Steel Melting Shop (SMS)

1. Rourkela Steel Plant
Steel Melting Shop-II
Tarun|Haresh|Saketh|Sameer|Deepak|Gautham|Pranay

2. Why SMS?

3. It is the first Plant in Asia to adopt
LD process of steel making.
It is the first steel plant in SAIL and the only
one presently, where 100% of the slabs rolled
are produced through the cost effective and
quality centered continuous casting route.
It is the first steel Plant in India to adopt
external desulphurization of hot metal by
calcium carbide injection process.

4. Is there any mill integrating all these processes?

5. STEEL MAKING PROCESS
• The aim of SMS ,in the steel making process, is to mould the hard
metal into steel which is both strong and flexible.
• Higher the carbon content in steel the stronger it is.But,with a
higher carbon content, there is lesser weldability.
• To tackle this problem, the steel finally obtained, should have a
lesser carbon content(less than 2%) while also maintaining
strength.
• The desired quality of steel can be obtained by three recognised
process.
1)LD CONVERTER PROCESS.
2)BESSEMER CONVERTER PROCESS.
3)SECONDARY STEEL MAKING PROCESS.

6. LD PROCESS
• In SMS Steel is made by LD process.
• Hot metal from Blast Furnaces, Oxygen (from Tonnage
Oxygen Plants) and Flux are the main input for steel
making.
• Hot Metal and Scrap are charged in requisite quantity in
converter. Oxygen is blown from the top and flux is added in
the converter.
• During oxidation of hot metal, impurities in the hot metal
get oxidised and are separated by mixing them with flux
(lime).

7. • The impurities thus generated are known as Slag.
• Ladle additives like Ferro Alloys and Aluminium are
added before or during steel produced in the
converter is tapped into a preheated ladle to produce
to the composition of required grades.
• The ladle containing liquid steel is homogenised by
purging argon through it from bottom.
• The ARS/LHF liquid steel is converted to slabs in
continuous casting machines in SMS-I & II.

9. Mixer and Desulphurization unit
 Two hot metal mixers store hot
metal, received from all the
four blast furnaces.
 1300 T capacity & avg. HM
temp. is 1250°C to 1350 °C
 homogenize the HM w.r.t.
temperature & composition
 Operating angle: 30 degrees
 burners are used to maintain
temp.

10.  Except the sulphur reaction all the
rest are oxidation processes and
are favored under the oxidizing
conditions of steel making.
Generally the S reaction is dealt
separately by means of external
desulphurization.
 Two Desulphurization units are
provided for removing excess from
the HM to the acceptable norms
before the HM is charged into the
converter.
 The DS agents used are CaC2/
MgAl based compound are injected
through top lance.

11. • CONVERTERS
• converters receive HM,
scrap & Fe alloys with
the help of cranes
• concentric vessels
• lined with refractories
• Fe-Si and Si-Mn in the
chip form and Al in the
form of bars of 20 kg
are added
• O2 from TOP is blown
from top through a
water-cooled lance at
11 atm pressure.
• tap to tap time (avg) is
45 min

12. PROCESS
 Lining of the converter is inspected
 lime and scrap is added
 hot metal is charged
 measurement of bath height by a one metre
steel pipe in one of the nozzles
 oxygen is blown from top at a flow rate of
1000-1200 Nm3/min for agitation of bath,
indicated by luminous flame at converter
mouth
 converter is tilted to tap the liquid steel in to
ladle

13. COMPOSITIONS

14. Ladle Preparation Bay
• Ladle bay is utilized for preparation of ladles
which is a vessel used to transport and pour out
molten metals.
 Ladle is steel shell, which is lined with refractory
bricks.
 After lining ,ladle is placed under burner for drying.
 Preheated Ladle is placed horizontally on the ladle
stand and inner surface is cleaned using
compressed air.

15. TUNDISH PREPERATION BAY
• In metal casting, a tundish is a broad, open
container with one or more holes in the bottom.
• It is used to feed molten metal into mould so as
to avoid splashing and give a smoother flow.
• This bay is equipped to clean the used tundish
and prepare this tundish for new sequence.

16. Ladle Heating Furnace (LHF)
 Steel (1650 C) is tapped from the converter into
the steel ladle by steel car and taken into a
Ladle Heating Furnace (LHF) by overhead crane.
 Steel is purged by means of argon from the
bottom.
 Final adjustment of temperature (arcing) and
chemical analysis of steel.
 Homogenizing the steel bath.

17. Argon Rinsing Station (ARS)
 Argon Rinsing Station (ARS) is also situated in
the same bay as LHF.
 It has the facilities of LHF like final adjustment
of temperature and chemical analysis of steel.
 This is utilized during LHF shutdown or any other
exigency condition.

18. Casters
 Provide steel on continuous basis.
 A water cooled copper mould, which gives the
required dimensions.
 Different zones of cooling.

19. Torch Cutting Machine(TCM)
 Cut the slabs to the required length.
 Done by oxy-acetylene gas flame.

20. Slab Yards
 Slabs produced are stored in two slab yards.
 Two slab marking machines installed.
 Slabs sent to Plate Mill and Hot Strip Mill.

21. SMS MATERIAL FLOW CHART

22. WASTE MANAGEMENT AND
POLLUTION CONTROL-SMS
• CO gas produced in the process is collected in
a gas holder. It is further used as fuel in
different units.
• The dust which is collected, is used as slurry.
• Slag generated during the steel making
process, is also recycled. It is dumped and
cooled, then it is used by blast furnaces, and
sometimes in SMS.