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LD#2 OVERVIEW

INTRODUCTION
The Converter unit was supplied by Voest Alpine of Austeria. The Plant was set up as a part of Modernization Phase III and commissioned in the year 1993 94 with a capacity of 1 MT Slab steel. In Secondary refining one Ladle Furnace in 1994 and RH degasser was set up in 1996 with two Casters for casting slabs. In Modernization Phase IV in 1999, 3 rd Converter, 1 LF with modern facilities in Ladle preparation and 3 rd Caster was added, to give plant output 2.18 MT Slab steel. Now the Plant is running at a capacity to produce more than 2.9 MT Slab steel. Expansion programme of 0.5 MT has been taken up to enhance the Plant capacity to produce 3.3 MT Slab steel.

PRODUCTS
LD#2 & SC department is part of the newly formed Flat product profit center. It produces continuously cast Slabs and deliver to HSM. It produces Grades for Auto ancillaries, Consumer durables, Construction/ Infrastructure, Capital goods, EDD & IF grades for Auto body application, LPG grades, Medium & High carbon Strips for Chain links, Strapping, Saw blades, Corten for packaging applications, E-34, E-38, BSK46 for Cross & Long member for Automobiles, Steel for Electrical application,Galvanized products etc.

LD#2 OVERVIEW

PROCESS

HOT METAL RECEIVING


The input Hot metal comes from Blast Furnaces A, B, E, C, D, F & G in torpedo of capacity 220 tons

TORPEDO AREA
Hot metal from torpedo is transferred to ordinary transfer ladle of 140 tons capacity by tilting the torpedo. From two torpedos we get metal for three heats.

DE-SULPHURIZATION UNIT
This is intermediate process between the BF & LD vessel to reduce S from Hot metal. The transfer ladle contains hot metal taken to DS unit. Initially BF slag is raked of with the help of raking m/c. Then the de-sulphurization starts with the injection of CAC2 and Mg injection through the refractory lance with N2 as the carrier gas. The lance deep inside the metal and injection starts. Sulphur of the Hot metal removes in the form of CaS & MgS and floats up. This is raked of . The time of DS depends on the initial S of the hot metal and the final product specification want to achieve. LD#2 OVERVIEW

LD VESSEL
LD#2 & SC have three LD vessels out of which two vessels are kept in operation, to produce 3 MT C/S at current stage. In 6th Modernization plan the capacity of the shop will be enhanced to 3.3 3.4 MT. A fume extraction system including two Electrostatic Precipitators was installed to extract fumes generated at DS operation, Charging, Blowing,and tapping to maintain a clean Environment in the Shop. The gas generated in LD converter during the blow contains good amount of CO gas for about 7-8 during the blow, the CO percentage varies 50 70% and is very useful as fuel gas. The total input (Scrap, Hot metal, Iron ore) is 156 tons in addition, Limestone, Lime (12-13 ton) charged in every heat to make high basic slag, basicity 3.6 3.7. The impurities (C, P, Silicon, Mn ) are removed by oxidation. The converters have provision for inert inert gas agitation from the bottom. Oxygen is blown from the top through the six hole lance which enable oxidation of the impurities. Primary refined steel from LD converters is tapped into preheated dolomite lined ladles. The Tap-to-Tap time of a heat ranges between 40-45. Each converter is equipped with two cars, one for placing steel ladle for tapping the primary refined steel from the converter and other one for placing slag pot for transferring slag from the vessel to the slag pit.The output from the converter varies between 135-140 tons. The steel tapped in the ladle is brought to online purging station where necessary additions are made with rinsing from top. This primary refined steel are send to Caster through different Process routes as per the Quality specification needs.

LD#2 OVERVIEW

M HS
All the Ferro Alloys, Scrap required for steel making is arranged by the section. In addition cleaning of the DS pit, LD Vessel pits, SMLP Slag pit is organized and the loss metal in the pit is accounted to take necessary actions to prevent/reduce the metal loss in pit in d ifferent activities.

ROUTES Different routes of steel making are mentioned below : OLP CASTER (about 35-45% Heats) OLPRHCASTER (about 15-20% Heats) OLP-LF-CASTER (45-55% Heats) OLP-LF-RH-CASTER (1-2% Heats) The routes are followed as per the quality specification of the products to be made, logistic constraint of the shop. The fifth route is not desirable but before starting of RHCASTER route, to ensure RH vessel warm up some heats are taken through RH-LFCASTER for warm up of RH vessel. If during RH treatment temperature drops or some problems in the system or analysis is not O.K, the steel is taken to LF and send to Caster.
LD#2 OVERVIEW

LADLE FURNACE
Supplier Indomag Steel technology (India) with Mannesman Demag Huttentechnik (Germany) The Ladle Furnace forms an intermediate processing unit between LD Converter and Slab Caster.

BENEFITS
Lower tapping temperature of LD vessel and hence increased lining life, higher yield, lower phosphorus in lower cycle time in LD converter resulting better production. steel and

Exact adjustment of steel temp. and composition as well as thermal and chemical homogenization of steel for the Slab Caster. Controlled De-Sulphurization Versatile buffering to accommodate delays and waiting time between the LD vessel and slab Caster. Make clean steel due to flotation of the inclusion by argon gas stirring, from the bottom of the ladle. LF essentially comprises a water cooled ladle cover with six openings for various process requirements.The roof can be raised/ lowered by hydraulic cylinders. Provision for arcing, wire feeding, auto temp./ sample measuring/ top lancing, addition of ferro- alloys, fluxes and a observation door for manual temp / sample taking and manual additions. A fume extraction system has been provided to collect, cool and clean fumes through stack. The dust contains of fumes discharged will not exceed 100 mg/Nm3. The ladle heating system is connected to 33 KV, three-phase AC power supply connected to a 20 MVA Three-phase step down heating transformer (33 KV/ 350-290-200V). The maximum secondary current 40.2 KA per electrode.

LD#2 OVERVIEW

LADLE PREPARETION
There are three tilters for the preparation of ladles and supplying to vessel for tapping heats. Modern facilities (introducing Riper) has been provided for cleaning of the ladle top jams and bottom slag, shorten the Ladle preparation time.

RH PROCESS

In Phase IV modernization a Circulatory type 130T RH degasser was installed in 1996 for making low carbon grades of steel and removal of gaseous (H, N2,O2) from the steel. The RH degasser was developed in 1957 in Hattigen Steel Works in Germany together with Heraeus Company in Harau. The vessel is connected to a vacuum system capable of obtaining as low as 0.5 torr (1 torr= 1mm Hg). The RH process is one of the most important method for production of Al killed fine grained steel, Deep drawing steel, IF steel, Electric grade steel and lower hydrogen level to 2-3 ppm in the Medium Carbon and High carbon strp steels. RH has been upgraded to RH_ MFB system in 0.5 MT expansion program. This enable us to achieve Carbon< 15ppm. There is provision of blowing O2 through a lance inserted through Gas uptake of RH. This enable to raise the temperature of the steel and forced de-carbonization.

LD#2 OVERVIEW

TUNDISH AND TUNDISH CAR


Tundish is refractory relined rectangular box with nozzle located at the bottom. The liquid metal from the tundish is controlled by a stopper and nozzle manually or automatically.

MOULD
The mould is an open ended box 900 mm length, which contains an inner lining fabricated from a Cu alloy, rigidly connected to an outer steel supporting structure for the mould cooling water. The mould oscillation is controlled by motor driven cams which support and reciprocate the mould or hydraulic actuation techniques are also employed.Mould powder are added continuously, forms liquid slag at the top, which infiltrates between the mould wall and the surface of the solidifying steel, provide lubrication. Mould width adjustment can be done either manually, electromechanically or hydraulically. The mould taper also can be adjusted by gear mechanism. Steel level in the mould is controlled by Radioactive with Electromechanical actuator.

SECONDARY COOLING SYSTEM


The rolls of the cooling zone prevent bulging of the slab and initiate further cooling. Each of the roll sections may be adjusted for width and thickness for casting different cross section of the slab.

PINCH ROLLS
These are designed for inserting dummy bar into the mould during the time the the m/c is prepared for casting. In addition these rolls also impart downward movement to the dummy bar & the slab. LD#2 OVERVIEW

DUMMY BAR
It provides a temporary base in the mould at the start of casting and withdraws slab from the mould, once casting has started. The dummy bar is made up of links, flexible.The dummy bar and its head are joined by a special bolt.

GAS CUTTING M/C


Slab is cut to the desired length by torch cutting m/c using propane gas. The carriage consists of two gas cutting torches, which are internally cooled, self propelled and move perpendicular to casting direction.

MARKING M/C The slabs are numbered at the side on line by the marking m/c using Al spray. RUNOUT TABLE
After being cut to the desired length the slabs moves on to the horizontal run out table and then stacked cast no wise. About 40% slabs are hot charged and 20-25% slabs are skinned & grinded.

SYMS
SYMS keeps an automatic tracking of slabs. The surface defect if any are removed by scarfing, transferred in CTRT car and send to HSM on roller table. LD#2 OVERVIEW

LD SERVICES

This is one of the section of LD#2 & SC, Following jobs are performed : Digging of ladle & Mech repair job of the ladle if it is necessary. Deskulling of tundish Emptied out slag pot Heating of the ladle after relining Preparation of ladle Sending the ladle and relined tundish to LD#2&SC

REFRACTORY

Any relining job related to ladle, tundish is done in Refractory section. LD#2 OVERVIEW

CAP EX PLAN
Up gradation of one Slab Caster and modification of its design to Vertical bending machine. Meet the requirements of auto exposed markets Improve Productivity Up gradation of RH to RH-OB Increase production of RH grades Production of high quality steel IR camera in LD converter To reduce slag carryover from vessel to ladle Wire feeders at OLP To reduce Al consumption Mechanized Scarfing machine Meet requirement of Auto exposed steel Upgrade downgraded slabs Tundish Tube Changer To reduce refractory cost To improve yield

LD#2 OVERVIEW

ONE MT EXPANSION PROGRAMME


PLAN FLAT PRODUCT CAPACITY WILL BE INCREASED BY 0.5 MT

LONG PRODUCT CAPACITY WILL BE INCREASED BY 0.5 MT G BF CAPACITY WILL BE ENHENCED TO 1.8 MT INTRODUCING 3 RD SINTER PLANT, LIME CALCINING PLANT

FLAT PRODUCT
CAPACITY OF LD#2 WILL BE ENHANCED TO 3.5 MT WITH ADDITION OF FOLLOWING :

VESSEL
Transfer ladle capacity will be enhanced to 170mt Torpedo capacity will be increased to 320mt 100% Hot metal will be de-sulphurized Crane capacity handling hot metal & liquid steel will be increased to 250mt & M/hoist motion 9 met/min. Slag pot capacity will be increased Total charge (Hot metal + Scrap) = 165 170mt Output from the vessel = 150-152mt Modification I the lining of the vessel, ID Fan, DES system

SMLP

Increase the steel ladle capacity to 165mt by changing design of the ladle Increase crane capacity to 250mt of main hoist and its motion to 9meter/min Up gradation of RH process ( Introducing RH-OB ) Increase in IF & EDD grades (4,50000tons/yr) CASTER

Upgrading Caster no#1 to vertical caster Introducing automatic Tube changer, Improvement in B.O detection system & Mould level system, Flume modification. Increase average casting speed to 1.2metr/min, by improving mould cooling system Mechanized scarfing in SYMS

fluctuation

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