WORKING

IN AN INTEGRATED
STEEL PLANT

S Pal
GM (Quality)
 ROADMAP OF PRESENTATION

 Integrated Steel Plant (ISP)

 Layout of an ISP

 Process Flow in an ISP

2
 INTEGRATED STEEL PLANT (ISP)
 An integrated steel plant has all the functions for
primary steel production:
 Coke Making (conversion of coal to coke)
 Sinter Making (agglomeration of iron ore fines)
 Iron Making (conversion of ore to liquid iron)
 Steel Making (conversion of liquid iron to liquid steel)
 Casting (solidification of liquid steel)
 Rolling (finished shapes)
 Auxiliaries (various service providers)

 Capacity is generally more than 1 million tonnes / year

3
INTEGRATED STEEL PLANTS (ISPs) in SAIL

Present Capacity after

Plant
Capacity modernization
IISCO Steel Plant, Burnpur 0.41 MT 2.37 MT

Bhilai Steel Plant, Bhilai 4.43 MT 6.53 MT

Rourkela Steel Plant ,

2.07 MT 3.80 MT
Rourkela
Durgapur Steel Plant,
1.72 MT 2.83 MT
Durgapur

Bokaro Steel Plant, Bokaro 4.85MT 5.77 MT

4
 OTHER ISPs in INDIA

Plant Present Capacity

Tata Steel, Jamshedpur 5.2 MT

RINL, Vizag 3.5 MT

JSW, Torangulu & Salboni 7.8 MT

Essar Steel, Hazira 4.6 MT

Bhusan Steel and Power,
2.0 MT + 3.0 MT
Jharsuguda and Angul
Tata Steel, Kalinganagar 6.0 MT

JSPL, Raigarh & Patratu 2.9 MT

Ispat Industries, Dolvi 3.0 MT

5
 MAJOR GLOBAL ISPs

Arcelor-Mittal POSCO

US Steel Corus

Nucor ThyssenKrupp

Severstal Baosteel

Nippon Steel Voest Alpine

6
 PROCESSES & MATERIAL FLOW
Lime stone Iron ore

SINTER PLANT
Coal
COKE OVENS BLAST FURNACE

PIG CASTING M/C & Slag Granulation

BY-PRODUCTS

BOF/ Twin Hearth / Electric Arc

Furnaces
INGOT/ Teeming
ROUTE
CC Slabs/Billets/Blooms
Rolled Slab

SLABBING/ RAIL / Merchant/ Hot strip/ Finished Products

Plate MILL

CR COILS/SHEET ANNEALING LINES CRM

PICKLING LINES

GPGC GALVANALISING LINES 7

 Blast Furnace

Oct’72 1st BF
commissioned
Present 5 Furnaces
4.585 MT

After Modernized
Modernisation Furnaces
5.77 MT

8
Raw Materials Required for Iron Making

1. Iron ore ( its prepared form; sinter,

pellets)
2. Coking coal or coke
3. Non-coking coal for injection
4. Limestone
5. Dolomite
6. Manganese ore
7. Quartzite
BLAST FURANCE

10
BLAST FURNACE REACTIONS

Major reactions are :

• Reduction of iron oxides by CO
• Gasification of carbon by CO2
• Reduction of FeO by carbon
• Combustion of coke

Fe2O3 Fe3O4 FeO Fe

11
BASIC FUNCTIONS IN BLAST FURNACE

• Reduction of Iron bearing burden

• Smelting of product of reduction
INDIRECT REDUCTION
3Fe2O3 + CO = 2 Fe3O4 + CO2 (exothermic)
Fe2O3 + CO = 3 FeXO + CO2 (exothermic)
FexO + CO = Fe + CO2 (Slight exothermic)

DIRECT REDUCTION
FeO+C = Fe+CO (endothermic)
 Combustion Zone
• The zone just in front of the tuyere, where coke burns
with oxygen of air is known as ‘Combustion Zone’.
• It is further divided into Oxidising and Reducing
Zones
• Oxidising Zone (Zone-A) :A soon as the hot blast
enters into the furnace it encounters hot coke and
complete combustion of coke carbon takes place as
follow:
C+ O2 = CO2
• Reducing Zone (Zone-B) : After the oxygen of hot
blast completely reacted CO2 reacts with carbon of
coke to form carbon monoxide as follow:
CO2 + C = 2CO
• The combustion zone is also known as ‘Raceway
Zone’. This is a cavity type of zone in which coke
Combustion zone
Functions of coke in blast furnace
• Provides heat for meeting the endothermic requirements

and melting of slag and metal.

• Produces and regenerates reducing gases for reduction

of oxides.

• Provides an open permeable bed for passage of slag

and metal down into the hearth and hot reducing gases

upwards.
Importance of high temperature properties of coke in dripping zone
 Types of Cohesive Zone
• Inverted-U type : O/C at centre is less (centre is
open)

• Inverted-V type : Burden profile is V-shaped, O/C at

centre is less (centre is comparatively more open)

• Flat : O/C at centre is more

• W-type : Burden profile is M-shaped, centre &

periphery both are open
Types of cohesive zone
Effect of Centre Coke Charging in Blast Furnace
TAPHO LE TAPHO LE
Different Cohesive zone shape
 PERFORMANCE INDICES OF A BLAST FURNACE
Short term indices

 Productivity
 Fuel rate
 Hot metal quality
Long term indices
 Campaign life
Furnaces achieving:

 Productivity – 2.5 – 3.0 t/m3/day

 Coke rate - 300 kg/thm
 Campaign life > 20 years
Systematic technological development of the BF process
BASIC FUNCTIONS IN BLAST FURNACE

• Reduction of Iron bearing burden

• Smelting of product of reduction
INDIRECT REDUCTION
3Fe2O3 + CO = 2 Fe3O4 + CO2 (exothermic)
Fe2O3 + CO = 3 FeXO + CO2 (exothermic)
FexO + CO = Fe + CO2 (Slight exothermic)

DIRECT REDUCTION
FeO+C = Fe+CO (endothermic)
OPTIMUM RATIO OF DIRECT & INDIRECT REDUCTION
 EFFECT ON BF COKE RATE

Hot blast temperature

Sinter in burden,10%
100oC

(1.5%)
Not dry,10%

Fe in burden,1%
BF Coke Rate
(2.0%)
Alkali, 1 kg/thm

Si in HM,0.1%

Slag rate,1kg/thm

Coke M10, 1% Coke ash,1%

WHY COAL DUST INJECTION?

• Replacement of coking coal with low cost non-

coking coal.

• Increase in major performance indices of BF

• Decrease in the cost of hot metal

• Environment friendly technology

 CDI LEVEL ATTAINED IN SAIL SINCE INSTALLATION OF
CDI SYSTEM (kg/thm – yearly average)

Year BF-6, BF-4,

BSP BSL
(Oct 98) (Dec 98)
98-99 81 15
99-00 80 66
00-01 55 68
01-02 71 56
BF-7,
02-03 63 43
BSP BF-1, BF-5, BF-5,
03-04 65 55 (Dec 04) BSP BSP BSL
04-05 73 60 (Nov 05) (Dec 05) (Dec 05)
12
05-06 65 0 33 16 20 26
BF-3, BF-4,
06-07 39 13 6 30 22 25 DSP DSP
(May’08) (Aug’08)
07-08 34 24 41 36 50 32
08-09 32 30 54 29 68 29 6 9
09-10 34 49 60 28 67 33 22 33
CDI LEVEL ATTAINED IN SAIL SINCE INSTALLATION OF
CDI SYSTEM (kg/thm – yearly average)

Year BSL BSP DSP SAIL

2010-11 11.7 33.1 24.0 19.5

2011-12 31 35.7 43.0 28.4

 BF’s in SAIL
Plant No.of Total No.of No.of No.of Best Best
Fces. WV BLT CDI Fces Shop fce.pro
Fces. Fces. with product. duct.
HTP
BSP 7 9235 4 4 7 1.81 2.19
Dec’06 BF3
Jan’07
DSP 4 5086 2 3 1.8 1.83
,Mar’07 BF2,
Mar’07
RSP 4 4430 3 1 1.48 1.63
Oct’07 BF4,
Oct’07
BSL 5 8790 5 4 5 1.62 1.79
Mar’07 BF5
Dec’06
ISP 4 2954
VISL 1 450
Total 25 30945 12 6 16
 Hot Metal Production (Mt) of SAIL
15.1

14.88

14.61
14.6
14.4
14.3
14.12

36
Coke rate (kg/thm) in SAIL Blast Furnaces

550
545 544
541
540
535 535

530
525 522 520
520 517 518
515
510
505
500
2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12
 OPERATIONAL FEATURES OF SOME EFFICIENT
BLAST FURNACE IN INDIA & ABROAD
Parameters Units SAIL Tata Steel JSPL Hoogoven Nippon Steel POSCO
BF#7, BF’G’ BF#2 Netherland Kimitsue#3 Korea BF#6
Bhilai BF#7

Inner volume, m3 2355 2648 1681 2678 4450 3800

Productivity t/m3/day 2.06 2.30 2.51 3.37 2.70 2.66

Coke rate Kg/thm 448 430 396 268 365 390

PCI rate Kg/thm 71 120 116 233 125 100
Sinter % 67.0 70.0 69.0 50.0 50.0 85.0
Ore(O), % 33(O) 30(O) 31(P) 50(P) 50(P) 15(O)
Pellet(P)

Al2O3 in sinter % 2.50 2.4 2.90 1.24 1.54 1.85

Slag rate Kg/thm 393 260 330 203 236 320
Blast Temp oC
1040 1120 1200 1180 1180 1200
Oxygen % 2.40 4.8 2.0 13.2 4.0 2.0
enrichment

Coke ash % 14.75 14.4 - 11.3 9.3 11.0

 Operating parameters of Indian larger
blast furnaces
Parameters TATA JSW VSP SAIL
STEEL ‘H’ BF # 3 BF # 2 BSP
BF # 7
Working volume,m3 3814 3445 2816 2104
Charging device BLT BLT Bell+MTA BLT
Productivity, 2.56 1.84 2.01 1.80
t/m3/day
Coke rate, kg/thm 436 423 505 450
PCI rate, kg/thm 133 72 - 82
O2 enrichment,% 5.85 3.82 1.74 2.84
Blast temp.oC 1180 1186 1002 1076
Slag rate, kg/thm 284 329 321 382
Coke Ash,% 16.0 13.1 13.9 16.2
Coke M10, % 5.33 - 7.40 8.0
Size of Upcoming Big Blast Furnaces in
INDIA
Steel Works Inner Volume, Capacity, Mtpa
m3
Vizag BF # 3 4000 3.0
TATA STEEL ‘I’ 3800 2.5
Bhilai BF ‘0’ 4060 2.7
ISP 4060 2.2
TATA STEEL, 4000X2 6.4
KPO
 Cost Components for hot metal production

• Iron Ore : Rs.800-1000/t

• Coke : 22000-26000/t
• Flux : 800-1000/t
• Mn ore : 1400-1500/t
• Sinter : 2800-3000/t
• Pellets : 7000/t
• Electricity : Rs.4.5/kwh
• Oxygen : Rs.5.7/m3
• Pig Iron : Rs.20000/t
RAW MATERIAL

42
RAW MATERIALS & HANDLING AT STEEL PLANT

Basic Functions

 Unloading of different raw materials by wagon tippler

 Blending of raw material by Stacker and Reclaimer

 Supplying raw materials to different shops

 Keeping a buffer stock of raw materials

43
 SAIL CAPTIVE MINES

 Iron Ore : Kiriburu, Meghatuburu, Barsua, Bolani, Gua &

Chiria located in Jamda – Koira Valley of Bonai Range

(BSL, DSP & RSP) and Dalli, Rajhara & Rowghat located

in Chattisgarh (BSP)

 BF grade Limestone & Dolomite : Kuteshwar in

Chattisgarh and Bhawanathpur in Jharkhand

 Medium Coking Coal : Chasnalla in Jharkhand (ISP)

44
45
 Coke Ovens

Sep’72 Battery
Commissioned

6 Battery
Present operation
2.52 MT BF Coke
After 7 Battery
Modernisation operation
3 MT BF Coke

46
COKE OVENS & BY-PRODUCT PLANT

Sections

 Coal handling plant

 Coke Oven Batteries

 Coke Sorting plant

 By-Product plant

47
 COAL HANDLING PLANT
WAGON

To coal tower & Battery

Coal Silo

48
 COAL TO COKE

CARBONISATION: HEATING IN ABSENCE OF AIR

COAL
C C
O O
H H
V V
A
E
A
E  De-moisturisation: Upto 200°C (Drying)
M M
N N
B B
 Softening: 250- 300°C
E E
R R
 Plastic Mass: 350- 500°C (Swelling)
R E R E
G E G E
N E N E  Resolidification/ Semi-Coke: 460- 510°C
R A R A
T O T O
R R  De-gasification: 400- 700°C
WHB WHB  Stabilisation: 700-1000°C

COKE
49
 COKE OVEN OPERATION

Carbonization Time
20–22 hrs / oven

• Ram Car
Battery Operation • Guide Car
• Charging Car
• Quenching Car
Ready Coke pushed out

Quenching with water

Dumping in Wharf

Screening
50
 COKE SCREENING

From WHARF

GRIZZLY, 80 mm +80 mm

- 80 mm COKE CUTTER

SCREENING, 25mm BF COKE (+25 mm to – 80 mm)

-25 mm

SCREENING,15 mm Pearl Coke (+15 mm to – 25 mm)

Coke Breeze (-15 mm) For Sinter making

51
SINTER PLANT

52
SINTER PLANT

53
 Raw Material Sources

Iron ore
Kiriburu -4.25 MT
Meghahataburu -4.30 MT
Lime stone
Bhawanathpur -0.1 MT
Kuteshwar -1.2 MT
Dolomite
Tulsidamar -0.3 MT

54
 Steel Making
Jan’74 LD Steel making

Present 5 x 130 T BOF in SMS-I

2 x 300 T BOF in SMS-II
= 4.36 MT Crude Steel

After 4.61 MT Crude Steel

Modernisation

55
 STEEL MAKING

 Steelmaking is an oxidising process

 It refines and oxidizes the impurities in hot metal

 Fluxes are added to form basic slag to fix S & P

 Hot metal supplies the necessary heat

56
 PROCESS FLOW CHART FOR SMS-II CCS, BSL

HOT METAL HOT METAL

FROM BLAST MIXER
FURNACE

BOF

PIT SIDE
LADLE CONTINUOUS CASTING
MACHINE

LADLE
FURNACE
STEELMAKING

Carried out in ‘LD

Converter’
At SMS - II, 2 nos. of 300
T converter

4 ton LD slag added at

SMS II converter for early
formation of slag which
helps dephosphorisation

Total Blowing Time:

16 mins (approx.)

Tapping Temperature
Lining: Mag- (Aimed):  16800C
Carbon Brick
OXIDATION OF ELEMENTS DURING BLOWING AT LD
CONVERTER
DEPHOSPHORISATION

• Oxidising atmosphere

• Higher basicity of slag

• Temperature

• Fluidity

DESULPHURISATION

• High temperature

• Higher basicity of slag

• Reducing atmosphere – Not applicable in LD converter

A. Aimed Hot Metal B. Required
Composition Lime Quality Dolo
Quality
C: 4 to 4.5 %
CaO : 85 % min. 50 – 60 %
S: 0.050 % max.
MgO : 3 % max. 25 – 30 %
P: 0.15 % max.
SiO2 : 4 % max. 6 % max.
LOI : 7 % max. 7 % max.
Reactivity : 350 min. 150 min.
-10 mm : 30 % max. 30 % max.

C. Aimed Slag Composition D. Aimed Bath Analysis

FeO: 20-22 % C: 0.04 % max.
MgO: 10.0 to 12.0 % S: 0.030 % max.
Basicity: 2.5 (in Combined Blowing) P: 0.015 % max.
: 2.8 (in Non Combined Blowing)
 THERMODYNAMIC CRITERIA FOR THE REFINING
CAPACITY OF SLAGS

Ideal Slag
Composition
CaO 45%
FeO 20%
SiO2 16%

Activity of FeO in CaO-FeO-SiO2 slags at 16000C

CBT (Combined Blowing Techniques)

Procedure Description Grades

5 Upto 14 mins blow - N2 then Tube Making Grade/

till tap finish – ‘Argon’ Structural Quality

6 Blow Start to Tap finish – Full Reconditioned heats

‘Argon’ mainly

7 Upto 9 mins blow - N2 then till LPG, EDD, Nb bearing,

tap finish – ‘Argon’ MC 11/12, etc
TAPPING STATUS

• Add pet. Coke 100 to 150 Kg at the bottom of ladle

• Fe – Alloy addition started after 1/3rd of the ladle

• Aluminium addition

• Micro-alloy (if reqd.) addition

• Jaisalmer Lime (1500 Kg) addition after 2/3rd of the ladle

Pre/Post Slag arrester to be used to restrict carryover slag

(Norm. < 5Kg/ton)

LADLE

Collector Nozzle

Capacity: 300 T

Alumina based
Mag. Brick

Porous plugs

Bottom View Side View

“Argon Purging” is carried through two porous plug

Flow Rate: 300 to 450 lit/min/plug Pressure: 12 to 14 Kg/cm2

SRU ie. Secondary Refining Unit (LF/LRS)

Object:

• De-Sulphurisation

• Trimming Addition (if regd.)

• Despatch Temperature fixation as per Liquidous temperature of the steel

• ‘Ca’ wire injection ie. CaSi/CaFe as per requirement of the grade of steel

Liquidous Temp. ie. TL = 1536.6 – [86% C + 5% Mn + 8% Si + 30% P + 25% S]

 THERMODYNAMIC CRITERIA FOR
DESULPHURISATION

Ideal Slag
Composition
CaO 40-45%
Al2O3 35-37%
SiO2 5-7%
FeO+MnO <2% CaO-Al2O3-SiO2 slag system at 16000C
 EFFECT OF ‘Ca’ WIRE INJECTION

• Increase flowability of

steel during casting

• Inclusion modification

ie. ‘globular’ in shape

from triangular of Al2O3

• Formation of C12A7 I.e.

12CaO.7Al2O3 – Ideal for

product quality

CaO-Al2O3 phase equilibrium diagram

 Continuous Casting

1998 Continuous Casting

started

Present 2 x 2 strand
2000 mm casters
= 2.16 MT Cast Steel

After 3.35 MT of Cast Slab

Modernisation

69
 TUNDISH PRACTICE:

Argon Shrouding
3-5 lpm
SHROUD CAPACITY 45 T

SHELL 1.1 MTR

PERMANENT OPERATING
CASTABLE DAM DEPTH
QUARTZITE
SAND
MgO based
Board (85% SEN
MgO) Submerged Entry
Nozzle TUNDISH NOZZLE
Argon Shrouding PORT ANGLE 150
3-5 lpm 5500 mm
SLAB CASTER

72
CAST SLAB

73
 Hot Strip Mill

Dec’75 HSM Commissioning

1998 Equipment
modernized
Present Only continuous Mill
in the country
= 3.955 MT HR Coils
After Equipment
Modernisation Upgradation
New HSM
= 4.5 MT of HR Coils

74
 ReheatingSLAB
Furnace:
SIZE:
3 W.2-hi
One B (300T/HR)
& Four 4-hiX 750-
SM + CCD 170-250 mm
Walking Walking Walking Pusher 1 PUSHER (260 T/HR)
Beam 4 Beam 3 Beam 2 Type-1 1850
Universal mm XStands
Roughing 7.5-
10.5 M
Furnace Discharge

VSB deg C R1
Temp: 1200-1250 R2 R3 R4 R5

180 bar 180 bar 180 bar 180 bar 180 bar 180 bar

F.SHEAR F1 F2 F3 F4 F5 F6 F7
Meas. Meas.
Box DELAY TABLE Box

Thickness, Temp, Width

180 bar Temp, Thickness,
Width, Profile, Flatness

Laminar Cooling 4 S.C HYD COILERS

1.6-16 mm (12.7-APX-70) X
Run Out Table (206 m) 930-1830 mm
1 2 3 4
HOT STRIP MILL

RDCIS
76
 Cold Rolling Mill
Dec’76 TM-I Commissioned

Feb’90 HDGL Commissioned

Present Widest Mill in Country

=1.66 MT CR Saleable

After Equipment Upgradation

Modernisation New CRM of 1.2 MT
=2.4 MT of CR Saleable

77
MATERIAL FLOW WITHIN COLD ROLLING MILL
HR: Hot Rolled
HR COIL PL: Pickling Line
TM: Tandem Mill
FULL ANN: Annealing Line
PL HARD
SPM: Skin Pass Mill
ECL: Electrolytic Cleaning Line
TM HDGL CAL: Continuous Annealing Line
DCR: Double Cold Rolled
SL: Slitting Line
SSL: Sheet Shearing Line
ANN ECL CAL HDGL: Hot Dip Galvanizing Line

GP / GC
SPM DCR

GP/GC
SHEET
SSL SL

CR GP
CR SHEET TMBP
COIL COIL RDCIS
78
PICKLING LINE
TANDEM COLD ROLLING MILL
CONTINUOUS ANNEALING LINE
BATCH ANNEALING FURNACES
HOT DIP GALVANISING LINE
GP / GC SHEET
 Marching Ahead

Million Tons
Item Capacity Capacity Capacit Capacit
Present 2011 y 2016 y 2020

Hot Metal 4.58 5.77 10.68 17.98

Crude Steel 4.36 4.61 10.11 17.11
Saleable 3.78 4.18 9.04 15.94
Steel

85
 INTEGRATED STEEL PLANT

 Long Product

 Flat Product
LONG PRODUCT

87
FLAT PRODUCT

88
89