ENERGY EFFICIENT REGIMENS IN BLAST FURNACE

AND THEIR EFFECTS ON OVERALL PRODUCTIVITY

OF IRON MAKING PROCESS

SK Chaurasiya
Aman Bajaj 1

Vipin Jat
 Steel Production Trend in India

 India has overtaken Japan to become the world's second largest producer of
crude steel in February, according to the Steel Users Federation of India
(Sufi). India overtook the US in 2015 to become the third largest producer of
crude steel.
 National Steel Policy 2017-18 implemented to encourage the industry to reach
global benchmarks.
 India's crude steel production was up 4.4 per cent and stood at 93.11 million
tonnes (mt) for the period April 2017 to February 2018, compared with April
2016 to February 2017, which has helped India to overtake Japan and
becomes the second largest producer of crude steel in the world
 Low per capita steel consumption of 63 Kg in India, as compared to world
average of 208 Kg.
 Crude steel capacity of 300 MT will be required by 2030-31
2
 CHHATTISGARH STATE

Raipur

Nagarnar
Bailadila Mines

Visakhapatnam
 Iron Ore
Mines-
Bailadila
Nearest Town- Rake
Bhilai,Raipur Facilities
& Vizag

NH43-
JAGDALPUR Power
Raipur/Vizag

Indravati Vizag. Port

River
Shabhri River Nearest
Airport-
Vizag/Raipur
Basis of Process Selection
 Proven technological route
 Most Energy Efficient
 Least Pollution
 High Productivity and Quality Product
 Flexible Mill to meet market demand
 Options are Corex, Hismelt/Finex and BF-BOF route
 Based on above Blast Furnace- Basic Oxygen Furnace (BOF)- Thin Slab
Caster coupled with Hot Strips Mills envisaged.

5
Envisaged sources of Raw Materials
Gross annual req. Mode of
Raw Material Sources
(MT) transportation
Iron ores (L+F) 5.6 Bailadila By rail

Satna,Devrapal/
Lime stone/ dolomite
0.9/0.8 Gumelwada, Kumbli,Machkot By rail/road
(L+F)
(Jagdalpur area)/Imported
Coking coal + Coal
2.8 Imported By rail by vizag port
dust
Indigenous
Purchased DRI/Scrap 0.235 By rail/road

Others 0.91 Indigenous By rail/road

 NISP : PROCESS-CUM-MATERIAL FLOW SHEET
COKING COAL
2,289,300

BURDEN SINTER IRON ORE LUMP BURDEN COKE

IRON ORE FINES COKE BREEZE
4,214,600 1,052,800 1,195,600
3,826,900 295,000

SP : 1 x 460 m2 BF : 1 x 4500 m3 CO : 2 x 67, 7m tall

3,321,200 GHM
282,000 HM

2,976,000 HM
BOF :
PCM
2 x 175 t
3,000,000 LS RH-OB: 175 t

LF : 2.9 MTPA
2 x 175 t TSC coupled with HSM HR COILS

3,000,000 Liq Steel

7
SALIENT FEATURES OF THE PLANT
• Capacity (Liquid Steel) : 3 MTPA
• Cost of Project : 15525 Crores
• Capacity (HR coils/sheets/plates) : 2.89 MT/yr.
• Coke Oven & CDCP : 7 mtr Tall Batteries, 2 Nos.
• Sinter Plant : 460 Sqm, 1 No.
• Blast furnace : 4500 Cum
• Pig Casting Machine : 1700 tpd, 3 machines
• Steel Melting Shop : 2 x175 T BOF Converters
• Thin Slab Caster + HSM : 2 Strand CC and HSM
8
• Other Units : By Product Plant, RMHS
Salient Features of Blast Furnace:
 Biggest Blast Furnace in India with 4506 m3 useful volume.
 Daily optimum production up to 9500 Tons, peak production up-to 9900Tons per
day.
 Slag Rate 269 kg/thm & daily slag production of 2560Tons/day.
 Fuel rate of 550kg/thm including Pulverized Coal Injection 150-180Kg with coke
replacement ratio 1:1.
 Latest dedusting systeminstalled which extracts 50 tons per day from
casthouse(16Tons) and stockhouse(34Tons) approx.
 Equipped with Oxygen enrichment facilities up to 6% for enhancing the production.
 Blast Humidification can be achieved via Steam Injection at a flow rate of 20 — 22
T/h.
 Usage of pellets up to 20% envisaged, Pellets have higher permeability & allows
more blast.

9
 About 40% energy required for the plant is being generated within the plant using BF
gas mixture instead of Coal via boiler route. Calorific Value of BF Gas around 936
Kcal/Nm3.
 Top Gas Recovery Turbine generating max output power of 14-16 KW.
 Copper Plate type coolers are installed for BF Shell and refractory cooling, which
are efficient & easy from maintenance point of view.
 Dual Tap Hole practice, connected cast house for easy operation.
 Slag Granulation System with slag flow rate of 10Tons/min and peak of 12Tons/min.
with the simplest design and ease of maintenance.
 3 no. hot blast stoves with a provision for 4th stove in the future.
 Level II automation and control system.
 Techno-economic parameters
International TATA JSW NMDC Steel
Parameter SAIL RINL
Standards Jamshedpur Bellary Plant (NISP)

1.58(1.15-
BF Productivity (t/m3/day) 2.5-3.5 1.45 (1.1-1.5) 2.41 (1.4-2.6) 2.64(2.5-2.7) 2.23
1.68)

BF Coke Rate (kg/thm) 275-350 489(464-499) 543 (532-571) 380 (353-545) 398-490 360

BF PCI/CDI Rate (kg/thm) 200-225 58(21-125) 5 (10-2) 168 (40-191) 85.0-135.3 150-180

LD Productivity 6315(6261- 10795 (9732-

10000-12000 6915 9097-10754 8910
(heats/conv/yr) 6372) 12523)

Specific Energy 6.51(6.42-

4.5-5 6.4 5.77 6.41 5.95
Consumption (Gcal/tcs) 6.70)

Specific CO2 Emission

1.8-1.9 2.6 2.8 2.26 2.61 2.57
(t/tcs)

Water Consumption
2-2.5 3.51 4.68 3.98 2.8 3.15
(m3/tcs)
 Manpower comparison
Organisation Capacity (MTPA) Manpower

NMDC 3.0 3500

RINL 3.5 16400
18395
2.8 1995
JSW 4.0 1689
* 3189
3.0 1500

* JSW out sources for maintenance & part of technical/operational jobs.

 Automobile and Rail Wagon Manufacturer

 LPG Cylinder Manufacturer

 Construction Company

 Infrastructure and Highway development company

 Pressure Vessels manufacturer

 Pipe manufacturer

 Ship builders

 Electrics manufacture
 Product Specification & Size Uses
Manufacture of bridges,
steel structures, ships, large
• IS 2062, IS 5986, IS 3039
diameter pipes, storage
• 5-10 x 1030-1650 (Thickness tanks, boilers, railway
x width) mm x mm wagons and pressure
HR Plates vessels.
• IS 2002 & IS 2041 Manufacture of bridges,
steel structures, ships, large
• 5-10 x 1030-1650 (Thickness diameter pipes, storage
x width) mm x mm tanks, boilers, railway
wagons and pressure
HR Plates vessels.

• API - 5L quality plates -upto

X 80.
Pipes used in transportation
• 6-12x upto 1550 (Thickness of liquid and gases.
API - 5L Quality x width) mm x mm
Plates
 Product Specification & Size Uses
• IS 3196 Manufacture of bridges, steel
• 2-4x1030-1650 (Thickness structures, ships, large
x width) diameter pipes, storage tanks,
boilers, railway wagons and
mm x mm
pressure vessels.
HR Sheets
• IS:6240
• 2.0-3.15x1000-1650 Used in manufacturing of LPG
(Thickness x width) cylinders.

LPG Cylinders mm x mm

• IS 10748, IS 1079. construction of tanks, railway

cars, bicycle frames, ships,
• 1.6-10 x 900-1650
engineering and military
(Thickness x width)
equipment and automobile
mm x mm and truck wheels, frames and
HR COILS body parts
 Product Specification & Size Uses
Used in making pipes,
• IS 1100-1650 cast iron pots, hot
water radiators etc
• 2.5-11.5 (Thickness x width)
mm x mm
High Carbon Steel

• DIN 46400-3
used in generators,
• 1.81-3.5 (Thickness x width)
motors, and
mm x mm transformers
Silicon steel
• IS 1250-1524.
• 2.5-11.5 (Thickness x width)
mm x mm Used in manufacturing
• IS 1250-1524. of automobiles etc.
• 1.8-6.5 (Thickness x width)
Automotive steel mm x mm
•The entire plant is installed in less than 1800 Acres having 25m width green belt all around
the boundary wall with wide in-plant roads.

•Optimum use of water and power.

•Biggest Blast Furnace in India with 4506 m3 useful volume.

•Totally Automated material handling system in the BOF Shop (First time in PSU steel
producer).

• All the units are designed for Zero Discharge.

• About 40% energy required for the plant is being generated within the plant.

•Latest dedusting system, ETP, Pollution monitoring system are adopted.

Favorable conditions: Low cost steel produced
by NISP
 Best Raw Material
 Latest State of the Art Technology
 Both Ore Based and Port Based
 Efficient Transportation ( Slurry Pipeline)
 Pellet Plant and Charging Facility
 Less Manpower(mostly outsourced)
 Energy Efficient
 Environment Friendly

18
BLAST FURNACE OVERVIEW

19
20
 COKE OVEN BATTERY-1
COKE OVEN STACK

21
SINTER PLANT TOPVIEW
SINTER PLANT OVERVIEW

22
SINTER PLANT LBDS

23
SINTER PLANT CONVEYORS AND PBB

24
CONVERTER AREA

25
DOGHOUSE

26
SMS GAS CLEANING PLANT

27
OXYGEN PLANT

28
Overhead Tank

29
RAW WATER RESERVOIR

30
Thank You 31