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Overview Report by
ROHIT PAL – USN:01FE15BME147
Under the guidance of Mr. Ravi Kiran
BACHELOR OF ENGINEERING
SCHOOL OF MECHANICAL ENGINEERING
KLE TECHNOLOGICAL UNIVERSITY
VIDYANAGAR, HUBLI-, KARNATAKA, INDIA
CERTIFICATE
This is to certify that the Report entitled “AN OVERVIEW OF HOT METAL DESULPHURIZATION
SYSTEM IN KANBARA REACTOR PROCESS-2” and submitted by ROHIT PAL having USN no
01FE15BME147 for the partial fulfilment of the requirements of B.Tech. (Mechanical Engineering)
degree of KLE Tech University, embodies the bonafide work done by him under my supervision
Place: Toranagallu
Date: 02/07/2018
‘
Mr Ravi kiran
Jr Manager (SMS-II)
JSW steel limited, Toranagallu
Mr Shant Kumar
Manger (SMS-II)
JSW steel limited, Toranagallu
ACKNOWLEDGEMENT
ROHIT PAL
Abstract
To achieve high productivity of hot metal desulphurization and also to meet the
increasing demands for lower Sulphur steel grades the mechanical stirring KR
process was introduced. But excess reagent consumption in De-S it affects the cost of
production. This project evaluates different factor responsible for reagent
consumption and analyses these factors for finding root causes.
Huge demand for automobile grades, interstitial free and electrical grade of
steel, these grades of steel consisting low percentage of Sulphur (20–50ppm). A large
number of techniques have been developed world wide over the year for
desulphurization of hot metal. Hot metal desulphurization was found to be most
economic in most of the process routes. In JSW steel limited adapted the two
different technologies. i.e. pneumatic (injection process) and mechanical stirring
(Kanbara reactor) process.
Introduction :
A multi-billion-dollar conglomerate, JSW Group is a part of O.P. Jindal Group
and played a key role in India's growth story. Ranked among India's top
business houses, JSW innovative and sustainable forays into the core sectors
of Steel, Energy, Cement and Infrastructure are helping build a new nation.
The Group continues to strive for excellence with its strengths, differentiated
product mix, state of the art technology, excellence in execution and focus on
sustainability.
The flagship company of JSW Group - JSW Steel, is India’s leading primary
and integrated steel producer. It has a production capacity of 18 MTPA with
plant located across six locations in South and West India, namely,
Karnataka, Tamil Nadu and Maharashtra.
• Specification…
• Boasts of a capacity of a whopping 18 million tonnes per annum
(MTPA).
• Houses India’s widest hot strip mill and one of India’s largest blast
furnaces.
• Produces 800+ tonnes per person per annum, making it the most
productive steel plant in India.
• Recognised for its ‘zero-effluent discharge’ status; reuses more than 95
per cent of process waste.
• Has a low carbon footprint, with 96% of coke oven gas for power
generation being recycled.
• Uses Corex technology for hot metal production.
• Employs a large-scale, low-grade iron ore beneficiation process
AN OVERVIEW OF HOT METAL DESULPHURIZATION PROCESS
IN MOVABLE KANBARA REACTOR Page 4
KLE Technological University
School of Mechanical Engineering, Hubli
History :
In 1994, Jindal Vijayanagar Steel (JVSL) was set up with its plant located at
Toranagallu in the Bellary - Hospet area in the State of Karnataka, the heart
of the high-grade iron ore belt and spread over 10,000 acres (40 km2) of
land. Over a decade. It also set up a plant at Salem with an annual capacity of
1 million tonne. It is on the threshold of a major expansion plan of adding 3.2
million tons per annum to its at Vijayanagar Plant to achieve 11 MTPA by
2011.
It has established a strong presence in the global value-added steel segment
with the acquisition of a steel mill in US and a Service Center in United
Kingdom. JSW Steel has also formed a joint venture for setting up a steel
plant in Georgia. The Company has further acquired iron ore mines in Chile
and coal mines in USA & Mozambique.
The current manufacturing capacity of company is 18 MTPA. In Aug 2014, it
acquired Welspun Maxsteel Ltd in a deal valued at around 1,000 Crores. JSW
has already acquired 3 MTPA Hot Rolling Plant in Dolvi Maharashtra (earlier
named Ispat Industries Ltd).
Milestones :
• Acquasition of
49.3% stake in
2012 • 4.3 MTPA
• Post Ispat merger
2014
Ispat • New CRM phase-1
• HSM capacity • 4 MTPA pallet plant
expansion to 5 • 1 MTPA coke oven
MTPA plant
• Acquired 50% stake in
2011 2013 Vallabh Tinplate
• Acquired Welpsun
Maxsteel
Input :
Raw Material
1. Iron Ore, Fe2O3, Fe3O4 5.Manganese ore
2. Limestone 6.Coal
3. Dolomite 7. Water
4. Quartzite
Energy
1. Electricity 4. BF Gas
2. Corex Gas 5.Mixed Gas
3. LD Gas
Iron Ore Lumps Iron Ore Fines Coal Lumps Coal Fines
Flux
Blast Furnace Slag
Air
Slab Billet
In the RMHS the all raw material is hold for some time as per its requirement.
All the raw material like Iron ore lump and fines, Pellet, Limestone,
Dolomite, Quartzite, Manganese ore, Coal, etc. is bring by means of
transport (Vehicles, Trains) and directly dumped in RMHS.
Major units: 2 wagon tippler, 3 stacker cum reclaimer, 1 barrel reclaimer.
Salient technical feature: Approximately 17 km long Conveyor System.
Sinter Plant :
▪ Sintering is an agglomeration process which produces strong and porous
lumps from a powdered uncompacted mass of iron ore with the application
of heat to the stage of incipient fusion.
▪ Necessary heat is supplied by the combustion of coke breeze.
▪ The process is performed on a travelling grate on which 500-600 mm thick
sinter mix consisting of iron ore, flux, coke breeze and industrial wastesn
along with moisture are fed continuously. The complete combustion of coke
breeze, initiated in the top layer produces a temperature of 1200-1300°C and
is maintained continuously by sucking air through the bed.
▪ The suction of air makes the combustion zone travel through the bed
raising its temperature layer by layer to sintering temperature.
▪ Process completes when combustion zone reaches to the lowest layer of
the bed.
▪ Sinter cake is tipped from the grate in hot condition, broken, screened and
cooled to produce desired fraction.
Pellet Plant :
Palletisation is the technological process designed to transform fines into
8 to 16 mm size balls with the help of balling disc or balling drum.
Three stages of palletisation process :-
1. Raw material preparation.
2. Formation of green balls.
3. Induration of green balls.
Coke Oven :
The coke making process involves carbonization of coal to high temperatures
(1300°C) in an oxygen deficient atmosphere in order to concentrate the
carbon. The commercial coke making process can be broken down into two
categories: a) Recovery Coke making and b) Non-Recovery Coke making.
Blast Furnace :
The purpose of a blast furnace is to chemically reduce and physically
convert iron oxides into liquid iron called "hot metal". The blast furnace is a
huge, steel stack lined with refractory brick, where iron ore, coke and
limestone are dumped into the top and preheated air is blown into the
bottom. The raw materials require 6 to 8 hours to descend to the bottom of
the furnace where they become the final product of liquid slag and liquid
iron. These liquid products are drained from the furnace at regular
intervals. The hot air that was blown into the bottom of the furnace ascends
to the top in 6 to 8 seconds after going through numerous chemical
reactions. Once a blast furnace is started it will continuously run for four to
ten years with only short stops to perform planned maintenance.
2. Galvanized Sheet:
• To make the galvanized pipes and galvanized wire.
• The body parts of trucks, cars and buses.
• It is used in high tension electrical towers, protective gears, and
highway signs.
• Galvanized metal has found its way into several household
appliances, such as washing machines, air conditioning
• Uses at in corrosive environment like as sewage, pipelines, fuel
storage tank.
3. TMT Bar
• Bridges
• Dams
• High-Rise Apartments
• Industrial Structure
• Fly Overs
4. Wire
• Machine tools are made from wire rod
• To make the wire ropes
• To make the ball of bearing.
• Uses in the Cosmetics parts
• To make the rings and use in the building pillars
• Secondary steel making: In this process the high quality grades steel
are produced which is depending upon steel application. Here LHF and
RH Process is coming, means here some alloying addition and refining of
liquid steel takes place.
After this liquid steel send to CCM unit where casting is takes place. Slab and
Billet is the output of steel melting shop.
Process :
CONTINUOUS CASTING
Desulphurization
SCARP FLUX
ARGON COOLANTS
HMDS KR
LHF
RH
CCP
Literature survey
KR (Kanbara reactor) is hot metal pre-treatment system for
desulphurization process, it was developed in Japan by Nippon Steel in
1963.Learning from this Japanese technique as a cost-effective process
JSW steel took initiative and installed the first reactor of such kind in
India.KR process in which reaction takes place by addition of reagents
and mixing through mechanical stirring refractory impeller. In the KR
process, lime is used as the main reagent. Sometimes also calcium
fluoride (CaF2, about 10%) and/or aluminium oxide (Al2O3) are
mixed with the lime. The reagent is usually added from the top [1].
lime is used more efficiently in the KR process, lime is cheap and easily
available from lime plant. As compared to Injection system it is very
simple process, further the treatment time is very short.
Two type of KR
3. Ladle(capacity 180ton)
transferring to KR
treatment position
4. Sampling and
temperature
measuring before
KR treatment
by a strong downstream and dispersed again and again into hot metal
bath. Such a cyclic behaviour of desulphurization reagent leads to high
efficiency of desulphurization reaction, resulting in less
desulphurization flux consumption than that in injection process. The
influence of hot metal temperature on S partition ratio (Ls), which is
defined as (%S) / [%S].
The addition of fluorspar to along with lime will increase the solubility
of CaO and thus give the slags greater desulfurization potential. It is
this increased CaO solubility (if the lime is added) that increases the
sulfide capacity of the slag, which results in improved desulfurization.
The addition of CaF2 to a fully liquid slag, without adding lime will do
nothing for desulfurization but drastically increase refractory wear.
3. Travelling car
➢Impeller
➢ Clamping device
➢ Dedusting Hood
6. Refractory Unit
CaO silo
CaF2 silo
AN OVERVIEW OF HOT METAL DESULPHURIZATION PROCESS
IN MOVABLE KANBARA REACTOR Page 38
KLE Technological University
School of Mechanical Engineering, Hubli
➢ Impeller
• The impeller is connected with
stirring shaft and bolts. The
impeller has four steel blades and
studs are placed into the blades
and shaft to be coated with
refractory castable material.
• The impeller shaft is hollow shaft
in the same way as the stirring
shaft and the inner shaft is
inserted in hollow shaft to let cool
air to flow up to the end.Exhaust
air is blown onto the impeller
moulting bolt ,playing a role of
protecting the bolts.
➢ Dedusting Hood
The KR dust collection Hood is
designed to control the Powder from
littering to the surroundings, which
occurs in operation . The Equipment
reduces the gap between the hood and
ladle and then decrease the littered
dust amounts by installing a lifting
type of skirt on the circumference of
the circular hood
6. Refractory Unit
STEPS:
• After the impeller is moved down the refractory material along with
the slag is removed by DE bricking machine.
• After removing the slag the anchor (made of steel material) is
checked if there is any damage or bending .
• After that the mixture is poured into the mould and kept for 36 hours
for settling .
• Then again the impeller is set for natural drying for about 36
hours.
• Then it is sent for the impeller pre heat treatment at a temp of
200 degree Celcius for 40 hours
CONCLUSION
KR process is the best process can be achieving the ultra-low Sulphur by
using local availability of cheap raw materials.
In this project excess addition of reagent is most favourable cause for
reagent consumption in KR process-2.The reagent consumption controlled
by small implementation.
REFERENCES
• www.jsw.in
• Technical training Manual for SMS II, JSW Steel LTD.
• Wikipedia
• www.ispatguru.com
• Modern Steel Making by Dr. R. H. Tupkary & V. R. Tupkary.
• ]M.K. Cho et al. Hot Metal Desulfurization by CaO-SiO2-CaF2-Na2O
Slag Saturated with MgO. ISIJ International. 2010. 50: 215-221.
• ISIJ International, Vol. 57 (2017), No. 2,217