Report

On training at Steel Melting Shop,

Jindal Steel and Power Limited


By K Sandeep
Emp. Code 2968




CONTENTS

1. Content...1
2. Overview...2
3. SMS 2
2.1 Working & Charging..3
2.2 Data Sheet Of Heat4
2.3 Observations SMS 2..6
4. SMS 3
4.1 Data Sheet Of Heat...7
4.2 Observations SMS 310









OVERVIEW :


JSPL has two SMSs in working i.e. SMS-2 & SMS-3. SMS feeds on
hot metal coming from the blast furnace. Hot metal is
transferred through Torpedo of capacity 350T. Hot metal from
torpedo is poured in the ladle of 100T and transferred to EAF
(Electric Arc Furnace) by hot metal car. In EAF, majorly
percentage of carbon, silicon, phosphorous is controlled. It is
then transferred to LRF ( Ladle Refining Furnace ) for chemistry
control i.e. controlling composition of other elements in hot
metal, then according to requirement hot metal is transferred to
VD ( Vaccume Degaser ) and R-H Degaser ( only for rails). After
attaining required temperature for casting, hot metal ladle is
send for casting to slab caster and combi caster.



SMS-2 :

After pouring hot metal in ladle from torpedo, it is weighed and then sent to
EAF. Charging materials of EAF are hot metal from Blast Furnace, Scrap (if taken
on requirement ), DRI, Lime Stone, Dolomite and Carbon ( as CPC ).
Working and Charging sequence of EAF :-
1. After tapping of heat and slag from previous heat, scrap is added at first to
hot heal left in the furnace. Adding scrap at first gets more time for melting
of solid scrap pieces till starting of arcing. Scrap charging is done from top
and slowly, otherwise causes damage to refractory lining.

2. After that hot metal is poured in vessel of EAF. Generally it is done through
launder car and hot metal is poured through slag door but to minimize
pouring time sometimes done from top. It harms the refractory lining and
requires regular coating of refractory lining.

3. When pouring is done through launder car and nearly 20-30T of hot metal is
poured, then arcing is started immediately to reduce tap to tap time. In this
case immediately after scrap charging DRI is charged as it acts as cushion for
electrodes during arcing and protects from damage.

4. Charging of limestone, dolomite and DRI is done continuously during process
and is not done all at a time because it reduces the dissolving and melting of
charge takes longer time, hence increases tap to tap time.


5. Oxygen lancing is started after 3-4 min of power on. Before that lances were
in burning + lancing mode to additional heat for scrap melting.

6. Carbon jet is used to produce foamy slag. It is started as per requirement. If
slag removal is continuous and foamy, carbon jet is not used.

7. After 25-30min of power on, temperature tip and sampling tip is used to read
temperature and take samples of heat.

8. Celox tips are also used to get instantaneous reading of carbon%,
temperature and oxygen ppm ( parts per million ).

9. After attaining required temperature, C% and P% heat is tapped in ladle
which is already Argon gas purged. During heat tapping, ferroalloy addition,
Al and carbon addition is done. Nearly 70% of addition is done here to save
processing time in LRF.

DATA SHEET OF 2 HEATS FROM EAF OF SMS-2 :-
Heat No. 2207865
MS Scrap 3.0T
Pig Iron 4.0T
HBI (Hot Briquetted Iron) 3.0T
Skull 5.0T
Hot Metal 67T
Sponge Iron (Lumps) 34T
Sponge Iron (fines) 25T
Oxygen consumption 5492Nm
3
Electrical Energy Consumption 40383Kwh
CPC ( Calcined Petroleum Coke) 971kg
Lime 5.2T
Dolomite 4.3T
Temperature tips 4
Sample tips 2
Celox 2
Lime Stone Chips 2.2T
Arcing Duration 38min
Tap to Tap time 57min

Heat No. 2207866
MS Scrap 3.0T
Pig Iron 4.0T
BF Skull 3.0T
Skull 5.0T
Hot Metal 66T
Sponge Iron (Lumps) 34T
Sponge Iron (fines) 15T
Oxygen consumption 4892Nm
3
Electrical Energy Consumption 43614Kwh
CPC ( Calcined Petroleum Coke) 1257kg
Lime 5.6T
Dolomite 4.9T
Temperature tips 4
Sample tips 2
Celox 2
Lime Stone Chips 2.1T
Arcing Duration 40min
Tap to Tap time 54min

OBSERVATIONS SMS 2 :-

1. In furnace where top pouring is done, after regular heats refractory
material is coated on upper shell to protect it from splashes of hot metal
during pouring.

2. Arcing is started with long arc i.e. metal pouring and scrap melting is in
process for very short durations, then move to short arc, so as to provide
more energy to produce heat.

3. As process moves towards completion, power is not lowered as in theory
to use more of chemical energy produced and lower the electrical power
use. As by doing this tap to tap time comes down.

4. As addition of DRI, limestone and dolomite is continous process but all
quantity is added in first 25min after power on time.

5. Life of EBT is measured by the tapping time. Normal tapping time is 4min.
if taping time is less then 4min than this decrease in time shows increase
in diameter of EBT due to erosion caused by tapping of metal.

6. Electrode consumption is about 1.6kg/ton of hot metal.

7. Oxygen Lancing is readily done in these three modes.
(i)Lower mode 800Nm
3

(ii)Pilot mode 1500Nm
3

(iii)Lancing mode 1800Nm
3


After percentage of carbon and phosphorus is achieved, hot metal is tapped in
ladle during which around 70% of ferroalloy addition is done. After tapping,
ladle is taken to the LRF for chemistry control.

SMS-3 :
SMS 3 consists of one EAF of 100T , two LRF (one in working other in erection
), one Vacuum Degasser and one Combi Caster. Working of EAF in SMS 3 is
same as in SMS 2, difference is in design of EAF which increases its efficiency
i.e. more efficient than EAF of SMS 2. Here EAF doesnt have Virtual Lance
Burning unit which removes oil consumption. Only Oxygen Lancing and carbon
jet is used for making heat.
DATA SHEET OF 2 HEATS FROM EAF OF SMS-3 :-

Heat No. 4208401
MS Scrap 24T
BF Skull 17T
Hot Metal 48T
Sponge Iron 33T
Sponge Iron (fines) 6T
EBT Filling 150kg
Oxygen Consumption 2825Nm
3

Power Consumption 45698kwh
CPC Consumption 694kg
Lime 4T
Dolomite 4T
Temperature Tips 4
Sampler Tips 1
Celox 0
Arcing Duration 39min
Tap to Tap time 56min
Tap Temperature 1620
0
C
Composition (%) :
C 0.197 Si 0.2244 Mn 1.35 S 0.0234
Al 0.0517 Cr -0.175 V 0.0018 Mo 0.0842
Nb 0.0008 Ti 0.0024 B 0.0005 Ca 0.0003
Ni 0.0098 Sn 0.0022 As 0.0008 Zr 0.0002
Sb 0.0004 Pb 0.0003 Co 0.0038 Fe 97.8366
P 0.0156 Cu 0.0099 N 0.0081 W 0.0008

Heat No. 4208427
MS Scrap 23T
HBI 3T
Hot Metal 50T
Sponge Iron 49T
Sponge Iron (fines) 5T
EBT Filling 150kg
Oxygen Consumption 2925Nm
3

Power Consumption 43774kwh
CPC Consumption 460kg
Lime 4T
Dolomite 4T
Temperature Tips 4
Sampler Tips 1
Celox 1
Arcing Duration 38.50min
Tap to Tap time 55min
Tap Temperature 1620
0
C
Composition (%) :
C 0.045 Si 0.0967 Mn 0.25 S 0.026
Al 0.013 Cr -0.0083 V 0.0005 Mo 0.001
Nb 0.0003 Ti 0.0008 B 0.0003 Ca 0.0002
Ni 0.0078 Sn 0.0012 As 0.0009 Zr 0.0003
Sb 0.0004 Pb 0.0002 Co 0.003 Fe 99.5199
P 0.0127 Cu 0.0049 N 0.0059 W 0.0007

OBSERVATIONS SMS 3 :-

1. In foamy slag practice, electrode arcing is submerged, hence its electrical
power efficiency is increased. Heat loss is also minimized as it acts as a
blanket.

2. Sample tips are always used above 1550
o
C because below this
temperature sample consists of blowholes and sparking at blowholes
gives variable C% and non-uniform results.

3. If slag temperature is not constant & low throughout process, then
phosphorus gets reverted. Therefore DRI should be uniformly & evenly
charged during entire process.

4. Great Melting Practice Synchronization between temperature required
& required C%.
(a) If carbon % is achieved earlier to temperature, then O
2
ppm
increases in hot metal and effects refractory lining.
(b) If temperature is achieved earlier to C%, then time loss occurs as
lances are on & arcing is powered off.

5. For low N
2
heat, energy should be provided by O
2
lancing & not by arcing,
as arcing ionizes air and increases N
2
dissolving in heat.

6. For V.D. heat quantity of hot metal in ladle should be low because during
vacuum degassing when vacuum is applied for degassing effective
volume of hot metal increases as gases try to escape through surface of
hot metal by making it foamy.

7. In scrap bucket preparation large and course forms & carbon and lime are
placed at bottom where as fine scrap at top or upper part of bucket.

8. If slag volume is less in hot metal during arcing then splashing of hot
metal & loss of energy takes place. This happens readily in case of new
bottom shell, as effective working volume is less & therefore most of slag
gets drained during tapping. The remedy for this is to keep the hot metal
quantity less for some heats, later size of heat can be increased.