC 16
 CONCLUSION
BF2 KPI ACHIEVEMENTS WITH PELLET : FY 23-24 FOR HIGH PELLET OPERATION RECOMMEND

CENTRE COKE CHARGING HIGH

BASIC PELLET : B2 >0.65 HIGH

TAPPING DISCIPLINE HIGH

ACHIEVEMENTS
HIGH PELLET OPERATION – STABILISED LOW FLUX INPUT MODERATE
TOTAL 261 DAYS OF >60% PELLET OPERATION
HIGHEST PRODUCTION FIGURES ACHIEVED – COKE QUALITY IMPROVEMENT HIGH
CONTINUOUSLY WITH AVERAGE 64% PELLET
IN BURDEN
INCREASE PELLET – LOW SLAG VOLUME,
MORE HOT METAL PER CHARGE
PDQC 17
PDQC 18