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Steel Melting Shop Presentation With EAF_LRF_CCM Route
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Steel Melting ShopSteel Melting Shop
Introduction:-Jindal Steel & Power Ltd. Has got a sophisticated STEEL MELTING SHOP with a capacity of 2.4 million tones/annum.The main units installed in SMS – II are:-1. Ultra high power EAF’S (EBT type) : 2nos.2. Ladle refining furnace : 03nos3. Tank Degasser : 01nos4. R-H Degasser : 01nos5. Combi caster : 01nos6. Billet caster : 01nos7. Slab caster : 01nos
main products are:-1.Beam Blanks2.Blooms3.Billets4.Rounds5.Slabs
STEEL MELTING SHOP -II
EAFBucket chargi
ng
Hot Metal Pouring to EAF
Ladle refining Furnace
Hot metal ladle
Process Flow Diagram Steel Melt Shop IIProcess Flow Diagram Steel Melt Shop II
Vacuum Degassing
Combi caster
Billet caster
Slab caster
Beam Blank,Bloom ,Round
Billet ,Round
Slab
Continuous feeding of DRI from DRI Plant
Two ultra high power Electric Arc Furnace• Make : SMS DEMAG• Capacity : 100 mT• Furnace transformer rating: 100 MVA• Electrode dia : 24"(600 mm)• No of VLB(for Oxygen lancing) : 4• Furnace lining : Magnesia
Carbon bricks.
• Tap Hole : EBT Type• Average production 52heats/day• SMS –II produced 1.76 MTPA of steel last year 2010
Electric Arc Furnace
• Furnace body – shell, hearth, walls, spout, doors etc.
• Gears for furnace body movement .• Roof and roof-lift arrangements.• 3 graphite Electrodes, there holders .• Electrical equipments – transformer ,
cables electrode control mechanism etc.
• Water cooled panels tube -to-tube design(steel and copper tubes)
• Cu –blocks in lining• Manipulator for – 2 oxygen lances, 1
carbon lance• Manipulator for sampling and
temperature taking• TOPARC (arc stability measurement)• Water spray cooled roof
Steel Melting shopSteel Melting shop
Inputs for EAFInputs for EAF Metallic inputs: Hot metal from blast furnace(50 to 55%).%C : 3.8 to 4.2%%Si : 0.7 % max%P : 0.13 maxTemp : 1280 deg min DRI (Lumps +Fines) from DRI Plant (40 to 49%).%C : 0.1 max%Fe(met) : 81 min%SiO2 : 3.5 Scrap(1-5%)
Flux: Lime from LDP (Lime and Dololime Plant) Burned dolomite from LDP
Other inputs: Oxygen from Oxygen plant. CPC (Calcined petroleum coke) HSD (High speed Diesel)
Functions of EAF:
1.Melting of Solid inputs and homogenization of steel bath.
2.Raising the temperature of the melt to ≈1620 C for tapping.
3.Decarburisation.
4.Dephosphurisation.
5.Slag free and compact stream tapping
6.Flexibility to produce a variety of grades of steel
ADVANTAGE:
1.Relatively small in size
2.cleaner environment
3.Flexibilty to produce a variety of grades of steel
4.Precise control
Heat cycle:
Tap to tap time : 48 minEBT filling time : 3 minSlag pot changing/ pit cleaning time : 8 minHot metal pouring time : 5 minArc time : 29 minTapping time : 3 min
Control parameters:
Power in put : 70 to 75 MW Oxygen input : 120 Nm3/minTap Chemistry
%C : 0.05 %P : 0.010% Other elements : Trace
Taping Temperature : 1620°C
Most important chemical reactions:
• Decarburization : [c] + o = co
• Manganese reaction : [Mn] + o =(MnO)
• Desiliconizing : [Si] + O = (SiO2)
(SiO2) + (CaO) = (2Cao.SiO2)
• Dephosphorization : [P] + O = (P2O5)
(P2O5)+ (CaO) = (3 CaO.P2O5)
• Iron Combustion : [Fe] + O = (FeO)• Desulphurization : [S] + (CaO) = (CaS) + O
• [] in steel bath, () in slag
Average Slag composition in JSPL
All are in percentage • SiO2 16.75
• FeO 31.06• CaO 28.52• MgO 12.70
• Al2O3 8.77
Basicity 1.70
FOAMY SLAG
• Principle of foamy slag – emulsion of metal droplets and gas bubbles in slag
• First step C(Steel)+ O =CO –bubbles
Gives energy
• Second step• Feo(slag) + C = Fe(back to steel) + CO- bubbles
Costs energy
• Third Step• C(slag) + O = CO – bubbles
• Fe + O= FeO
Gives energy
Advantage of modern developmentin EAF
Advantage of Foamy slag practice• Decrease electrical energy consumption• Increase refractory life and panel life• Reduce nitrogen problem by shielding effect• Decrease electrode consumption• Increase productivity
Advantage of UHP• Enables Faster melting of solid charge• Decrease tap to tap time hence increase productivity
Advantage of oxygen lancing• Faster removal of carbon & other impurities • Faster generation of foamy slag
Ladle refining Furnace(LRF)Ladle refining Furnace(LRF)No of LRF : 3Make : SMS DEMAGCapacity : 100T eachTransformer ratingLRF I : 10 MVALRF II & III : 18 MVA
Main function of LRF:
1.Refining of steel2.Achieving desired chemistry as per the requirement by adding various Ferro alloys.3.Thermal and Chemical homogenization of the bath by argon purging.4.Attaining the lifting Temperature of the steel to maintain the desired super heat.
Vacuum DegasserVacuum Degasser
VACUUM DEGASSER• Design, Engg and Supply : Danieli ,Italy
• Vacuum degassing mainly based on siverts law
• Salient Features• Suction Capacity : 350 Kg/hr at 0.5 torr
• Pump down time : 5 minutes at 0.5 torr
• Vacuum System : 9 Steam ejectors
3+1 condensers works on successive compression of off-gas in a series of stream ejectors.
• Argon Stirring : Continuous 14 Nm3/hrs
Functions
• remove gaseous element, non-metallic inclusion and sulphur from the steel
Process-Vacuum evacuation of main chamber.-Steel is raising in to lower vessel equivalent to Ferro static pressure.-Circulation effect is produced by bubbling Ar in the inlet snorkel.-Dissolved gasses and Ar released into the vacuum.-Steel accelerates through the inlet snorkel ( 3 1.5m/sec or 3 1mt/min).-Steel returns to ladle through 2 chamber vacuum-lock and alloy chute.-Temperature loss is low (RH-vessel preheated).
Advantages:-Shortening of the primary metallurgy process short treatment -> high availability.-Achievable metallurgical results: ̴ 1.5 ppm H, ̴15 ppm C, ̴ 1 ppm O-High alloy recovery yields.- Homogenization, improved cleanliness.
RH-DegasserRH-Degasser
Steel Melt Shop II Steel Melt Shop II No of casterNo of caster : :
331.Four strand Combi 1.Four strand Combi
caster.caster.2.Six strand Billet caster.2.Six strand Billet caster.3.Single strand Slab caster.3.Single strand Slab caster.
Continuous Casting MachineContinuous Casting Machine1.Four strand combi caster:1.Four strand combi caster: Products : 420x480x120 mm Beam blank,
355x280x90 mm Beam blank, 285x390 mm 250x250 mm, 305,280,255 mm
Round.
Continuous Casting MachineContinuous Casting Machine2.Six strand Billet caster:2.Six strand Billet caster: Products : 142 mm,162 mm, 200 mm, 220 mm Round , 130x130
mm ,150x150 mm , 200x200 mm
Continuous Casting MachineContinuous Casting Machine3.Single strand slab caster:3.Single strand slab caster:Products : Width 1300 mm to 2600 mm
Thickness 215 mm, 250 mm and 280 mm
Thank YouThank You