This document discusses a study conducted on the effect of moisture content on turndown temperature at LD#1. It begins with an introduction and acknowledgements. The contents section lists topics to be covered including an overview of the BOS process, hot metal, oxygen lance technology, and turndown conditions. It also discusses the aim of analyzing the impact of wet versus dry iron ore on heat comparison.
This training report summarizes Santosh Kumar's summer training at the Rourkela Steel Plant from May to July 2014. It thanks the employees who supported and guided his training, particularly Mr. Panda and Mr. Patra. The report focused on gaining knowledge about the various processes used at the steel plant, especially in Steel Melting Shop-II.
This document provides an overview of the steel industry in India. It discusses key topics such as the major players in the industry, the market structure and competition, policies supporting the sector, and recent developments. The industry has seen significant growth in recent decades and consolidation, with a few large companies now dominating production. The government aims to facilitate the industry's continued development and competitiveness on the global stage.
Industrial Training Report on Steel Melting Shop(SMS)Shani Kumar Singh
1. The document provides an overview of Jindal Steel and Power Limited (JSPL), describing its facilities, products, and status as one of India's largest steel producers.
2. It then summarizes the steel melting shop (SMS) process, which involves primary and secondary steelmaking using equipment like electric arc furnaces, ladle refining furnaces, and continuous casters to produce high quality steel from raw materials.
3. Key equipment in the SMS plant are described briefly, including the electric arc furnace, ladle refining furnace, vacuum degassing unit, and various continuous casters.
The document provides information on the production, properties, and applications of magnesium and magnesium alloys. It discusses the various extraction methods for magnesium including calcination, the Pidgeon process, and the Dow process. It also outlines casting techniques for magnesium alloys such as die casting, squeeze casting, and thixocasting, and describes approaches for grain refinement.
This document discusses welding defects and their causes. It outlines the four zones in a welded joint and how they appear on an iron-carbon phase diagram. The zones are the fusion zone, weld interface zone, heat affected zone, and base metal. Solidification can be epitaxial or non-epitaxial depending on whether filler metal is used. Common welding defects include cracks, porosity, inclusions, incomplete fusion, imperfect shape, and residual stresses. Various defect types like longitudinal cracks and underbead cracks are described in more detail.
Preparation of metal matrix composites by stir-casting methodIAEME Publication
The document discusses the preparation of metal-matrix composites (MMCs) using the stir-casting method. Specifically, it focuses on producing aluminum-silicon carbide (AlSiC) MMCs. Six samples were created with varying silicon carbide percentages from 5-30%. The samples were then tested for hardness, impact strength, and microscopic examination. Stir-casting is described as a process that involves continuously stirring reinforcing particles into molten metal before pouring and solidification. The document provides details on the equipment and process used, including a graphite crucible, coal-fired furnace, motorized stirrer, and raw materials of aluminum and silicon carbide.
Fabrication of metal matrix composites using stir casting methodAbhishekKumarSingh252
This document summarizes a project to fabricate metal-matrix composites using stir casting. The project aims to produce aluminum-silicon carbide (AlSiC) composites through stir casting to create strong, lightweight materials for use in industries like automotive and aerospace. Experiments are conducted by varying the composition of silicon carbide added to molten aluminum from 5-30% and stirring to ensure homogeneous mixing. The composites are then tested for properties like hardness and impact strength. The goal is to develop low-cost metal-matrix composite materials for industrial applications requiring high strength, stiffness, and other properties.
The document discusses the process of steelmaking at Tata Steel's plant in Jamshedpur, India. It describes the key units involved, including hot metal receiving and desulfurization, basic oxygen steelmaking in converter vessels, secondary metallurgy treatments in ladle furnaces, and continuous casting of final products. It focuses on the secondary metallurgy processes used to refine molten steel and achieve the desired compositions for different grades, such as additions of alloys and slag.
This training report summarizes Santosh Kumar's summer training at the Rourkela Steel Plant from May to July 2014. It thanks the employees who supported and guided his training, particularly Mr. Panda and Mr. Patra. The report focused on gaining knowledge about the various processes used at the steel plant, especially in Steel Melting Shop-II.
This document provides an overview of the steel industry in India. It discusses key topics such as the major players in the industry, the market structure and competition, policies supporting the sector, and recent developments. The industry has seen significant growth in recent decades and consolidation, with a few large companies now dominating production. The government aims to facilitate the industry's continued development and competitiveness on the global stage.
Industrial Training Report on Steel Melting Shop(SMS)Shani Kumar Singh
1. The document provides an overview of Jindal Steel and Power Limited (JSPL), describing its facilities, products, and status as one of India's largest steel producers.
2. It then summarizes the steel melting shop (SMS) process, which involves primary and secondary steelmaking using equipment like electric arc furnaces, ladle refining furnaces, and continuous casters to produce high quality steel from raw materials.
3. Key equipment in the SMS plant are described briefly, including the electric arc furnace, ladle refining furnace, vacuum degassing unit, and various continuous casters.
The document provides information on the production, properties, and applications of magnesium and magnesium alloys. It discusses the various extraction methods for magnesium including calcination, the Pidgeon process, and the Dow process. It also outlines casting techniques for magnesium alloys such as die casting, squeeze casting, and thixocasting, and describes approaches for grain refinement.
This document discusses welding defects and their causes. It outlines the four zones in a welded joint and how they appear on an iron-carbon phase diagram. The zones are the fusion zone, weld interface zone, heat affected zone, and base metal. Solidification can be epitaxial or non-epitaxial depending on whether filler metal is used. Common welding defects include cracks, porosity, inclusions, incomplete fusion, imperfect shape, and residual stresses. Various defect types like longitudinal cracks and underbead cracks are described in more detail.
Preparation of metal matrix composites by stir-casting methodIAEME Publication
The document discusses the preparation of metal-matrix composites (MMCs) using the stir-casting method. Specifically, it focuses on producing aluminum-silicon carbide (AlSiC) MMCs. Six samples were created with varying silicon carbide percentages from 5-30%. The samples were then tested for hardness, impact strength, and microscopic examination. Stir-casting is described as a process that involves continuously stirring reinforcing particles into molten metal before pouring and solidification. The document provides details on the equipment and process used, including a graphite crucible, coal-fired furnace, motorized stirrer, and raw materials of aluminum and silicon carbide.
Fabrication of metal matrix composites using stir casting methodAbhishekKumarSingh252
This document summarizes a project to fabricate metal-matrix composites using stir casting. The project aims to produce aluminum-silicon carbide (AlSiC) composites through stir casting to create strong, lightweight materials for use in industries like automotive and aerospace. Experiments are conducted by varying the composition of silicon carbide added to molten aluminum from 5-30% and stirring to ensure homogeneous mixing. The composites are then tested for properties like hardness and impact strength. The goal is to develop low-cost metal-matrix composite materials for industrial applications requiring high strength, stiffness, and other properties.
The document discusses the process of steelmaking at Tata Steel's plant in Jamshedpur, India. It describes the key units involved, including hot metal receiving and desulfurization, basic oxygen steelmaking in converter vessels, secondary metallurgy treatments in ladle furnaces, and continuous casting of final products. It focuses on the secondary metallurgy processes used to refine molten steel and achieve the desired compositions for different grades, such as additions of alloys and slag.
Ladle Metallurgy: Basics, Objectives and ProcessesElakkiya Mani
Worldwide steel production in 2019 reached 1869 million tons, with China as the largest producer at 996 million tons. India was the second largest steel producer at 111 million tons. Ladle metallurgy involves further refining of molten steel in a ladle after tapping from a converter or electric furnace. It allows for homogenization, deoxidation, desulfurization, and other processes. Key ladle metallurgy techniques include ladle furnace treatment, argon stirring, vacuum degassing, and alloy additions to adjust steel chemistry and properties.
Continuous casting is a process used to cast metal into a continuous length. Molten metal is poured into a mold and solidifies into a casting as it travels downward. New molten metal is continuously supplied to the mold to keep the process going and produce a casting of indefinite length. The process requires precise control of parameters like molten metal flow to ensure smooth, continuous casting.
Advanced High Strength Steels and their Heat Treatment processesSudarshan Sundar
This document provides information on advanced high strength steels (AHSS) used in the automotive industry. It defines AHSS as steels with yield strengths over 550 MPa and discusses various strengthening mechanisms employed. Different types of AHSS are described, including dual phase steels, ferritic bainitic steels, and complex phase steels. Their microstructures and properties are summarized. Key factors for material selection like crash performance, stiffness, and formability are also outlined. The document provides an overview of the evolution of steels in the automotive industry to enable lightweight design through improved strength-ductility combinations realized by AHSS.
BSP Project (Based on Continuous Casting) [Final]Subham Shit
MARS-2 is a machining, assembly, and re-engineering department of Bhilai Steel Plant. It has light and heavy machining bays and an assembly bay. MARS-2 specializes in machining high-value parts, repairing and reclaiming worn parts, and assembling machinery. Some key assemblies MARS-2 performs include five roll sets, ten roll sets, and pinch roll assemblies for the continuous casting shop. MARS-2 aims to support most departments of BSP. It is well-equipped with machines like lathes, mills, grinders, and has an annual machining capacity of 2,200 tons and assembly capacity of 6,000 tons.
Material Engineering,
Heat treating (or heat treatment) is a group of industrial and metalworking processes used to alter the physical, and sometimes chemical, properties of a material. The most common application is metallurgical. Heat treatments are also used in the manufacture of many other materials, such as glass. Heat treatment involves the use of heating or chilling, normally to extreme temperatures, to achieve a desired result such as hardening or softening of a material. Heat treatment techniques include annealing, case hardening, precipitation strengthening, tempering, carburizing, normalizing and quenching
EFFECT OF CASTING PARAMETERS ON MACROSTRUCTURE OF STEELSurya Teja Botu
The document summarizes a student project conducted at Vizag Steel Plant investigating the effect of casting parameters on the macrostructure of steel. It was presented by five students and guided by P.V. Bhujanga Rao of Vizag Steel Plant. The project examined how melt temperature and casting speed influence steel structure and defect formation during continuous casting, and modeled temperature and melt flow in the caster sump. It provides background on Vizag Steel Plant and describes its raw material sources, production units including coke ovens, sinter plant, blast furnaces, and rolling mills.
Introduction to modern concept of steel making through induction furnaces by ...steadfast123
Introduction to modern concept of steel making through induction furnaces by stead fast engineers.Find here
Induction Furnace manufacturers,
Induction heater manufacturers,
Induction Billet heater Manufacturers,
Induction Melting furnace manufacturers,
Induction Furnace Manufacturers in India,
Induction Billet heater manufacturers in India,
Induction heating system,
Induction Melting Furnace
for your sourcing needs.
SAIL was formed in 1973 as a holding company for various steel plants and mines. It later became an operating company, merging the steel plants and spinning off other businesses. Over time it acquired several other steel companies. SAIL is currently India's largest steel producer, with various integrated steel plants, mines, and other facilities. It has extensive business operations and joint ventures within India and internationally.
1) The document discusses different steelmaking processes including the Bessemer converter process, open hearth furnace process, and basic oxygen converter process.
2) The Bessemer converter process was the first major steelmaking technique but has been replaced by basic oxygen converters. It used hot metal and an oxygen blast to oxidize impurities.
3) The basic oxygen converter process is now the dominant steelmaking method. It uses a pear-shaped vessel, oxygen lancing, and produces steel in 40-60 minutes by oxidizing impurities into slag.
PPT Includes physical Metallurgy for Titanium and its alloys, Weld ability of them and two welding processes : GTAW and EBW. PPT also describes the Problems with the Welding of Titanium and alloys.
Metals and alloys for high temperature applicationsmohannad hameed
This document discusses metals and alloys for high temperature applications. It describes various steels and their suitable temperature ranges, such as plain carbon steels being suitable up to 400-500°C, low alloy steels up to 500-600°C, and chromium steels up to 800°C. Austenitic stainless steels can be used up to 450°C. Nickel and nickel chromium alloys dominate the 600-1100°C range. Refractory metals like tungsten, molybdenum, and tantalum are available up to 1200°C but are very costly. The choice of metal depends on factors like temperature, oxidation resistance, strength, and cost.
High temperature materials & super alloys pptSREE KRISHNA
This document discusses superalloys, which are metallic alloys that exhibit excellent strength and creep resistance at high temperatures. It describes how superalloys develop strength through solid solution strengthening and alloying techniques. The document also classifies superalloys into generations based on their composition, and lists some of their key properties and applications in gas turbines, jet engines, steam turbines, and other high-temperature industrial systems.
Vacuum de-gassing is a process to remove entrapped gases like hydrogen, nitrogen, and oxides from liquid metals. It works by creating a vacuum at the melt surface, which shifts dissolution equilibriums towards gas evolution and removal. Two main methods are vacuum degassing in a ladle and electric arc degassing, which can maintain vacuum longer for better cleaning. Vacuum degassing improves metal purity by removing gases and inclusions.
The document provides a vocational training report submitted by Gunjesh Kumar detailing his training at Bokaro Steel Limited from June 16th to July 12th 2014. It includes:
- An introduction to Steel Authority of India Ltd (SAIL) and Bokaro Steel Plant.
- Summaries of Gunjesh's training and exposure to various processes at Bokaro Steel Plant including the sinter plant, blast furnace, steel melting shops, continuous casting, slab mill, and hot strip mill.
- Acknowledgements from Gunjesh thanking those who supported and guided him during his training.
This document provides details about Nikhil Agrawal's summer internship at the Rourkela Steel Plant mechanical shop department from June 13th to July 22nd. It summarizes the history and special features of the Rourkela Steel Plant, describes the various machines and operations of the mechanical shop, and lists the products manufactured at the plant and their applications. The conclusion expresses that the internship provided valuable practical experience complementing theoretical knowledge.
The document discusses various steel making processes including vacuum treatment, vacuum oxygen decarburization (VOD), ladle desulfurization, and electroslag remelting. Vacuum treatment removes gases like carbon monoxide, hydrogen, and nitrogen from molten steel. VOD uses oxygen blowing and argon stirring under vacuum to decarburize steel and remove inclusions. Ladle desulfurization injects agents like calcium and magnesium to actively remove sulfur while stirring. Electroslag remelting melts a consumable electrode through an electrically conductive slag layer, producing very pure steel.
The document discusses the hardening process used to increase the hardness of metals. Hardening involves heating metals to their hardening temperature, holding at that temperature, and then rapidly cooling via quenching. This rapid cooling results in the formation of martensite, giving the metal a high hardness. The main purposes of hardening are to improve wear resistance, tensile strength, and yield strength. Factors like chemical composition, size and shape of the metal, and the quenching medium used affect how effective the hardening process is. Various hardening methods are discussed, like conventional quenching, quenching in stages, spray quenching, and quenching with self-tempering. Hardened metals find
A PROJECT REPORT ON
“Eliminating corner gap in sc mould at LD2 SNC”.
During the internship the following research is evaluated and being verified by the authorized TATA steel employee.
This document summarizes Rohit Babu's summer training project at Tata Steel's coke plant in Jamshedpur from July 9th to August 5th, 2019. The project aimed to implement a mathematical model to achieve optimal underfiring heat input in Coke Oven Batteries 8 and 9. It provides details of Rohit's guide, the certificate awarded upon completion, and thanks various colleagues who assisted with the project.
Tata Steel is one of the largest steel companies in the world, with operations across five continents. It was established in 1907 and is headquartered in Jamshedpur, India. The document discusses Tata Steel's history, products, strengths, and performs a SWOT analysis. Some of Tata Steel's key strengths include its large mineral reserves in India, investments in information technology, a credible management team, brand value as part of the respected Tata Group, and a focus on sustainability and corporate governance.
Ladle Metallurgy: Basics, Objectives and ProcessesElakkiya Mani
Worldwide steel production in 2019 reached 1869 million tons, with China as the largest producer at 996 million tons. India was the second largest steel producer at 111 million tons. Ladle metallurgy involves further refining of molten steel in a ladle after tapping from a converter or electric furnace. It allows for homogenization, deoxidation, desulfurization, and other processes. Key ladle metallurgy techniques include ladle furnace treatment, argon stirring, vacuum degassing, and alloy additions to adjust steel chemistry and properties.
Continuous casting is a process used to cast metal into a continuous length. Molten metal is poured into a mold and solidifies into a casting as it travels downward. New molten metal is continuously supplied to the mold to keep the process going and produce a casting of indefinite length. The process requires precise control of parameters like molten metal flow to ensure smooth, continuous casting.
Advanced High Strength Steels and their Heat Treatment processesSudarshan Sundar
This document provides information on advanced high strength steels (AHSS) used in the automotive industry. It defines AHSS as steels with yield strengths over 550 MPa and discusses various strengthening mechanisms employed. Different types of AHSS are described, including dual phase steels, ferritic bainitic steels, and complex phase steels. Their microstructures and properties are summarized. Key factors for material selection like crash performance, stiffness, and formability are also outlined. The document provides an overview of the evolution of steels in the automotive industry to enable lightweight design through improved strength-ductility combinations realized by AHSS.
BSP Project (Based on Continuous Casting) [Final]Subham Shit
MARS-2 is a machining, assembly, and re-engineering department of Bhilai Steel Plant. It has light and heavy machining bays and an assembly bay. MARS-2 specializes in machining high-value parts, repairing and reclaiming worn parts, and assembling machinery. Some key assemblies MARS-2 performs include five roll sets, ten roll sets, and pinch roll assemblies for the continuous casting shop. MARS-2 aims to support most departments of BSP. It is well-equipped with machines like lathes, mills, grinders, and has an annual machining capacity of 2,200 tons and assembly capacity of 6,000 tons.
Material Engineering,
Heat treating (or heat treatment) is a group of industrial and metalworking processes used to alter the physical, and sometimes chemical, properties of a material. The most common application is metallurgical. Heat treatments are also used in the manufacture of many other materials, such as glass. Heat treatment involves the use of heating or chilling, normally to extreme temperatures, to achieve a desired result such as hardening or softening of a material. Heat treatment techniques include annealing, case hardening, precipitation strengthening, tempering, carburizing, normalizing and quenching
EFFECT OF CASTING PARAMETERS ON MACROSTRUCTURE OF STEELSurya Teja Botu
The document summarizes a student project conducted at Vizag Steel Plant investigating the effect of casting parameters on the macrostructure of steel. It was presented by five students and guided by P.V. Bhujanga Rao of Vizag Steel Plant. The project examined how melt temperature and casting speed influence steel structure and defect formation during continuous casting, and modeled temperature and melt flow in the caster sump. It provides background on Vizag Steel Plant and describes its raw material sources, production units including coke ovens, sinter plant, blast furnaces, and rolling mills.
Introduction to modern concept of steel making through induction furnaces by ...steadfast123
Introduction to modern concept of steel making through induction furnaces by stead fast engineers.Find here
Induction Furnace manufacturers,
Induction heater manufacturers,
Induction Billet heater Manufacturers,
Induction Melting furnace manufacturers,
Induction Furnace Manufacturers in India,
Induction Billet heater manufacturers in India,
Induction heating system,
Induction Melting Furnace
for your sourcing needs.
SAIL was formed in 1973 as a holding company for various steel plants and mines. It later became an operating company, merging the steel plants and spinning off other businesses. Over time it acquired several other steel companies. SAIL is currently India's largest steel producer, with various integrated steel plants, mines, and other facilities. It has extensive business operations and joint ventures within India and internationally.
1) The document discusses different steelmaking processes including the Bessemer converter process, open hearth furnace process, and basic oxygen converter process.
2) The Bessemer converter process was the first major steelmaking technique but has been replaced by basic oxygen converters. It used hot metal and an oxygen blast to oxidize impurities.
3) The basic oxygen converter process is now the dominant steelmaking method. It uses a pear-shaped vessel, oxygen lancing, and produces steel in 40-60 minutes by oxidizing impurities into slag.
PPT Includes physical Metallurgy for Titanium and its alloys, Weld ability of them and two welding processes : GTAW and EBW. PPT also describes the Problems with the Welding of Titanium and alloys.
Metals and alloys for high temperature applicationsmohannad hameed
This document discusses metals and alloys for high temperature applications. It describes various steels and their suitable temperature ranges, such as plain carbon steels being suitable up to 400-500°C, low alloy steels up to 500-600°C, and chromium steels up to 800°C. Austenitic stainless steels can be used up to 450°C. Nickel and nickel chromium alloys dominate the 600-1100°C range. Refractory metals like tungsten, molybdenum, and tantalum are available up to 1200°C but are very costly. The choice of metal depends on factors like temperature, oxidation resistance, strength, and cost.
High temperature materials & super alloys pptSREE KRISHNA
This document discusses superalloys, which are metallic alloys that exhibit excellent strength and creep resistance at high temperatures. It describes how superalloys develop strength through solid solution strengthening and alloying techniques. The document also classifies superalloys into generations based on their composition, and lists some of their key properties and applications in gas turbines, jet engines, steam turbines, and other high-temperature industrial systems.
Vacuum de-gassing is a process to remove entrapped gases like hydrogen, nitrogen, and oxides from liquid metals. It works by creating a vacuum at the melt surface, which shifts dissolution equilibriums towards gas evolution and removal. Two main methods are vacuum degassing in a ladle and electric arc degassing, which can maintain vacuum longer for better cleaning. Vacuum degassing improves metal purity by removing gases and inclusions.
The document provides a vocational training report submitted by Gunjesh Kumar detailing his training at Bokaro Steel Limited from June 16th to July 12th 2014. It includes:
- An introduction to Steel Authority of India Ltd (SAIL) and Bokaro Steel Plant.
- Summaries of Gunjesh's training and exposure to various processes at Bokaro Steel Plant including the sinter plant, blast furnace, steel melting shops, continuous casting, slab mill, and hot strip mill.
- Acknowledgements from Gunjesh thanking those who supported and guided him during his training.
This document provides details about Nikhil Agrawal's summer internship at the Rourkela Steel Plant mechanical shop department from June 13th to July 22nd. It summarizes the history and special features of the Rourkela Steel Plant, describes the various machines and operations of the mechanical shop, and lists the products manufactured at the plant and their applications. The conclusion expresses that the internship provided valuable practical experience complementing theoretical knowledge.
The document discusses various steel making processes including vacuum treatment, vacuum oxygen decarburization (VOD), ladle desulfurization, and electroslag remelting. Vacuum treatment removes gases like carbon monoxide, hydrogen, and nitrogen from molten steel. VOD uses oxygen blowing and argon stirring under vacuum to decarburize steel and remove inclusions. Ladle desulfurization injects agents like calcium and magnesium to actively remove sulfur while stirring. Electroslag remelting melts a consumable electrode through an electrically conductive slag layer, producing very pure steel.
The document discusses the hardening process used to increase the hardness of metals. Hardening involves heating metals to their hardening temperature, holding at that temperature, and then rapidly cooling via quenching. This rapid cooling results in the formation of martensite, giving the metal a high hardness. The main purposes of hardening are to improve wear resistance, tensile strength, and yield strength. Factors like chemical composition, size and shape of the metal, and the quenching medium used affect how effective the hardening process is. Various hardening methods are discussed, like conventional quenching, quenching in stages, spray quenching, and quenching with self-tempering. Hardened metals find
A PROJECT REPORT ON
“Eliminating corner gap in sc mould at LD2 SNC”.
During the internship the following research is evaluated and being verified by the authorized TATA steel employee.
This document summarizes Rohit Babu's summer training project at Tata Steel's coke plant in Jamshedpur from July 9th to August 5th, 2019. The project aimed to implement a mathematical model to achieve optimal underfiring heat input in Coke Oven Batteries 8 and 9. It provides details of Rohit's guide, the certificate awarded upon completion, and thanks various colleagues who assisted with the project.
Tata Steel is one of the largest steel companies in the world, with operations across five continents. It was established in 1907 and is headquartered in Jamshedpur, India. The document discusses Tata Steel's history, products, strengths, and performs a SWOT analysis. Some of Tata Steel's key strengths include its large mineral reserves in India, investments in information technology, a credible management team, brand value as part of the respected Tata Group, and a focus on sustainability and corporate governance.
Tata Steel is an Indian steel company and subsidiary of Tata Group. It has manufacturing operations in 26 countries and employs around 80,500 people. Some key points:
- Tata Steel was established in 1907 and is headquartered in Mumbai, India. It acquired UK steelmaker Corus in 2007 in its largest international acquisition.
- It has an annual crude steel capacity of 25.3 million tonnes and is the 11th largest steel producer globally.
- The company's vision is to be a global benchmark in value creation and corporate citizenship through excellence of people, innovation, and conduct.
- Tata Steel has manufacturing facilities in India, Europe, Southeast Asia and produces a variety of
This document provides information about Prashant Kumar's vocational training project on the study of CNC machine control systems at Tata Steel in Jamshedpur, India. It includes an acknowledgements section thanking those who supported the project. The document then covers the history and departments of Tata Steel, including Spare Manufacturing Department where the training took place. It provides technical details about CNC machines and their components like PLC, sensors and advantages of CNC systems.
1. Tata Group is a successful conglomerate with 114 companies. Tata Steel is one of its companies and a leading steel producer in India.
2. Tata Steel's vision is to become a global benchmark in value creation and corporate citizenship. It was founded in Jamshedpur, India in 1907 and has since expanded operations globally through acquisitions.
3. As of 2015, Tata Steel employs over 86,000 people worldwide and produces a wide range of steel products. It aims to balance business success with social responsibility through various CSR initiatives.
The document discusses the marketing mix (4Ps) of Tata Steel - one of the largest steel companies in India. It provides details of Tata Steel's products, pricing strategy, distribution channels, and promotional activities. It also analyzes Tata Steel's major competitors like JSW Steel, SAIL, and Essar Steel and their strategies. Tata Steel focuses on market penetration pricing and has established efficient distribution channels like Mjunction to reach customers across India.
This document describes a report submitted by three students on their in-plant training at the Salem Steel Plant. It includes an abstract, table of contents, and sections on the introduction to the steel plant, the steel industry profile, SAIL's mission and vision, the company profile, key functions of the plant including HRM and CRM, strengths/weaknesses/opportunities, and a conclusion. The students conducted their in-plant training to study the various production processes and management functions at the Salem Steel Plant, which is one of the largest stainless steel producers in India.
This document provides a vocational training report submitted by Prabhat Kumar, an undergraduate student at NIELIT Aurangabad, for their training at Tayo Rolls Ltd from June 8th to July 7th 2015. The report focuses on motor control through a variable frequency drive (VFD) used to control machines in the forge shop. It includes a certificate signed by the training and project supervisors, as well as sections on the company profile, introduction to lathe machines, what a VFD is and how it works, applications of VFDs, and a conclusion.
Conducting an Organizational Assessment 4
Conducting an Organizational Assessment
Name: Michael Carlson
Instructor: Godwin Igein
Course: MGT416
Institution: Argosy University Online
Date: Nov 25, 2015
Tata Steel, the flagship company of Tata group, has crude steel production capacity of 30 million tonnes per annum. It was founded by Jamsetji Nusserwanji Tata. It is the world’s second-most geographically diversified steel producer (Tata Steel, n.d.). They have their presence in almost 50 countries with an employee base of 80,000 people. As on March 31, 2015, the group had an overall turnover of Rs 139,504 crores (India Infoline, 2015).
They established their first steel plant in 1907 in Jamshedpur, India. From there on they have moved on to setting up new steel projects in Jharkhand, Odisha and Chhattisgarh.
Raw material integration is the strategy that sets them apart from their competitors. The prices of the raw materials used by them are highly volatile. The basic raw materials used by them are iron ore and cooking coal. They have their own mines and collieries which satisfy their raw material requirement. For additional requirement, they enter into future contracts with suppliers so as to ensure a continuous flow of raw material and have a hedge against price volatility. In fact, the company is exploring mining opportunities overseas also. The minerals that are grabbing their eyeballs overseas are Limestone and Ferro chrome. They want to have full control on raw material resources so that there is no interruption with its supply. This strategy also ensures that they are able to provide very competitive prices for their products.
The company has also been a continuous investor in various research and development projects to improve its quality and provide better rates to the customers. Tata Steel’s R&D centres are now conducting research programmes to improve the life cycle and sustainability of its products. These include projects to reduce energy consumption, CO2 and other emissions (Tata Steel, n.d.).
Tata Steel had also launched a program, Kar Vijay Har Shikhar. This program involves the use of Total Quality Management and various statistical tools to improve their process.
The company’s strategy for global markets is to become global benchmark in value creation and corporate citizenship in steel industry (Tata Steel, n.d.). They have their main focus on innovating new and distinct products for the international markets that satisfy the needs of their customers. They have been continuously investing in terms of time and money to improve their manufacturing facilities and provide best quality products at competitive prices.
The company has also been investing in a number of mergers and acquisitions to improve their global presence. They have acquired NatSteel and Millenium Steel thereby increasing their pr.
This project is based on the study of the wireless communication and its maintenance in Tata Steel. In the MED dept. of Tata Steel I have studied the maintenance and fault diagnostics methodology in Motorola wireless set. Tata Steel uses Motorola W/T sets. Currently GP 338/328 is used for handheld sets and GM-338 is used for Static Sets.
- Tata Steel was established in 1907 in India and is now the fifth largest steel producer in the world, with annual production of 18 million tonnes in India and 52.32 million tonnes overseas.
- It has set an ambitious target to increase production capacity to 100 million tonnes by 2015 through both greenfield facilities and acquisitions.
- Tata Steel is a pioneer in employee welfare measures in India and aims to be a global benchmark in corporate citizenship and value creation.
Tata Steel is an Indian multinational steel company established in 1907. It is Asia's first and India's largest private sector steel company with a production capacity of 34 million tonnes per year. Tata Steel launched Tata Ticson in 2000, which is India's only rebar 'superbrand' that offers superior quality products through technological innovation. Tata Ticson has over 6,200 dealers and serves over 500,000 consumers annually with its portfolio of hot and cold rolled coils/sheets, wires, rods, and construction bars. Tata Steel focuses on innovation, customer satisfaction, and sustainability through various initiatives such as the GreenPro certification for rebars, Ready Build customized rebar solutions, and implementing total quality management
The document is a student assignment on Tata Steel Ltd's export policies and challenges. It includes an introduction to Tata Steel and the Indian steel industry. The assignment covers various topics related to Tata Steel's exports such as export finance sources, pricing policies, export promotion practices, the impact of COVID-19, and government incentives for steel exports. It also provides an index and conclusion. Key points include Tata Steel exporting steel products to over 100 countries, factors that influence its export pricing like production costs and competition, and the impact of high input costs and volatile demand due to COVID-19 on its export management.
This document provides background information on Tata Steel, including:
- Tata Steel is India's largest private sector steel company with an annual production capacity of 31 million tons.
- Its vision is to be a global benchmark for value creation and corporate citizenship through its people, products/services, innovative approach, and ethical conduct.
- The company's key products include finished steel, ferroalloys, tubes, bearings, and more which it distributes via direct supply, stockyards, agents, and processing agents.
- Tata Steel focuses on customer service, innovation, operational excellence, responsible business practices, and developing its people to achieve sustainable growth.
This document provides background information on Tata Steel, including its vision, mission, products, pricing strategies, distribution channels, and promotional strategies. Tata Steel is India's largest private sector steel company with an annual production capacity of 31 million tons. It aims to be a global benchmark for value creation and corporate citizenship through its people, products and services, innovative approach, and ethical conduct. The company produces a variety of finished and semi-finished steel products and uses various pricing, placement, and promotional strategies to market these products.
Tata Steel is one of the largest and most geographically diversified steel producers in the world. It has manufacturing operations in India, Europe, and Southeast Asia, with a total crude steel production capacity of over 30 million tons per year. As a Fortune 500 company and subsidiary of the Tata Group, Tata Steel seeks to excel in the global steel industry through innovation, customer service, responsible business practices, and creating value for shareholders and communities. The document provides an overview of Tata Steel's operations and vision.
Tata Steel acquired Corus Steel in 2007. The acquisition provided Tata Steel with access to Corus' operations in major European markets as well as its advanced technology and high-value steel product portfolio. It helped Tata Steel become one of the top 10 global steel producers. While Corus struggled with debt and high costs, Tata Steel saw the acquisition as an opportunity to enter new markets at a lower cost than building new plants. The deal created a globally diversified steel producer and provided benefits from synergies between the two companies.
This document provides an overview of the city of Jamshedpur and the key organizational areas covered in the project report. Jamshedpur is located in Jharkhand and is home to Tata Steel, India's first private steel company. The report focuses on the steel tube division of Tata Steel, which manufactures a broad range of structural steel tubes. Other major companies in Jamshedpur mentioned include Tata Motors and Tata Power. The project report aims to study the demand for structural steel tubes in Jamshedpur to provide insights to Tata Steel's tube division management.
DEEP LEARNING FOR SMART GRID INTRUSION DETECTION: A HYBRID CNN-LSTM-BASED MODELgerogepatton
As digital technology becomes more deeply embedded in power systems, protecting the communication
networks of Smart Grids (SG) has emerged as a critical concern. Distributed Network Protocol 3 (DNP3)
represents a multi-tiered application layer protocol extensively utilized in Supervisory Control and Data
Acquisition (SCADA)-based smart grids to facilitate real-time data gathering and control functionalities.
Robust Intrusion Detection Systems (IDS) are necessary for early threat detection and mitigation because
of the interconnection of these networks, which makes them vulnerable to a variety of cyberattacks. To
solve this issue, this paper develops a hybrid Deep Learning (DL) model specifically designed for intrusion
detection in smart grids. The proposed approach is a combination of the Convolutional Neural Network
(CNN) and the Long-Short-Term Memory algorithms (LSTM). We employed a recent intrusion detection
dataset (DNP3), which focuses on unauthorized commands and Denial of Service (DoS) cyberattacks, to
train and test our model. The results of our experiments show that our CNN-LSTM method is much better
at finding smart grid intrusions than other deep learning algorithms used for classification. In addition,
our proposed approach improves accuracy, precision, recall, and F1 score, achieving a high detection
accuracy rate of 99.50%.
ACEP Magazine edition 4th launched on 05.06.2024Rahul
This document provides information about the third edition of the magazine "Sthapatya" published by the Association of Civil Engineers (Practicing) Aurangabad. It includes messages from current and past presidents of ACEP, memories and photos from past ACEP events, information on life time achievement awards given by ACEP, and a technical article on concrete maintenance, repairs and strengthening. The document highlights activities of ACEP and provides a technical educational article for members.
CHINA’S GEO-ECONOMIC OUTREACH IN CENTRAL ASIAN COUNTRIES AND FUTURE PROSPECTjpsjournal1
The rivalry between prominent international actors for dominance over Central Asia's hydrocarbon
reserves and the ancient silk trade route, along with China's diplomatic endeavours in the area, has been
referred to as the "New Great Game." This research centres on the power struggle, considering
geopolitical, geostrategic, and geoeconomic variables. Topics including trade, political hegemony, oil
politics, and conventional and nontraditional security are all explored and explained by the researcher.
Using Mackinder's Heartland, Spykman Rimland, and Hegemonic Stability theories, examines China's role
in Central Asia. This study adheres to the empirical epistemological method and has taken care of
objectivity. This study analyze primary and secondary research documents critically to elaborate role of
china’s geo economic outreach in central Asian countries and its future prospect. China is thriving in trade,
pipeline politics, and winning states, according to this study, thanks to important instruments like the
Shanghai Cooperation Organisation and the Belt and Road Economic Initiative. According to this study,
China is seeing significant success in commerce, pipeline politics, and gaining influence on other
governments. This success may be attributed to the effective utilisation of key tools such as the Shanghai
Cooperation Organisation and the Belt and Road Economic Initiative.
KuberTENes Birthday Bash Guadalajara - K8sGPT first impressionsVictor Morales
K8sGPT is a tool that analyzes and diagnoses Kubernetes clusters. This presentation was used to share the requirements and dependencies to deploy K8sGPT in a local environment.
Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
TIME DIVISION MULTIPLEXING TECHNIQUE FOR COMMUNICATION SYSTEMHODECEDSIET
Time Division Multiplexing (TDM) is a method of transmitting multiple signals over a single communication channel by dividing the signal into many segments, each having a very short duration of time. These time slots are then allocated to different data streams, allowing multiple signals to share the same transmission medium efficiently. TDM is widely used in telecommunications and data communication systems.
### How TDM Works
1. **Time Slots Allocation**: The core principle of TDM is to assign distinct time slots to each signal. During each time slot, the respective signal is transmitted, and then the process repeats cyclically. For example, if there are four signals to be transmitted, the TDM cycle will divide time into four slots, each assigned to one signal.
2. **Synchronization**: Synchronization is crucial in TDM systems to ensure that the signals are correctly aligned with their respective time slots. Both the transmitter and receiver must be synchronized to avoid any overlap or loss of data. This synchronization is typically maintained by a clock signal that ensures time slots are accurately aligned.
3. **Frame Structure**: TDM data is organized into frames, where each frame consists of a set of time slots. Each frame is repeated at regular intervals, ensuring continuous transmission of data streams. The frame structure helps in managing the data streams and maintaining the synchronization between the transmitter and receiver.
4. **Multiplexer and Demultiplexer**: At the transmitting end, a multiplexer combines multiple input signals into a single composite signal by assigning each signal to a specific time slot. At the receiving end, a demultiplexer separates the composite signal back into individual signals based on their respective time slots.
### Types of TDM
1. **Synchronous TDM**: In synchronous TDM, time slots are pre-assigned to each signal, regardless of whether the signal has data to transmit or not. This can lead to inefficiencies if some time slots remain empty due to the absence of data.
2. **Asynchronous TDM (or Statistical TDM)**: Asynchronous TDM addresses the inefficiencies of synchronous TDM by allocating time slots dynamically based on the presence of data. Time slots are assigned only when there is data to transmit, which optimizes the use of the communication channel.
### Applications of TDM
- **Telecommunications**: TDM is extensively used in telecommunication systems, such as in T1 and E1 lines, where multiple telephone calls are transmitted over a single line by assigning each call to a specific time slot.
- **Digital Audio and Video Broadcasting**: TDM is used in broadcasting systems to transmit multiple audio or video streams over a single channel, ensuring efficient use of bandwidth.
- **Computer Networks**: TDM is used in network protocols and systems to manage the transmission of data from multiple sources over a single network medium.
### Advantages of TDM
- **Efficient Use of Bandwidth**: TDM all
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Embedded machine learning-based road conditions and driving behavior monitoringIJECEIAES
Car accident rates have increased in recent years, resulting in losses in human lives, properties, and other financial costs. An embedded machine learning-based system is developed to address this critical issue. The system can monitor road conditions, detect driving patterns, and identify aggressive driving behaviors. The system is based on neural networks trained on a comprehensive dataset of driving events, driving styles, and road conditions. The system effectively detects potential risks and helps mitigate the frequency and impact of accidents. The primary goal is to ensure the safety of drivers and vehicles. Collecting data involved gathering information on three key road events: normal street and normal drive, speed bumps, circular yellow speed bumps, and three aggressive driving actions: sudden start, sudden stop, and sudden entry. The gathered data is processed and analyzed using a machine learning system designed for limited power and memory devices. The developed system resulted in 91.9% accuracy, 93.6% precision, and 92% recall. The achieved inference time on an Arduino Nano 33 BLE Sense with a 32-bit CPU running at 64 MHz is 34 ms and requires 2.6 kB peak RAM and 139.9 kB program flash memory, making it suitable for resource-constrained embedded systems.
1. 1
EFFECT OF MOISTURE CONTENT ON
TURNDOWN TEMPERATURE AT LD#1
SUMMER INTERNSHIP 2017
PRESENTED BY:
Keerthik Mohanan
Kevin George
Under the auspice of
Mr. Amarnath Mukherjee, Sr. Manager PSM,LD1
Mr. Abhinav Singhvi, Manger PSM,LD 1
2. 2
DECLARATION
I Keerthik Mohanan student of Mahatma Gandhi University Id No 14002956
hereby declare that the internship Report is submitted by me in partial
fulfilment of the requirement for the award of the degree of Bachelor of
Technology
Place: Jamshedpur
Date: 11-08-2017
3. 3
CONTENTS
1) Acknowledgement
2) The TATA group
3) TATA steel
4) Plant layout
5) Importanceof steel
6) Overview of the BOS process
7) BOF structureside
8) Hot metal
9) Oxygen Lance technology
10) Basic operation
11) Importanceof slagin LD
12) Iron oreaddition
13) Blow practices
14) Turndown conditions
15) Blowing controland turndown
16) Turndown control
17) Correction of temperature and analyses
18) Reblow
19) The automation model
20) Problem facing in LD1
21) Cause and effect diagram
22) Aim
23) Sample study and moisturetesting
24) Calculation work
25) Heat Comparison of wet and dry iron ore
5. 5
Acknowledgement
Great success can only be attained when we have the shoulders of colossus to
stand over and look yonder. At Tata Steel we met people who have excelled in
their respective fields. They have proved time and again that they are the ones
who are shaping the presentand future of this great institution. Holding our
hands, they haveguided us through this endeavour, morphing and shaping the
technical as well as operational aspect of our outlook
Mr Amarnath Mukherjee, Sr Manger primary steel making, LD#1 our guide who
gave us his precious time; shared with us his insight and experiences,
appreciated us and inspired us throughoutour stay we thank him profusely for
being a wonderfulmentor.
Mr. Zachariah Chacko our co-guide is acknowledged for being our pillar of
strength and our motivator who made us dream big and channelled our efforts
in the right direction
Mr Abhinav Singhvi, who constantly oversaw our proceedings and who left no
stone unturned to make our experience at Tata Steel wonderful.
Sincere thanks to SNTI team for making all the arrangement and safety
training.
I would like to thank my own College, AMAL JYOTHI COLLEGEOF ENGINEERING
and Department of Metallurgy for giving us an opportunity to do an internship
at TATA Steel
Special thanks to all the operators at PSM, LD1, who contributed selflessly in
making us understand the whole working of the vesseland controlroom.
A special thanks to everyoneat TATA Steel who touched our lives in the due
courseand made us feel at home. We are proud to visitthis beautiful city of
Jamshedpur
Keerthik Mohanan
Kevin George
6. 6
The TATA Group
The TATA Group: A Legacy of Trust
TATA is India’s largestand most diversified business conglomeratewith more
than 100 operating companies spread over 85 countries in six different
continents, employing 350,000 people, TATA companies share fivecore values-
Integrity
Understanding
Excellence
Unity
Responsibility
Each TATA company agrees to the TATA code of conduct by signing the TATA
Brand Equity and Business Promotion Agreement with TATA Sons Ltd. This
ensures adherenceto the TATA ethos and value system. Adherenceto ethics
and excellence and the commitment towards serving communities have been
at the core of TATA’s unblemished growth and sustenancefor over 140 years.
This heritage evokes trustand goodwill among consumers, employees,
shareholders and the larger community. Today, the TATA name is a unique
assetrepresenting ‘Leadership with Trust’. This legacy has earned the
admiration of the group’s stakeholders in a manner few business houses can
ever hope to match.
The business operations currently encompass seven business sectors namely:
Engineering
Materials
Services
Energy
Customer products,
Communications and IT,
Chemicals
7. 7
The major companies in the group of TATA include:
TATA Steel
TATA Motors
TCS
TATA Power
TATA Chemicals
8. 8
TATA Steel
Established in 1907, TATA Steel is more than 100 years old company and is
among the top ten Global Steel companies. Itis now one of the world’s most
geographically-diversified steel producers, with operations in 26 countries and
a commercial presence in over 50 countries.
The TATA Steel Group, with a turnover of US$ 22.8 billion in FY’ 10, has over
80,500 employees across fivecontinents and is a Fortune 500 company.
TATA Steel’s vision is to be the world’s steel industry benchmark through the
excellence of its people, its innovativeapproach and overall conduct.
Underpinning this vision is a performanceculture committed to aspiration
targets, safety and social responsibility, continuous improvement, openness
and transparency.
TATA Steel’s larger production facilities include those in India, the UK, the
Netherlands, Thailand, Singapore, China and Australia. Operating companies
within the group include TATA Steel Limited (India), TATA Steel EuropeLimited
(formerly Corus), Natsteel, and TATA Steel Thailand (formerly Millennium
Steel).
TATA Steel has believed that the principle for mutual benefit- between
countries, corporations, customers, employees and communities- is the most
effective route to profitable and sustainable growth.
TATA Steel limited is a multinational steel company headquartered in Mumbai,
India and subsidiary of TATA group. It is the tenth largest steel producing
company in the world with an annual steel crude capacity of 23.88 million
tonnes(FY17), and the second largest steel company in India(measured by
domestic production) with an annualcapacity of 9.7 million tonnes after SAIL.
Tata Steel’s largest plant is located in Jamshedpur, Jharkhand, with its recent
acquisitions; the company has become a multinational with operations in
various countries. The company is listed on Bombay Stock exchange and
National Stock Exchange of India and employs about 80,500 people.
Tata Steels products include:
9. 9
Cold/hot rolled coils and sheets
Billets
seamless bars(RCS, RDS & Gothic bars)
forged rounds
rolled & forged rings
tubes & bearings
In an attempt to ‘ decommoditise’ steel, the company has introduced brands
like:
Tata Steelium (the world’s firstbranded cold rolled steel)
Tata Shaktee (galvanazed corrugated sheets)
Tata Tiscon (rebars)
Tata Bearings
Tata Agrico (Hand tools and implements)
Tata Wiron (galvanized wireproducts)
Tata Pipes (Pipes for construction)
Tata Structura (Contemporary construction Materials)
Apart fromthese productbrands, the company also hass its folds a service
brsand called ‘STEEL JUNCTION”
10. 10
The Process Flow at TATA Steel
Vision
Its vision is to be the globalsteel industry benchmarkfor value creation and
corporate citizenship.
Tata Steel achieves its vision through :
Its People
By fostering teamwork, nurturing talent, enhancing leadership capability and
acting with pace, pride and passion.
Its Offer
By becoming the supplier of choice, delivering premier products and services
and creating value for its customers.
Its InnovativeApproach
By developing cutting edge solutions in technology, processes and products.
Its Conduct
By providing a safeworkplace, respecting the environment, caring for
communities and demonstrating high ethical standards.
11. 11
AWARDS AND ACHIEVEMENTS
Tata Steel was awarded the ‘ 2015 World’s MostEthicalCompany’
award under the Metals Category by the Ethisphere Institute. This was
the third time that Tata Steel won this award.
The Ministry of Steel awarded Tata Steel the Prime Minister’s Trophy for
‘ Best Performing Integrated Steel Plant’ in the year 2010-11, thus
making it the eighth time that it received this award since the trophies
institution in 1992-93.
In 2015, Tata Steel’s Climate disclosurereceived highest rating of 100 %
CDLI (Climate DisclosureLeadership Index) score.
13. 13
IMPORTANCE OF STEEL
Steel has had a major influence in our lives. The cars we drive, the buildings we
work in, the homes in which we live and countless other facets in between.
Steel is used in our electricity-power-line towers, natural-gas pipelines,
machine tools, military weapons-thelist is endless.
Steel has earned a place in our homes in protecting our families, making our
lives convenient, its benefits are undoubtedly clear.
Steel is by far the most important, multifunctional and the most adaptable of
materials. The development of mankind would havebeen impossiblebut for
steel. The backboneof developed economies was laid on the strength and
inherent uses of the steel.
The characteristics of steel are:
Hot and cold formable
Weldable
Suitable machinability
Hard, tough and wear resistant
Corrosion resistant
Heat resistant and Resistance to deformation at high temperatures.
Steel compared to other materials of its type has low production costs. The
energy required for extracting from ore is about 25% of whatis needed for
extracting Aluminium. Steel is environment friendly as it can be recycled. 5.6%
of element iron is presentin Earth’s crust, representing a secure raw material
base.
Steel production is 20 times higher as compared to production of all non-
ferrous metals.
The steel industry has developed new technologies and has strived hard to
make the world’s strongestand mostversatile material even better. There are
14. 14
altogether about2000 grades of steel developed of which 1500 grades arehigh
grade steels. There is still immense potential for developing new grades of
steel with varying properties.
Steel has changed our world like no other substance. New high performance
steel allows a jet pilot to reach new heights, a surgeon to perform a delicate
operation. Itis the solid rocketbooster casings that allow shuttle astronauts to
explore new frontiers and the roller coaster ridden by a child. Each piece of
steel we makeis engineered to fit precise specifications. Itis an industry where
productquantity is measured by the millions of tons, but quality is measured
by the millionth of an inch.
The same utmost precision applies to the processes employed throughout
today’s steel plant. Tata Steel is truly a high-tech industry, with automation
and advanced technologies driving the way it does its business. Someof the
most advanced technologies available today are utilised throughoutthe steel
making process, which enables the industry to maximise the efficiency while
minimising the environmentalfootprint.
15. 15
OVERVIEW OF BOF PROCESS AT LD1
Oxygen steelmaking has become the dominant method of producing steel
fromblast furnacehot metal. Although the use of gaseous oxygen (rather than
air) as the for agent for refining molten and scrap mixture to producesteel by
pneumatic processes received the attention of numerous investigator from
Bessemer onward, it was not until after World War ll that commercial success
was attained.
The primary raw materials for the BOP are 85-90% liquid hot metal from the
blast furnace and the balance is steel scrap. These are charged into the Basic
16. 16
Oxygen Furnace(BOF) vessel. Oxygen(>99.5% pure) is "blown" into the BOF at
supersonic velocities(1.5 times to that of speed of sound) and oxygen per
blow is around 7200 NM3. It oxidizes the carbon and silicon contained in the
hot metal liberating great quantities of heat which melts the scrap.Total Argon
of 25 Nm3 is purged from the bottom of the furnace for perfect stirring and to
maintain homogeneity throughout the bath during the process The post
combustion of carbon monoxide as it exits the vessel also transmits heat back
to the bath.
The product of the BOS is molten steel with a specified chemical anlaysis at
1590°C-1650°C. From here it may undergo further refining in a secondary
refining process or be sent directly to the continuous caster where it is
solidified into semi finished shapes: blooms, billets, or slabs.
Basic refers to the magnesia (MgO) refractory lining which wears through
contact with hot, basic slags. These slags are required to removephosphorus
and sulfur fromthe molten charge
17. 17
BOF- THE STRUCTURAL SIDE
An operating BOF,consists of the vessel and its refractory lining, vessel
protective slag shields, the trunnion ring, a vessel suspension system
supporting the vessel within the trunnion ring, trunnion pins and support
bearings, and the oxygen lance. It consists of a spherical bottom, cylindrical
body and conical top with a tap hole in between the conical and cylindrical
portion.
The BOF vesselconsists of the vessel shell, made of a bottom, a cylindrical
center shell (barrel), and a top cone; reinforcing component
18. 18
to the cone, such as a lip ring and top ring; auxiliary center shell and top cone
flanges for bolted-on top cones; auxiliary removable bottoms for bottom reline
access, or for individual bottom reline of bottom-blown vessels; and a taphole.
This list is not intended to be either restrictive or comprehensive, e.g., top
cone flanges are not universal.
BOF vessels can be one of the general classifications presented in. These are
top-blown vessels, in which the oxygen is injected above the hot metal bath by
means of a retractable lance; top-blown vessels, in combination with bottom
stirring, the latter usually by introducing metered amounts of inert gas at
specific locations under the hot metal bath—the introduction of the inert gas is
either through porous plugs or tuyeres; bottom-blown vessels, in which the
oxygen is injected under the molten metal bath through tuyeres arranged in
the bottom of the vessel, and usually carrying pulverized additives; bottom-
blown vessels utilizing a calculated source of heat energy provided by
hydrocarbon fuel, in a very similar arrangement as the bottom blown vessel;
and combination-blown vessels, in which the oxygen is introduced under the
bath through tuyeres in the bottom of the vessel, as well as above the bath
through a lance—the oxygen blown through the bottom usually carries
pulverized additives.
The Vessel Bottom: Itis influenced by the process and the weight balance
required to optimize the tilt drive system. The common shapeis torispherical.
For processes requiring the introduction of gases from thebottom of the vessel
(through tuyeres), the shapeof the bottom tends to be flatter than those
which have only top blowing. Also, because somebottom stirring/blowing
processes posemoreof a burden on the bottom refractory, thebottom is
designed to be interchangeable to enhance relining. For example, in the OBM
(Q-BOP) process, therefractory lining in the bottom of the vessel wears more
than twice as fastas that in the rest of the vessel. Therefore, the bottomis
replaced at mid-campaign. This also allows for the maintenance of the tuyeres.
19. 19
HOTMETAL
Hot metal is liquid iron fromthe blastfurnace saturated with up to 4.3%
carbon and containing 1% or less silicon, Si. Itis transported to the BOF shop
either in torpedo cars or ladles. The hotmetal chemistry depends on how
theblast furnaceisoperated and whatburden (iron bearing)materials are
charged to it. The trend today is to run at high productivity with low slag
volumes and fuel rates, leading to lower silicon and higher sulphur levels in
hot metals. If BOF slag is recycle, P and Mn level rise sharply sincethey report
almost 100 % to the hot metal. The sulphur level from the blast furnacecan be
0.05 % but an efficient hot metal desulfurizing facility ahead of the BOF will
reduce this to blow 0.1%.AS mentioned abovethe most common
desullphuring reagents lime, calcium carbide and magnesium – used alone or
in combination are injected into the hot metal through a lance .the sulphur
containing compound reportto the slag; however, unless the sulphur rich slsg
is skimmed before the hot metal is poured in to the BOF, the sulfur actually
charged will abovethe level expected from the hot metal analysis.
20. 20
OXYGEN LANCE TECHNOLOGY
In modern steelmaking production, a water-cooled lance is used as the
refining tool by injecting a high velocity stream of oxygen onto a molten
bath. The velocity or momentum of the oxygen jet results in the penetration of
the slag and metal to promote oxidation reactions over a relatively small area.
The jet velocity and penetration characteristics are functions of the nozzle
design. This section will discuss the design and operation of water-cooled
oxygen lances as they apply to modern steelmaking practices in the BOF.
Oxidation Reactions
The primary reason for blowing oxygen into steel is to remove carbon to
endpoint specifications. The principle reaction which results from theoxygen
lancing is the removal of carbon from the bath as CO. This is an exothermic
reaction which adds heat to the system. A small amount of CO2 is also
produced, but 90% or more is usually CO. As will be discussed later, the
burning of this CO inside the furnace by reacting with oxygen is called post-
combustion. Other elements such as Si, Mn, and P are also oxidized and are
absorbed in the slag layer. These reactions are also exothermic, further
contributing to the required heat to melt scrap and raise the steel bath to the
necessary temperature. The oxidation of the silicon is particularly important
because it occurs early in the oxygen blow and the resultant silica combines
with the addedlime to form the molten slag. Table below presents the
oxidation reactions during the steelmaking process.
21. 21
Supersonic Jet Theory
Nozzles are designed for a certain oxygen flow rate, usually measured in scfm
(Nm3/min), resulting in a certain exit velocity (Mach number), with the
required jet profile and force to penetrate the slag layer and react with the
steel bath in the dimple area.
Supersonic jets are produced with convergent/divergentnozzles, Figure below.
A reservoir of stagnant oxygen is maintained at pressure, Po. The oxygen
accelerates in the converging section up to sonic velocity, Mach = 1, in the
cylindrical throat zone. The oxygen then expands in the diverging section. The
expansion decreases the temperature, density, and pressureof the oxygen and
the velocity increases to supersonic levels, Mach > 1.
As the oxygen jet exits into the furnace, at a pressureP°, it spreads and decays.
A supersonic core remains for a certain distance from the nozzle. Supersonic
jets spread at an angle of approximately12°.
Proper nozzle design and operation are necessary both to efficiently produce
the desired steelmaking reactions and to maximize lance life. If a nozzle is
overblown, which means that the oxygenjet is not fully expanded at the time it
exits the nozzle, shock waves will develop as the jetexpands outside of the
nozzle. Useful energy is lost in these shock waves, and an overblown jet will
impact the steel bath with less force than an ideally expanded jet.
Nozzles are underblown when the jet expands to a pressure equal to the
surrounding pressure and then stops expanding before it exists the nozzle. In
this case, the oxygen flow separates from the internal nozzlesurface. Hotgases
22. 22
from the steel vessel then burn back or erode the nozzle exit area. This erosion
not only decreases the lance life, but also results in a loss of jet force, leading
to a soft blowing condition. Overblowing and underblowing conditions are
demonstrated in figure below
This figure displays the major components of the BOF oxygen lance. These
include oxygen inlet fittings, the oxygen outlet (lance tip), which is made of a
high thermal conductivity cast copper design with precisely machined nozzles
to achieve the desired flow rate and jet parameters. Cooling water is essential
in these lances to keep them from burning up in the vessel. The lance barrel is
a series of concentric pipes, an outer pipe,an intermediate pipe and the central
pipe for theoxygen. Lances must be designed to compensate for thermal
expansion and contraction. The outer barrel/pipe of the lance is exposed to the
high temperatures in the furnace. As its temperature increase it expands and
the overall lance construction internally is constructed with O-ring seals and
various joints, but can accommodate the thermal expansion and contraction
while in service. The lance also has a stress-free design and it must be built
with mill duty construction quality to be able to withstand the normal steel mill
operating conditions.
23. 23
BASIC OPERATION
Once the hot metal temperature and chemical analaysis of the blast furnace
hot metal are known, a computer charge models determine the optimum
proportions of scrap and hot metal, flux additions, lance height and oxygen
blowing time.
A "heat" begins when the BOF vessel is tilted about 45 degrees towards the
charging aisle and scrap charge (about 10 to 15% of the heat weight) is
dumped from a charging box into the mouth of the cylindrical BOF.
The hot metal is immediately poured directly onto the scrap from a transfer
ladle. Fumes and kish (graphite flakes from the carbon saturated hot metal)
are emitted from the vessel's mouth and collected by the pollution control
system. Charging takes 3-4 minutes.
Then the vessel is rotated back to the vertical position and lime/dolomite
fluxes are dropped onto the charge from overhead bins while the lance is
lowered to a few feet above the bottom of the vessel. The lance is water-
cooled with a multi-hole copper tip(convergence-divergence Laval shaped
nozzle). Through this lance,oxygen of greater than 99.5% purity is blown into
the mix. If the oxygen is lower in purity, nitrogen pick up starts.
As blowing begins, an ear-piercing shriek is heard. This is soon muffled as
silicon from the hot metal is oxidized forming silica, SiO2, which reacts with
the basic fluxes to form a gassy molten slag that envelops the lance. The gas
24. 24
is primarily carbon monoxide (CO) from the carbon in the hot metal. The rate
of gas evolution is many times the volume of the vessel and it is common to
see slag slopping over the lip of the vessel, especially if the slag is too viscous.
Blowing continues for a predetermined time based on the metallic charge
chemistry and the melt specification. This is typically 15 to 20 minutes, and
the lance is generally preprogrammed to move to different heights during the
blowing period.
The lance is then raised so that the
vessel can be turned down towards the
charging aisle for sampling and
temperature tests. Furthermore, below
0.2% C, the highly exothermic oxidation
of iron takes place to a variabledegree
along with decarburization. The "drop"
in the flame at the mouth of the vessel
signals low carbon.
In some shops, sublances provide a
temperature-carbon check about two
minutes before the scheduled end of the blow. This information permits an "in
course" correction during the final two minutes and better turn-down
performance. However, operation of sublances is costly, and the required
information is not always obtained due to malfunctioning of the sensors.
Once the heat is ready for tapping and the preheated ladle is positioned in the
ladle car under the furnace, the vessel is tilted towards the tapping aisle, and
steel emerges from the taphole in the upper "cone" section of the vessel. To
minimize slag carryover into the ladle at the end of tapping, various "slag
stoppers" have been designed. These work in conjunction with melter's
eyeballs, which remain the dominantcontrol device. Slag in the ladle results in
phosphorus reversion, retarded desulfurization, and possibly "dirty steel".
Ladle additives are available to reduce the iron oxide level in the slag but
nothing can be done to alter the phosphorus.
25. 25
IMPORTANCE OF SLAG IN THE LD PROCESS
Slag has in the LD-process various functions and roles.Primarily, itis
spontaneously formed by the non-volatileoxides resulting in the
oxidation of hot metal minorconstituents and iron (SiO2, MnO, P2O5, TiO2,
VOx, and FeO). In order to flux the impurity oxides to form a lowmelting, fluid
slag, lime and sometimes dolomite (a mixture of CaO and MgO) and, if
necessary, fluorspar (CaF2) are charged into the converter. Secondly, molten
slag is areaction environment for impurity elimination like desulphurization
and dephosphorization, although ladle treatments have diminished the
importance of the LD process in this respect. Slag, when forming an emulsion
with carbon monoxide and metal droplets—slag foaming—obviously plays
some role in post-combustion of primary carbon monoxide to carbon dioxide,
and affects the radiation heat transfer from the ‘hot spot’ formed in the
oxygen jet-iron melt impingement cavity, levelling out the temperature
distribution in the furnace. Foaming slag obviously also decreases dust
generation rate by absorbing some fraction of dust. From the slag formation
point of view, there are two limiting blowing practices:
1. Soft blowing with high lance position without inert gas bottom stirring,
characterized by low iron bath mixing intensity, and
2. Hard blowing with ‘low lance’ and bottom stirring (in combined blown
converters), characterized by more intensive iron bath mixing and
deeper interaction of oxygen jet with the bath.
In the firstcase the interaction of the oxygen jet with the iron bath
is‘superficial’, mass transfer from the bath interior is slowdue to weak mixing,
and iron is in the first place oxidized and slagged.
In the second case interaction between theoxygen jet and the bath, as well as
mass transfer from thebath interior to the superficial layers, is more intensive
andthe minor elements of the bath are in the first placeoxidized. The effects of
blowing practice i.e. soft blowingversus hard blowing, can be summarized as
follows:
• soft blowing increases the slag formation rate
• results in higher FeO content in slag (as well as raises oxygen super-
saturation in the metal)
• favours slag foaming
• promotes dephosphorization at least at a high carbon level
26. 26
• increases the oxidation rate of Mn, V, Ti etc.
• increases refractory wear
• raises the risk of slag slopping out of the furnace.
Formation of the Slag: Slag formation starts with the dissolution of oxygen in
iron melt and simultaneous oxidation of iron and minor bath constituents in
the oxygen jet impact zone. As the bathtemperature in the impact zone is very
high, over 2000°C, iron can dissolve a great amount of oxygen (up to 1 wt%).
Iron oxide forms and the primary oxidation zone and high oxygen iron
penetrate the bath and meet ‘fresh’ iron melt with higher contents of carbon
and other minor bath constituents oxidizing them. Part of the primary reaction
products are splashed into the slag and furnace atmosphere. Iron oxide and
other
nonvolatile oxidation products (SiO2,MnO, P2O5, TiO2, VOx etc.) mix with
existing slag and more lime (doloma) is dissolved into the molten slag. Slag is,
accordingly, formed by a complex chain of reactions. The overall slag forming
can be presented by the following set of reactions.
These reactions are followed by secondary oxidation-reduction reactions,
especially by decarburization takingplaceon the surfaceof metal droplets
circulating in the slag.
27. 27
In the start-up period of a converter blow, when the bath temperature is low,
slag might be saturated by dicalcium silicate, but with theprogress of hot metal
oxidation the slag composition departs from the dicalcium silicate ‘nose’
returning in the later stage of the blow back to it and passing it to the
tricalcium silicate saturation or even lime saturation range (seeFigure 3). The
evaluation of the slag path passing the high temperature liquidus surfaces such
as the dicalcium silicate nose or liquidus surfaces of the tricalcium silicate or
lime and corresponding precipitation of solid phases from the melt, is
somewhatobscured by the fact that slags are multicomponent phases and the
slag temperatures have been reported to exceed, even by severalhundred
degrees, the averagetemperature of the iron bath.
28. 28
THE ADDITION OF IRON ORE
IRON ORE ADDITION
Scrap, slag and iron ore addition are made to the furnacefor a variety of
reasons
To adjustthe liquid the metal temperature
To adjustthe liquid metal composition
To change the slag composition and thereby its properties
An optimum addition of iron ore is essential because:
If the addition is more than required, a heavy cooling can take place. one ton
of extra iron ore reduces the temp by 30 deg c
Slag fe can increaseleading to liquid slag
Iron oremay not go in to the metal
If the addition are less than required, the temp may shootup and go much
above the aim temp leading to the vessel damage
The chance of rephos increases after the steel is made and from the
carrying over slag phos can again go in to the metal
Slag Fe decreases and thick slag can be found
Depends on
1) Si content
2) Scrap added
3)HMtemperature
4) Dolomite addition
5) Vessel condition
Increases in
1) HM weight
2) HM Temperature
3) Si content
Will affect
1) Turndown
temperature
2) Turndown P
3) Slag condition
(viscosity)
29. 29
BLOWPRACTICE
The blow practice depend upon following parameter
Initial vesselcondition (initial temp)
Retain slag (slag wash)
Hot metal temp and composition
Lime ,oreand raw dolomite addition
Number of TBMs open (stirring)
Lace height and lance moment
Bath ;height control to adjustblow and slag formation
Hard blow make the slag dry and cause phosphorus reversal.
Two softblow will increaseFe content in slag.
AT LD #1 the operators follow a basic procedureduring the blow as mention as
under:
Lance hood and skirtis checked for any water leakage
The model is run by the controller giving remaining slag, aim temp.
Then the “PREP” button and Blow startbutton is pressed after
checking all the inter locks.
Then the ignition switch is pressed which starts the timer and oxygen
counting.
Now the skirtis lowered for :
Positivepressureatthe vessel mouth.
To stop excessiveingress of air
All lime and dolomite added with in first 3 min.
Now the both slopping and drying condition of slag can be watch
which there basically governed by the sound by the vesselmakes.
Lance height and venture is maintained and adjusted automatically
Iron oreis added as per the model or previous heat experienced.
Higher addition may lead to slopping.
The blow is then terminated
The vessel is purged for 30 sec for homogenisation .
The sample and temp is taken.
The slag is analysed by controller based on its thickness .
Some slag is retained for next heat and for slag coating
30. 30
TURNDOWN CONDITIONS
DEPHOSPHORISATION
Out of all these, removalof phosphorus from the steel is of prime
importance and should be done with care so as to avoid rephos from the
slag to the steel
Best condition from the phosphorus removal from the liquid steel from
a thermodynamic view point can be summarised as a highly basic, lime –
rich slag.
A satisfactorily high level of oxidation of iron .(if it is much more than
Ca0 wt% will decrease)
2 p+5feo=p2o5=5fe
Lower possibletemp
The lowest possibleamount of undissolved freelime in slag. (this is
because of low kinetics)
END POINTCARBONABD TEMPERATURE CONTROLL
GOOD
TURNDOWN
REQUIRESOPTIMUM BASICITY
(3 – 3.4)
GOOD AMOUNT OF
SLAG Fe (15-18%)
TURNDOWN TEMPERATURE WITHIN A GIVEN RANGE (1640 – 1680 deg
C)
PHOSPHOUS REMOVAL
31. 31
Following parameter are employed to evaluate the efficency of end point
carbon and temp control:
Hit rate: reportas %heats wherethe heat point C & T are within
specified tolerance bands.
Standard deviation; from the aim value of C&T.
Percentage of reblows requireds to arriveat aimed end points (non
reblows is ideal)
32. 32
REACTION IN THE VESSEL
OXYGENPICK UP BY THE METAL:
O2 (g)=2O
(FeO)=Fe+ o
Fe2O3 =2FeO + O
Co2(g) = Co(g) + O
Oxidation of element in metal:
C + O =Co(g)
Fe + O =(FeO)
Si +2O =Si
Mn +O=(MnO)
2P+5O=(P2O5)
OXIDATIONOF COMPOUND INTHESLAG
2(FeO)+1/2O2(g)=(Fe2O3)
2(FeO)+CO2(g)=Fe2O3)+CO
FLUX REACTION
MgO(s)=(MgO)
CaO(s)=(CaO)
GAS REACTION
CO(g)+1/2o2(g)=CO2
34. 34
BLOWING CONTROL AND TURNDOWN
The primary objective of refining or blowing control is to oxidise the metalloid
impurities in the chargeand to form a basic slag as rapidly as possible in order
to protect the lining and to permit adequate sulphur and phosphorus removal.
the controlof the refining cycle can be attained by proper combination of
lance practice , flux practice and oxygen flow rate. It is essential to develop a
refining strategy which form an early basic slag and maximises carbon removal
rates withoutadversely affecting the lime solution and sulphur and
phosphorus removaland which minimise slopping and ejection from the vessel
during the blow. Last but mostimportant,the temp at turndown should be
optimum.
TURNDOWN CONTROL
The time required between firstturndown and start tap is an importantfactor
in overall productivity of a BOF shop. Heat require for large correction for temp
or analysis will significantly productivity last decay has seen mean very
development aimed at improving turndown or end point control .
The control of end point condition should start with a good static charge
control practice which requires both good thermodynamic model and close
attendance to the accuracy of the input to the model in turn of weight ,temp
and chemical analysis of the charge materials. Every effect should me to
employ a consistence scrap charge on all heats in term of the relative amount
of each type of scrap. A well standardised blowing and flux addition practice
should to be used on each type of heat in order to reduce the heat to heat
variability in decarburisation and slag development kinetics consistent
application of the above criteria will performance of each of the dynamic end
point methods
35. 35
CORRECTION OF TEMPERATURE AND ANALYSES
IN TATA Steel correction of temperature is done by adding scrap to hot metal.
Scrap addition is done as per the hot metal availability, that is we consider 5
ton hot metal we add 10 ton of scrap it. The maximum scrap addition will be
up to 20ton (limited the size of the scrap charging chute/pan and
thermodynamic heat balancing)
If the slag is thick as is the case with the use of large percentage of dolomite
lime or where the FeO is low , as high carbon heat, the limestone chips are less
effective. Occasionally even iron ore will land on top of every thick slag and
remain there without reaction.
The furnace may be rocked to promote a more rapid reaction with the coolant.
Reblowing with the lance raised can shape up the slag, and accelerate cooling
with limestone when slag are very thick.
The use of limestone and particularly iron ore for cooling can result in further
bath decarburisation particularly on higher carbon heats.
When coolant scrap is added the slag is usually penetrated readily and the
temperature drop obtained is more predictable. However, when large
amounts of scrap are used, sufficient time must be allowed for the scrap to
melt before the heat is tapped
REBLOW
If the bath temperature is too cold (less than 1630 deg C) the heat will
normally be reblown immediately without waiting for the analysis of the
turndown sample. Some shop do not even sample the bath if it is cold and
requires a reblow for temperature .for a 200 ton BOF heat approximately
15000 SCF of re blow oxygen will raise the bath temperature by 30⁰F
If the turndown bath analysis for carbon, sulphur, phosphorus or manganeseis
above the tapping specification for the scheduled grade, correctivereblows
36. 36
can normally be used to reduce the analysis to the required specification. The
following reblow practice are used for these corrections
Type of reblow Lance height Vessel addition
For temperature Low None
For carbon reduction Low None
For manganese
reduction
High None
For phosphorus
reduction
High Iron ore
For sulphur reduction High Lime and fluorspar
37. 37
THE AUTOMATION MODEL
The static model used in BOF is based on pre-set calculation which are based
on the input mechanismof parameter data, its processing in accordancewith a
well defined chemistry and the overall material and heat balance process.
The BOF model used at LD#1 is a static model and takes into accountvarious
parameters/variables for calculating the addition require for each single blow.
The relationship between various parameters are customised and set in
accordancewith pre-existing literature.
MODEL WORKS IN FOLLOWING FASHION
INPUT OFDATA FROMTHE SYSTEM
PROCESSINGIT IN ACCORDANCEWITH CHEMICAL AND HEAT BALANCE
EQUATION
PRECDICTINGAN OUTPUT ON THE BASISOFTHE INPUT DATA
38. 38
INPUTS TO STATIC BOF MODEL ATLD
OUTPUT TO STATIC MODEL AT LD 1
BOF MODEL
HOT METAL
ANALYSIS
HOT METAL
WEIGHT
HOT METAL
TEMPERATURE
SCRAP RETAINED
SLAG
ORE
LIME
LIMESTONE
DOLOMITE
OXYGEN
CAST NO
RET STEEL
GRADE
CONVERTERNO
LADLE NO
PAN NO
BATH HEIGHT
BLOWER
AIM
ANALYSIS
AIMWt
AIMTemp
BOF model
PREDICTED
VALUE
1.ORE
2.LIME
3.LIMESTONE
4.DOLOMITE
5.OXYGEN
PREDICTED VALUES
EOB SLAG ANALYSIS
PREDICTED VALUES
STEEL ANALYSIS
39. 39
STATIC MODELS CAN BEUSED TO CALCULATE
a. Optimum chargemix,
b. Requirement of addition during blowing
c. Total oxygen required.
d. Time of blow.
THEY CANNOT PREDICT
a. blowing parameters like oxygen flow rate .
b. lance height or bath height.
c. Any parameter as a function of time.
The soundness of the prediction depends on severalfactors
a. Accuracy chargecontrol mode.
b. Accuracy of input to the computer system.
c. Consistency of steelmaking practices.
d. Reliability of computersystem and its use.
40. 40
For making such estimate dynamic models a required. The presented model
can be used for semi dynamic control taking the help of sub lance
measurements. However by their very nature static models are not able to
predict many variation as mentioned above.
Dynamic model contains all the feature of static models and in addition having
terms for reaction kinetic and process dynamic. The possibleapproaches
include the following.
Instantaneou sequilibria amongstthe reacting phasemay be assumed
and the process can be treated as being thermodynamically reversible.
Reaction are assumed to be mass transfer control.
After SI oxidation, the major reaction are those of iron and carbon.in
the caseof fully dynamic control ,exit gas will be help.
41. 41
FLAWS INTHE PRESENT AUTOMATIONMODEL
The BOF model fails if all the input are not given; although the
main inputs are HMtemp, weight, scrap, and si.
The retained slag input is some fixed value of 0,2,5and 10 tons
,etc and cannot be altered as per requirements.
Although the model take care of history but still feedback given
that can be improved.
Operators deviate greatly from the models.
The model is unable to rectify these changes as it mostly follow
strict theoretical calculation.
42. 42
PROBLEMS FACED IN LD 1
Fastproductivity and slow demand
Over capacity in steel
Market distortion
Sticking of ore
Slurry formation
Non uniformdischargeof lump formation
Delay in shooting time
Problems in steel making in rainy season
In rainy season the raw materials such as lime, iron ore, scrap, dolomite
contain moisture presencewhich affect steel making.
WET RAWMATERIAL
LIME may be used for sulphur and phosphorus removalatthis stage as well.
Most importantly, quicklime is typically added to the mixture in the
steelmaking furnaceafter the beginning of the oxygen “blow” whereit reacts
with impurities (primarily silica and phosphorus) to form a slag which is later
removed.lime plays a key role in fine tuning steel chemistry, lowering oxygen
content, removal of impurities such as sulphur and reduction in inclusions
trapped by the basic slag.
Lime is used in these secondary processes, LadleMetallurgical Furnace, (LMF)
and Vacuum Degassing. moisturecontent in the lime make loss on ignition
which will lead to higher lime consumption
CaO+H2OCaOH2+HEAT
IRONORE:- Iron ores are rocks and minerals from which metallic iron can be
economically extracted. The ores are usually rich in iron oxides and vary in
43. 43
colour from dark grey, brightyellow, or deep purple to rusty red. The iron itself
is usually found in the formof magnetite (Fe. 3O. 4, 72.4% Fe), hematite
(Fe2O3)when iron ore having moisture content is used, temperature
malfunction will carry out in the vesselfeeder jamming is another problem
facing with moisturecontent
Dolomiteis an anhydrous carbonatemineralcomposed
of calcium magnesium carbonate, ideally CaMg(CO3)2. Theterm is also used
for a sedimentary carbonaterock composed mostly of the mineral dolomite.
An alternative name sometimes used for the dolomitic rock type is dolostone.
Dolomite having moisturecontent will have a problem that temperature
malfunction will take place in the vessel
SCRAP:- Scrap consists of recyclable materials left over from product
manufacturing and consumption, such as parts of vehicles, building supplies,
and surplus materials. Unlike waste, scrap has monetary value, especially
recovered metals, and non-metallic materials are also recovered for recycling
when we use wet scrap for steel making it will leave to explosion
44. 44
AIM OF THE PROJECT
Effect of moisturecontent on turndown temperature
The study and analysis of moisturepresent in ironoreand dolomite.
SAMPLESTUDY AND MOISTURETESTING
INTATA steel moisturepresence is noted by the normalmethod of moisture
testing. RAC lab 3 is mentioned for the operation. the given samples are
weighted and heated in furnace which having a heat rangeof 150-200 deg c
for 15- 30 min. after that the heated sample is taken out and weighted again
and now we can find the moisture content by substracting by intial weight and
final weight
Moisture% =( intial weight- final weight) *100
RESULT OF SAMPLETESTING
SAMPLES MOISTUREOF IRON
ORE
MOISTUREOF
DOLOMITE
SAMPLE-1 4.75% 2.86%
SAMPLE-2 5.56% 2.62%
SAMPLE-3 3.25% 2.32%
SAMPLE-4 3.0% 1.9%
SAMPLE-5 4.28% 2.44%
Average moisture percentageof ironore =5%
We have found that moisture percentageof dolomite is very small sowe
neglectedthe moisturepercentage of dolomite
45. 45
IRON ORE HAVING 5% MOISTURE
Calculationof corresponding dropintemperature of steel due tothe
additional presence of moisture in Fe2O3 addedduring the blow
Tonnage of FeO =10.577
%H2O in FeO =5%
Tonnage of liquid steel in the vessel=160
Temperature of Flue gas at Vesselmouth during blowing =650⁰C
Room temperature =30⁰C
Specific heat of water= 4.185 J/g/K
Specific heat of steam (approx. from 100deg C to 650 deg C) = 2.675
Specific heat capacity of liquid steel at 1600deg C =0.82
Latent heat of vapourisation =2257
Tonnage of H2O in FeO =0.52885
Heat required to heat H2O from room temp to 100 deg c =154.9266075
Heat required to convert H2O to H2O at 100degc =1193.61445
Heat required to heat steam from 100deg c to 650 degC=778.0705625
Total heat extracted by moisture in FeO=2126.61162
Corresponding dropin temperature of liquidsteelat 1600⁰c =16⁰c
46. 46
EFFECT ON STEEL MAKING (∆H +∆H(MOISTURE))
3Fe2O3 + CO(g) 2Fe3O4 +CO2 (S) ---------------------------------------------1
Fe2O4 + CO(g)3FeO (s)+CO2(g) ---------------------------------------------2
FeO(S)FeO(SLAG) ---------------------------------------------------------------3
When we add 10 ton Fe2O3 heat is extracted
1) Raise in temp
2) Enthalpy change
If weadd 10 ton dry Feo3 what is absolute temp drop in liquid steel
160ton * Cp *[Xa – 1637] = 1+2
If weadd 10 ton moistFe2O3 whatis the absolute temp drop in liquid steel
160 ton * Cp * [Xb – 1637] =1 + 2 + (Mw*Cp*∆t) + (Mw *latent heat) +
(Mw* Cp*(600-100))
3Fe2o3 + CO Fe3O4 + CO2
2Fe3O4 +2CO 6 FeO +3CO2
3Fe2O3 + 3CO 6FeO +3CO2
Fe2O3 +CO 2FeO + CO2
By mole fraction method we can say that enthalpy formation
Fe2O3 = 814.1
CO = 114.4
2FeO =2* 263.7
47. 47
CO2 =395.3 KJ/mol
Therefore wesay that the equation,
Fe2O3 + CO 2FeO + CO2
=5.8 KJ/mol
1 mol Fe2O3= 56 * 2 + 16 * 3
=160
1 tonne of Fe2O3 = 36,250 KJ/tonne
FeO(S)FeO(SLAG )
FeO(S)FeO(l)
By mole fraction we can say that enthalpy formation
FeO(S) =263.7
FeO(l)=225.6
Per mole of FeO= 38.1kj/mol
FeO =56+16 =72 gm
Per ton of FeO = 38.1*2/0.000072
=1058333KJ
FeO FeO SLAG
Per ton at Fe2O3 HEAT extracted
=1*Cp fe2o3 [1637-3] +1*[1058333+36250]KJ
=1*0.8864*1000[1637-30] +[1094583]
=1424444.8+1094583
=2519027.8KJ
For 10 ton Fe2O3
48. 48
Q =25190278KJ
Original temp of steel =T⁰s
160*1000*0.82*(TS-1637)=25190278
T⁰s = 1637+192
For 9.5Fe2O3+0.5H2O
Q Fe 2O3=2519027.8*9.5=23730764kj
For 0.5ton of H20
Q H2O=2010600 KJ (thepredetermine value of heat extracted by the moisture
in FeO)
TOTAL Q=25941364
(T⁰S=1637+197.7 ⁰c)
191
192
193
194
195
196
197
198
199
200
0% 1% 2% 3% 4% 5% 6% 7%
Temparturedrop,degC
Moisture in Iron Ore, %
Drop in temperature of 160t of liquid steel for addition of 10t Iron ore
with different moisture content
49. 49
KEY LEARNING OUTCOMES
The internship has provided good learning outcomes which included
Practical understanding of corporateenvironment
Importanceof punctuality and time management
Enhanced inter personalskills and learnt how to deal with seniors and
colleagues
Learnt team work
Learnt the working operation
Learnt basic process carry out
Try to find effect of moisture