International Paper Published in STEEL TECH (ISSN 0976-4232) Vol:7 No:3 in April 2013
Ferroalloys are added as deoxidizing agents and additives to increase strength, elasticity and abrasion & corrosion resistance of steel. The preferred size of ferroalloy lumps for steel making is 10mm – 80 mm to optimize the operational efficiency. Ferroalloy lumps are produced by manual breaking of casted alloy cakes which generates 5-10% fines which cannot be used in bulk steel making process (like the commonly used LD process) because of handing and operational difficulties. Therefore, we at Tata Steel developed an agglomeration process for ferroalloy fines and used the briquettes thus produced for making steel. The developed process described in the paper is an economic, environment friendly and efficient way to utilize the ferroalloy fines in steel making.
Briquetting of Ferro Manganese Fines & Use in Steel MakingPRABHASH GOKARN
Ferro Manganese(FeMn) is used for alloying & refining of steel. During manufacture of FeMn fines are generated which are not useable (except in small induction furnaces). This paper describes a process for agglomeration of FeMn fines and its use in steel making.
Paper submitted for NMD 2012.
Industrial Training Project Report on B.S.PPiyush Verma
B.S.P a unit of steel Authority of India Ltd. Inagurated at 1959 by the President of India Dr. Rajendra Prasad with a production capacity of 1.0 million ton.
B.S.P is Indian sole procedure for rails and heavy steel plates and major producer of structural.
The plant is the sole suppliers of the country’s longest rail tracks of 260 meters. With annual production capacity of 3.153MT
We are the professional manufacturer of wire rod rolling mill, we also provide complete design for your rolling mill workshop, not only turnkey project but also tailor-made service, and we provide all the parts for roughing rolling mill, intermediate rolling mill process, including pinch roll, all kinds of shears, laying head, all of these crucial parts work extremely precisely and reliably.
Hani is a well-experienced enterprise; we have more than 20 year experiences in manufacturing rolling mill machinery, our core technology team is very experienced and they are all well-known in this industry in China, with high technology and best service, after decades of researching and developing in this industry, we gain really high reputation, and customer satisfaction.
Briquetting of Ferro Manganese Fines & Use in Steel MakingPRABHASH GOKARN
Ferro Manganese(FeMn) is used for alloying & refining of steel. During manufacture of FeMn fines are generated which are not useable (except in small induction furnaces). This paper describes a process for agglomeration of FeMn fines and its use in steel making.
Paper submitted for NMD 2012.
Industrial Training Project Report on B.S.PPiyush Verma
B.S.P a unit of steel Authority of India Ltd. Inagurated at 1959 by the President of India Dr. Rajendra Prasad with a production capacity of 1.0 million ton.
B.S.P is Indian sole procedure for rails and heavy steel plates and major producer of structural.
The plant is the sole suppliers of the country’s longest rail tracks of 260 meters. With annual production capacity of 3.153MT
We are the professional manufacturer of wire rod rolling mill, we also provide complete design for your rolling mill workshop, not only turnkey project but also tailor-made service, and we provide all the parts for roughing rolling mill, intermediate rolling mill process, including pinch roll, all kinds of shears, laying head, all of these crucial parts work extremely precisely and reliably.
Hani is a well-experienced enterprise; we have more than 20 year experiences in manufacturing rolling mill machinery, our core technology team is very experienced and they are all well-known in this industry in China, with high technology and best service, after decades of researching and developing in this industry, we gain really high reputation, and customer satisfaction.
FellowBuddy.com is an innovative platform that brings students together to share notes, exam papers, study guides, project reports and presentation for upcoming exams.
We connect Students who have an understanding of course material with Students who need help.
Benefits:-
# Students can catch up on notes they missed because of an absence.
# Underachievers can find peer developed notes that break down lecture and study material in a way that they can understand
# Students can earn better grades, save time and study effectively
Our Vision & Mission – Simplifying Students Life
Our Belief – “The great breakthrough in your life comes when you realize it, that you can learn anything you need to learn; to accomplish any goal that you have set for yourself. This means there are no limits on what you can be, have or do.”
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Billet defects - transverse cracking formation prevention and evolutionJorge Madias
Transverse cracking occurs often in billets, as well as in blooms and slabs. This presentation includes a characterization of the defect as observed in billets, as well as its evolution during rolling. A comparison is made between artificial and natural transverse cracks after rolling of rebar. A discussion of different variables influencing on its occurence is made, taking into account the ductility through and the effect of microalloying and sulphur content on it, corner temperature, friction in the mold, etc.
Billet defects off-corner cracks formation, prevention and evolutionJorge Madias
Presentation on a solidification defect in billets. After a characterization of the defect and a discussion on the mechanism for its formation, preventive measures are analysed, taking into account several plant experiences. The evolution of the defect during rolling and further processing and application is reviewed, too.
Computer Science
Active and Programmable Networks
Active safety systems
Ad Hoc & Sensor Network
Ad hoc networks for pervasive communications
Adaptive, autonomic and context-aware computing
Advance Computing technology and their application
Advanced Computing Architectures and New Programming Models
Advanced control and measurement
Aeronautical Engineering,
Agent-based middleware
Alert applications
Automotive, marine and aero-space control and all other control applications
Autonomic and self-managing middleware
Autonomous vehicle
Biochemistry
Bioinformatics
BioTechnology(Chemistry, Mathematics, Statistics, Geology)
Broadband and intelligent networks
Broadband wireless technologies
CAD/CAM/CAT/CIM
Call admission and flow/congestion control
Capacity planning and dimensioning
Changing Access to Patient Information
Channel capacity modelling and analysis
Civil Engineering,
Cloud Computing and Applications
Collaborative applications
Communication application
Communication architectures for pervasive computing
Communication systems
Computational intelligence
Computer and microprocessor-based control
Computer Architecture and Embedded Systems
Computer Business
Computer Sciences and Applications
Computer Vision
Computer-based information systems in health care
Computing Ethics
Computing Practices & Applications
Congestion and/or Flow Control
Content Distribution
Context-awareness and middleware
Creativity in Internet management and retailing
Cross-layer design and Physical layer based issue
Cryptography
Data Base Management
Data fusion
Data Mining
Data retrieval
Data Storage Management
Decision analysis methods
Decision making
Digital Economy and Digital Divide
Digital signal processing theory
Distributed Sensor Networks
Drives automation
Drug Design,
Drug Development
DSP implementation
E-Business
E-Commerce
E-Government
Electronic transceiver device for Retail Marketing Industries
Electronics Engineering,
Embeded Computer System
Emerging advances in business and its applications
Emerging signal processing areas
Enabling technologies for pervasive systems
Energy-efficient and green pervasive computing
Environmental Engineering,
Estimation and identification techniques
Evaluation techniques for middleware solutions
Event-based, publish/subscribe, and message-oriented middleware
Evolutionary computing and intelligent systems
Expert approaches
Facilities planning and management
Flexible manufacturing systems
Formal methods and tools for designing
Fuzzy algorithms
Fuzzy logics
GPS and location-based app
Computer Science
Active and Programmable Networks
Active safety systems
Ad Hoc & Sensor Network
Ad hoc networks for pervasive communications
Adaptive, autonomic and context-aware computing
Advance Computing technology and their application
Advanced Computing Architectures and New Programming Models
Advanced control and measurement
Aeronautical Engineering,
Agent-based middleware
Alert applications
Automotive, marine and aero-space control and all other control applications
Autonomic and self-managing middleware
Autonomous vehicle
Biochemistry
Bioinformatics
BioTechnology(Chemistry, Mathematics, Statistics, Geology)
Broadband and intelligent networks
Broadband wireless technologies
CAD/CAM/CAT/CIM
Call admission and flow/congestion control
Capacity planning and dimensioning
Changing Access to Patient Information
Channel capacity modelling and analysis
Civil Engineering,
Cloud Computing and Applications
Collaborative applications
Communication application
Communication architectures for pervasive computing
Communication systems
Computational intelligence
Computer and microprocessor-based control
Computer Architecture and Embedded Systems
Computer Business
Computer Sciences and Applications
Computer Vision
Computer-based information systems in health care
Computing Ethics
Computing Practices & Applications
Congestion and/or Flow Control
Content Distribution
Context-awareness and middleware
Creativity in Internet management and retailing
Cross-layer design and Physical layer based issue
Cryptography
Data Base Management
Data fusion
Data Mining
Data retrieval
Data Storage Management
Decision analysis methods
Decision making
Digital Economy and Digital Divide
Digital signal processing theory
Distributed Sensor Networks
Drives automation
Drug Design,
Drug Development
DSP implementation
E-Business
E-Commerce
E-Government
Electronic transceiver device for Retail Marketing Industries
Electronics Engineering,
Embeded Computer System
Emerging advances in business and its applications
Emerging signal processing areas
Enabling technologies for pervasive systems
Energy-efficient and green pervasive computing
Environmental Engineering,
Estimation and identification techniques
Evaluation techniques for middleware solutions
Event-based, publish/subscribe, and message-oriented middleware
Evolutionary computing and intelligent systems
Expert approaches
Facilities planning and management
Flexible manufacturing systems
Formal methods and tools for designing
Fuzzy algorithms
Fuzzy logics
GPS and location-based app
FellowBuddy.com is an innovative platform that brings students together to share notes, exam papers, study guides, project reports and presentation for upcoming exams.
We connect Students who have an understanding of course material with Students who need help.
Benefits:-
# Students can catch up on notes they missed because of an absence.
# Underachievers can find peer developed notes that break down lecture and study material in a way that they can understand
# Students can earn better grades, save time and study effectively
Our Vision & Mission – Simplifying Students Life
Our Belief – “The great breakthrough in your life comes when you realize it, that you can learn anything you need to learn; to accomplish any goal that you have set for yourself. This means there are no limits on what you can be, have or do.”
Like Us - https://www.facebook.com/FellowBuddycom
Billet defects - transverse cracking formation prevention and evolutionJorge Madias
Transverse cracking occurs often in billets, as well as in blooms and slabs. This presentation includes a characterization of the defect as observed in billets, as well as its evolution during rolling. A comparison is made between artificial and natural transverse cracks after rolling of rebar. A discussion of different variables influencing on its occurence is made, taking into account the ductility through and the effect of microalloying and sulphur content on it, corner temperature, friction in the mold, etc.
Billet defects off-corner cracks formation, prevention and evolutionJorge Madias
Presentation on a solidification defect in billets. After a characterization of the defect and a discussion on the mechanism for its formation, preventive measures are analysed, taking into account several plant experiences. The evolution of the defect during rolling and further processing and application is reviewed, too.
Computer Science
Active and Programmable Networks
Active safety systems
Ad Hoc & Sensor Network
Ad hoc networks for pervasive communications
Adaptive, autonomic and context-aware computing
Advance Computing technology and their application
Advanced Computing Architectures and New Programming Models
Advanced control and measurement
Aeronautical Engineering,
Agent-based middleware
Alert applications
Automotive, marine and aero-space control and all other control applications
Autonomic and self-managing middleware
Autonomous vehicle
Biochemistry
Bioinformatics
BioTechnology(Chemistry, Mathematics, Statistics, Geology)
Broadband and intelligent networks
Broadband wireless technologies
CAD/CAM/CAT/CIM
Call admission and flow/congestion control
Capacity planning and dimensioning
Changing Access to Patient Information
Channel capacity modelling and analysis
Civil Engineering,
Cloud Computing and Applications
Collaborative applications
Communication application
Communication architectures for pervasive computing
Communication systems
Computational intelligence
Computer and microprocessor-based control
Computer Architecture and Embedded Systems
Computer Business
Computer Sciences and Applications
Computer Vision
Computer-based information systems in health care
Computing Ethics
Computing Practices & Applications
Congestion and/or Flow Control
Content Distribution
Context-awareness and middleware
Creativity in Internet management and retailing
Cross-layer design and Physical layer based issue
Cryptography
Data Base Management
Data fusion
Data Mining
Data retrieval
Data Storage Management
Decision analysis methods
Decision making
Digital Economy and Digital Divide
Digital signal processing theory
Distributed Sensor Networks
Drives automation
Drug Design,
Drug Development
DSP implementation
E-Business
E-Commerce
E-Government
Electronic transceiver device for Retail Marketing Industries
Electronics Engineering,
Embeded Computer System
Emerging advances in business and its applications
Emerging signal processing areas
Enabling technologies for pervasive systems
Energy-efficient and green pervasive computing
Environmental Engineering,
Estimation and identification techniques
Evaluation techniques for middleware solutions
Event-based, publish/subscribe, and message-oriented middleware
Evolutionary computing and intelligent systems
Expert approaches
Facilities planning and management
Flexible manufacturing systems
Formal methods and tools for designing
Fuzzy algorithms
Fuzzy logics
GPS and location-based app
Computer Science
Active and Programmable Networks
Active safety systems
Ad Hoc & Sensor Network
Ad hoc networks for pervasive communications
Adaptive, autonomic and context-aware computing
Advance Computing technology and their application
Advanced Computing Architectures and New Programming Models
Advanced control and measurement
Aeronautical Engineering,
Agent-based middleware
Alert applications
Automotive, marine and aero-space control and all other control applications
Autonomic and self-managing middleware
Autonomous vehicle
Biochemistry
Bioinformatics
BioTechnology(Chemistry, Mathematics, Statistics, Geology)
Broadband and intelligent networks
Broadband wireless technologies
CAD/CAM/CAT/CIM
Call admission and flow/congestion control
Capacity planning and dimensioning
Changing Access to Patient Information
Channel capacity modelling and analysis
Civil Engineering,
Cloud Computing and Applications
Collaborative applications
Communication application
Communication architectures for pervasive computing
Communication systems
Computational intelligence
Computer and microprocessor-based control
Computer Architecture and Embedded Systems
Computer Business
Computer Sciences and Applications
Computer Vision
Computer-based information systems in health care
Computing Ethics
Computing Practices & Applications
Congestion and/or Flow Control
Content Distribution
Context-awareness and middleware
Creativity in Internet management and retailing
Cross-layer design and Physical layer based issue
Cryptography
Data Base Management
Data fusion
Data Mining
Data retrieval
Data Storage Management
Decision analysis methods
Decision making
Digital Economy and Digital Divide
Digital signal processing theory
Distributed Sensor Networks
Drives automation
Drug Design,
Drug Development
DSP implementation
E-Business
E-Commerce
E-Government
Electronic transceiver device for Retail Marketing Industries
Electronics Engineering,
Embeded Computer System
Emerging advances in business and its applications
Emerging signal processing areas
Enabling technologies for pervasive systems
Energy-efficient and green pervasive computing
Environmental Engineering,
Estimation and identification techniques
Evaluation techniques for middleware solutions
Event-based, publish/subscribe, and message-oriented middleware
Evolutionary computing and intelligent systems
Expert approaches
Facilities planning and management
Flexible manufacturing systems
Formal methods and tools for designing
Fuzzy algorithms
Fuzzy logics
GPS and location-based app
Effect of Fly Ash Particles on the Mechanical Properties of Zn-22%Al Alloy vi...IOSR Journals
In the present investigation, a Zn-22%Al alloy is used as the matrix material and fly ash as the filler material. The composite is produced using powder metallurgy techniques. The fly ash is added in 2%, 4%, and 6% by wt% to the sintering metal. The composite is tested for hardness, density and tensile strength test. Microstructure examination is done using a high resolution optical microscope to obtain the distribution of fly ash in the Zn-Al matrix. Test results indicate that as fly ash content is increased, there is a considerable increase in hardness and tensile strength but decrease in density.
A Study on Mechanical Properties of Aluminium Alloy (LM6) Reinforced with SiC...IOSR Journals
This work deals with fabricating or producing aluminium based metal matrix composite and then
studying its microstructure and mechanical properties such as tensile strength, impact strength and wear
behavior of produced test specimen. In the present study a modest attempt has been made to develop aluminium
based MMCs with reinforcing material, with an objective to develop a conventional low cast method of
producing MMCs and to obtain homogeneous dispersion of reinforced material. To achieve this objective stir
casting technique has been adopted. Aluminium Alloy (LM6) and SiC, Fly Ash has been chosen as matrix and
reinforcing material respectively. Experiment has been conducted by varying weight fraction of Fly Ash ( 5%
and 15%) while keeping SiC constant(5%). The result shown that the increase in addition of Fly Ash increases
the Tensile Strength, Impact Strength, Wear Resistance of the specimen and decreases the percentage of
Elongation
DEVELOPMENT AND TRIBOLOGICAL CHARACTERIZATION OF DUAL PARTICLE AND TRIPLE PAR...ijmech
The this work the study on hardness and wear behaviour of dual particle and triple particle size Alumina (Al2O3) reinforced aluminium alloy based metal matrix composite (Al2O3-Al MMC) was carried out. AlMMCs were prepared using 10 vol% Al2O3 reinforcement into aluminium metal matrix and developed using stir casting process. Stir casting is a most suitable process for the production of particulate MMC in which the reinforcement is introduced in to the molten matrix material with simultaneous stirring. The reinforcement in the range of particle size with Dual particle and Triple particle at 10% olume fraction with range from coarse to fine size were used (210µ, 180µ, 80µ & 10µ).The hardness of the composite was
determined by Vickers hardness tester and Brinell Hardness Tester. Tensile strength was determined by Universal Testing Machine (UTM). The wear rate was found by pin-on-disc type wear testing machine with steel disc of 60HRC hardness in dry sliding condition. Wear test was conducted on all the samples
at speeds of 300,600 and 900 rpm by varying the load (2kg, 4kg, 6kg & 8kg) at a constant sliding distance of 55mm. The wear track studies were carried out by optical microscope .The test results showed that Dual particle composite and triple particle composite exhibited better hardness compared to as cast AL- 7075. Strength of Triple particle reinforced MMC was found to be higher than that of dual particle reinforced composite material. The wear resistance properties of dual particle MMC was higher compared to triple particle reinforced MMC. The secondary process will further enhances the wear resistance of the composite and also that heat treatment will promote the wear resistance.
Effect of Milling Time on Al-Fe-Cr-20 Wt. % Al2O3composite Prepared Through B...IJERA Editor
One of the main challenges towards achieving a homogeneous distribution of the ceramic phase in the metal matrix composites is agglomeration of the reinforcement particles. Mechanical alloying is among the most important processing techniques used for manufacturing of metal matrix composites (MMCs).An attempt was made to synthesize Al-Fe-Cr-Al2O3composites synthesized through mechanical alloying. Al2O3 is used as reinforcement. Ethanol (5 wt. %) has been used as a process control agent (PCA). Mechanical alloying is carried out in a conventional ball mill using stainless steel grinding media at 115 rpm in the argon environment for 5h, 10h and 15h. The ball to powder weight ratio was maintained at 20:1. The characterization of the ball milled powder was followed by scanning electron microscopy (SEM). Showed the formation of a homogeneous phase for all compositions after milling for 15 h. XRD patterns were recorded for the milled powders, and analyzed using Williamson–Hall method and Scherrer’s equation to determine the lattice strain and grain size.EDX is performed to check the contamination of composites during the mechanical alloying.XRD is used to study structural evolution of synthesized aluminium composite. Effect of milling time is investigated on synthesized Al-Fe-Cr-20 wt. % Al2O3 composites.
The present research work is on bronze alloy metal matrix composite reinforced with fly ash particulate in
weight percentage of 3%, 6% and 9%. The specimens can be produced by Liquid metallurgy technique (Stir casting
method) will be used to produce metal matrix composites using Aluminum Copper alloys as matrix material. The
produced composites will be characterized with respect to mechanical properties and wear properties. Results
obtained from the above investigation, it can be seen that the rate of wear is decreased with increasing bronze and
will be helpful for the end of users in the foundry of automobile and aerospace industries.
A Study on Mechanical Properties of Fly Ash and Alumina Reinforced Aluminium ...IOSR Journals
The results of an experimental investigation of the mechanical properties of fly ash and Alumina
reinforced aluminium alloy (LM25) composites samples, processed by stir casting route are reported in this
paper. Three sets of composites with constant weight fraction of fly ash (particle size of 3-100 μm) and
Al2O3(particle size of 150 μm) with different wt% were used. Composite samples have the reinforcement weight
fractions of constant 3% fly Ash and varying %wt of 5, 10 and 15% Al2O3 . The main mechanical properties
studied were the tensile strength,ductilityimpact strength & hardness. Unreinforced LM25 samples were also
tested for the same properties. It was found that the tensile strength & hardness of the aluminium alloy (Lm25)
composites increases with the increase in %wt of Al2O3 upto certain limit. in addition of more amount of
reinforcement the Tensile strength decrease due to poor wettability of the reinforced material with metal
aluminium matrix .And the charpy test shows decrease in impact load absorption with increase in %weight
reinforcement.The Microstructure study of the samples indicated near uniform distribution of the fly ash and
Al2O3 particles in the matrix. LM25 alloy is mainly used where good mechanical properties are required in
castings of a shape or dimensions requiring an alloy of excellent castability in order to achieve the desired
standard of soundness.The alloy is also used where resistance to corrosion is an important consideration
particularly where highstrength is also required.
TRIBOLOGICAL CHARACTERISTICS OF ALUMINIUM HYBRID COMPOSITES REINFORCED WITH S...Blaza Stojanovic
This paper presents tribological characteristics of hybrid composites with aluminium
matrix, reinforced with silicon carbide (SiC) and graphite (Gr). Newly
formed Al/SiC/Gr hybrid composites are the combination of the two different hybrid
materials. Namely, hard particles of silicon carbide increase the hardness and
resistance to wear, while soft particles of graphite improve lubrication and reduce
friction coefficient and wear. It is possible to obtain Al/SiC/Gr hybrid composites
by different methods of casting. Tribological tests show that load, sliding speed,
sliding distance, content and size of reinforcement particles influence the size
and the type of wear and friction coefficient of Al/SiC/Gr hybrid composites with
aluminium matrix.
Exploratory Data Analysis Example - Credit Risk Analysis (Second Attempt)PRABHASH GOKARN
An attempt to analyze Bank Data on loans and find patterns in the data that are predictors of loan defaults. This will ensure that future loan decisions are made more logically and reduce possible defaults. The analysis has been done using Python.
Magnetic Separation of Metallics from Ferrochrome SlagPRABHASH GOKARN
At a Ferroalloy Plant producing High Carbon Ferro Chrome, the slag co-produced is granulated. The separation between slag and metal is not perfect and the granulated slag contains ~1% to 3% of entrapped ferrochrome. Apart from being a loss of valuable Ferro Chrome, local miscreants climb the unstable slag heaps to manually recover and steal the carry over Ferro Chrome granules, which is both a security and safety risk. We have successfully implemented a magnetic separation method for the recovery of metallics from the slag.
60 not out - sixty successful years of continuous ferro alloy making at jodaPRABHASH GOKARN
On 20th April 2018, Tata Steel’s Ferro Alloy Plant at Joda turned sixty. It is India’s oldest continuously operating ferroalloy plant, and one of the oldest continuously operating ferroalloy plants in the world. The Ferro Alloy sector globally, and especially in India, is notoriously short-lived for reasons detailed in the paper. It also elaborates the reasons for the longetivity of FAP Joda.
On 20th April 2018, Tata Steel’s Ferro Alloy Plant at Joda turned sixty. It is India’s oldest continuously operating ferroalloy plant, and one of the oldest continuously operating ferroalloy plants in the world. The plant was set up as a wholly owned subsidiary(Joda Ferro Alloy Pvt Ltd). It was the first assignment of M/s M N Dastur and completed eight months ahead of schedule. This is a booklet published by M/s MN Dastur on the occasion.
SEWAGE AND ITS TREATMENT - Experience from setting up Sewage Treatment Plants PRABHASH GOKARN
Growing population has resulted in a steep increase in demand for freshwater coupled with increased contamination from untreated wastewater. Along with steps taken to clean our polluted rivers and streams, laws for disposal of wastewater are becoming stricter, resulting in an urgent need for setting up facilities for treatment of sewage. There are several treatment options, each with its own set of advantages and disadvantages. Drawing from our experience in setting up and running sewage treatment plants across various locations involving multiple technologies, this paper discusses the major technologies for sewage treatment.
Sewage and its treatment - experience from setting up STPs PRABHASH GOKARN
Growing population has resulted in a steep increase in demand for fresh water coupled with increased contamination from untreated waste water. Along with steps taken to clean our polluted rivers and streams, laws for disposal of waste water are becoming stricter, resulting in an urgent need for setting up facilities for treatment of sewage. There are several treatment options, each with its own set of advantages and disadvantages. Drawing from our experience in setting up and running sewage treatment plants across various locations involving multiple technologies, this paper describes most of the popular technologies adopted for sewage treatment and the possible reasons for their selection.
Pre – fabricated buildings in mining - an environment friendly alternativePRABHASH GOKARN
Pre-fabricated buildings (or simply, pre-fabs), are buildings that are manufactured off-site in advance, usually in standard sections that can be easily shipped, and are assembled at site. There are many advantages of Pre-Fabricated buildings which make it especially suited to Mining Locations. With the improvement in the materials used in making pre-fab buildings, the rising cost of labour, safety & quality concerns, and environmental concerns of construction waste disposal; pre-fab buildings are poised to increase in popularity. This article discusses the experience in making a pre-fabricated office building at a mining location.
Safety Challenges in the Construction of a Large Water Recovery PlantPRABHASH GOKARN
The Ferro Alloy Plant at Joda was commissioned in 1958 and is in continuous operation since. It currently produces 50,000 MTPA of HC Ferro Manganese in two Submerged Arc Furnaces.
Gas Cleaning Plant (GCP) slurry generated in wet venture scrubbers is collected in slurry pits inside the plant for drying and subsequent disposal. Because of space constraints, and in order to recycle the water used in the wet venture scrubbers, Tata Steel is upgrading its GCP slurry handling process by the installation of a GCP slurry dewatering plant.
Construction of large structures within an operating plant, without affecting operations is always a challenge. The job is even more challenging, since the plant is 58 years old, with many unmarked structures, pipes, and cables lying underneath.
This paper discusses how new and unexpected challenges are tackled during the construction of the Slurry Dewatering Plant without compromising on safe working.
Constructing on of India's largest single location Effluent Treatment PlantsPRABHASH GOKARN
Tata Steel operates one of the largest chromite mines in India at the Sukinda Valley in Odisha. The chrome ore produced is subsequently converted it to Ferro Chrome and sold to customers across the world, making Tata Steel one of the top ten Chrome players in the world. A large quantity of water, generated during mining and due to rainfall, needs to be handled during the mining operations. Chrome Ore mainly contains tri-valent chromium oxide and a very small fraction of hexavalent di-chromate. Water coming in contact with chromium ore preferentially leaches out soluble hexavalent chromium from the ore body, as a result, water from the mine contains 0.2 – 4 mg/l of hexavalent chromium against a safe limit of 0.05 mg/l for human consumption; requiring all water to be treated before its release from the mines. Thus, Tata Steel has set up an Effluent Treatment Plant at Sukinda with a capacity of ~108 million litres/day, the largest in the region, and possibly one of the largest single location ETPs in India. This paper discusses how the challenges faced during construction of this Effluent Treatment Plant were successfully tackled.
Brazil's Mining Tragedy : Lessons for the Mining IndustryPRABHASH GOKARN
The Brazilian mining tragedy was an eye-opener for the mining fraternity to introspect on the existing tailing management processes, identify gaps, complete hazard identification and risk assessments, and modify or develop safe operating procedures and emergency preparedness plans in line with the guidelines issued by Statutory Authorities from time to time. This is necessary to avert the occurrence of similar incidents in the future.
Presentation at the 9th WORLD AQUA CONGRESS on 26th-27th Nov 15PRABHASH GOKARN
Tata Steel operates chromite mines at the Sukinda Valley in Odisha producing chrome ore which is subsequently converted it to Ferro Chrome and sold to customers across the world. A large quantity of water, pumped out from the mining pit and due to rainfall, needs to be handled during the mining operations. Chrome Ore mainly contains tri-valent Chromic oxide and a very small fraction of hexavalent di-chromate. Water coming in contact with chromium ore preferentially leaches out soluble hexavalent chromium from the ore body, as a result, water from the mine contains 0.2 – 4 mg/l of hexavalent chromium against a safe limit of 0.005 mg/l for human consumption; requiring all water to be treated before its release from the mines. Thus, Tata Steel is setting up an additional state of art effluent treatment plant at Sukinda with a capacity of 108 million litres/day; one of the largest in the region; which will be completed by Sept 2015. This paper discusses how the technology for the Effluent Treatment Plant was chosen amongst various alternatives, how the capacity of the plant was decided, the challenges during construction of the said Effluent Treatment Plant that were faced, and how these were successfully tackled. The paper also describes how, because the outlet water is of a better quality than the water from the local water body, the outlet water will be used as the input to the Water Treatment Plant, aiding water consumption and lowering operating cost.
Improving Water Quality by Constructing an Effluent Treatment PlantPRABHASH GOKARN
Tata Steel operates chromite mines at the Sukinda Valley in Odisha producing chrome ore which is subsequently converted it to Ferro Chrome and sold to customers across the world. A large quantity of water, pumped out from the mining pit and due to rainfall, needs to be handled during the mining operations. Chrome Ore mainly contains tri-valent Chromic oxide and a very small fraction of hexavalent di-chromate. Water coming in contact with chromium ore preferentially leaches out soluble hexavalent chromium from the ore body, as a result, water from the mine contains 0.2 – 4 mg/l of hexavalent chromium against a safe limit of 0.005 mg/l for human consumption; requiring all water to be treated before its release from the mines. Thus, Tata Steel is setting up an additional state of art effluent treatment plant at Sukinda with a capacity of 108 million litres/day; one of the largest in the region; which will be completed by Sept 2015. This paper discusses how the technology for the Effluent Treatment Plant was chosen amongst various alternatives, how the capacity of the plant was decided, the challenges during construction of the said Effluent Treatment Plant that were faced, and how these were successfully tackled. The paper also describes how, because the outlet water is of a better quality than the water from the local water body, the outlet water will be used as the input to the Water Treatment Plant, aiding water consumption and lowering operating cost.
Project Management Challenges in an Effluent Treatment Plant Construction PRABHASH GOKARN
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Agglomeration of Ferroalloy Fines for use in Bulk Steelmaking Processes
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Agglomeration of Ferro Alloy Fines for Use in Bulk Steel Making Process
Authors
Prabhash Gokarn*, Veerendra Singh, A Kumar, B D Nanda & A Bhattcharjee, Tata Steel Ltd., India.
(*corresponding author - prabhash@tatasteel.com)
Abstract
Ferroalloys are added as deoxidizing agents and additives to increase strength, elasticity and abrasion
& corrosion resistance of steel. The preferred size of ferroalloy lumps for steel making is 10mm – 80
mm to optimize the operational efficiency. Ferroalloy lumps are produced by manual breaking of
casted alloy cakes which generates 5-10% fines which cannot be used in bulk steel making process
(like the commonly used LD process) because of handing and operational difficulties. Therefore, we at
Tata Steel developed an agglomeration process for ferroalloy fines and used the briquettes thus
produced for making steel. The developed process described in the paper is an economic, environment
friendly and efficient way to utilize the ferroalloy fines in steel making.
1. Introduction
Ferroalloys are used in Steel Making as deoxidizing agents and additives to increase mechanical
properties (strength, toughness, wear resistance, springiness), high temperature properties(creep
strength, hardness), electrical properties or corrosion resistance.
Most bulk ferroalloys - like FeMn, SiMn, FeSi and FeCr manufactured by carbo-thermic reduction of
ores in submerged arc furnaces. Noble ferroalloys like FeMo, FeV, FeTi etc. manufactured through
the Alumino-Thermic process. In both cases, the ferroalloy is produced in form of liquid metal.
The liquid metal is cast into cakes and crushed into ~10mm to ~60mm size lumps, with co-
generation of fines during sizing.
The fines generated during the sizing of metal cake cannot be used in the bulk steel making
processes like the BOF(LD) process, as these fines get oxidized quickly and this reduces the overall
recovery during steel making [1-2]. Though, ferroalloy fines in the size range of 3 to 20mm have
better dissolution characteristics, the higher surface area (due to small size) also transports
undesirable gases and moisture into the furnace. Small alloy size also increases dust losses and
leads to handling difficulties [3-6].
Agglomeration into lumps is the best method to utilize these fines. Binder composition and physical
strength of the agglomerate are two main constraints to develop a cost effective method. Various
attempts have been made in the past to agglomerate these fines using conventional binders like
molasses, tar, resin, etc [6-10], which failed due to a variety of reasons and could not be adopted
commercially.
A briquetting process has been developed in this study to utilize ferroalloy fines of manganese
alloys (ferro-manganese and silico-manganese) in the steel making process. The briquettes
produced by the patented process developed was tested in the laboratory as well as in
commercially in the LD shops of Tata Steel.
2. Lab Scale Studies
2.1. Characterization of Fines: Samples of ferroalloy fines were collected from Ferro Alloy Plants
being operated by Tata Steel (viz FeMn at Joda, FeCr at Cuttack and SiMn under tolling at
Durgapur). These were classified into three different size ranges (>10mm; -10+3mm; -3mm). Five
important constituents (Mn/Cr, Si C, S, and P) were analyzed using ICP-OES (Spectro-Analytical
Instruments; Ciros) to find the chemical composition of the prepared agglomerate. Particle shape
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and surface characteristics were also analyzed using scanning by electron microscope to study the
agglomeration behavior of fines.
2.2 Briquetting of Fines: Selection of binder for alloy fines determines the strength of briquettes
and thus is most important. The binders should not add any unwanted ingredient like sulphur,
phosphorus, nitrogen etc. in the steel, and it should be cost effective. Molasses and other
conventional organic binders were rejected because these binders contain sulphur and phosphorus.
Sodium silicate, Bentonite, Acrylic resins and Phenolic resins were tried as binders and tested, and
the results are given in Table-1. The experimental work plan is described in Table 1 and Fig. 1.
Ferroalloy fines were mixed thoroughly with the binder in a muller mixer. Sixty to seventy grams of
the mixture was compacted in a cylindrical die of diameter 3cm at different loads and the green
compact was cured at different temperatures (100˚ and 150˚ C) for one hour. Briquette density,
compressive strength, tumbling index, abrasion index, shatter index and dissolution characteristics
were studied.
Binder % Load (ton) Curing Condition
Sodium Silicate 5, 7.5 & 10 1 & 5 100 C, 1 hour
Sodium Silicate+ Bentonite 5+2, 7.5+2 & 10+2 1 100 C, 1 hour
Acrylic Resin 5, 8 & 10 1 & 3 100 C, 1 hour
Phenol formaldehyde Resin 5, 8 & 10 1 & 5 100 & 150 C, 1 hour
Table-1: Briquetting conditions
Figure-1: Process Methodology for Binder Selection
2.3. Smelting of Briquettes: Twenty kilograms of steel scrap was melted in a 25 kg induction
furnace and 5 kg of ferro manganese (FeMn) lumps were added. Experiments were repeated for
FeMn fines and FeMn briquettes under the same test conditions for comparison. The mixing
behavior of the materials was observed. Slag and metal samples were collected and the manganese
recovery was calculated. Figure-2 shows the lab scale setup to test the dissolution behavior of
lumps, fines and briquettes. Similar trials were conducted for SiMn and FeCr fines, for reasons of
space and clarity trials with FeMn fines have been described in detail in this paper.
Sample Preparation
(0-3mm) FeMn fine)
Mixing
Pressing
(1-5ton)
Curing
(100 & 150° C, 60 minutes)
Compressive strength Test
Binder
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(a) (b) (c)
Figure-2: Lab Scale trials in Induction furnace (a) Induction furnace (25kg) (b) Melting of scrap (c) Sample
collection before and after the addition
3. Results and Discussions
3.1 Characterization Studies: Chemical analysis of various size fractions is given in Table-2.
Despite the slightly lower percentage of silicon (Si) and manganese (Mn) in fines compared to
lumps, fines are suitable for use in steel making. Size analysis of the samples of ferro manganese
fines (0-10mm) was carried out and it was found that ~70 % fines are of 0 to 3mm size (fines) and
30 % are of 3 to 10mm size (chips). Particle size and shape analysis is shown in Figure-3 and 4.
Finer particle sizes are preferred for briquetting, but presence of significant amount of very angular
particles makes the agglomeration process more challenging. Very angular particles enhance the
mechanical interlocking but require high pressure compaction.
Size Range % C Mn S P Si
>10mm 93 6 >68 0.01 0.193 0.54
-10, +3mm 2 6.75 66.30 0.01 0.175 1.72
<3mm' 5 6.7 65.90 0.01 0.188 1.33
Table-2: Size and Size wise chemical analysis of Ferromanganese fines
0.0 0.5 1.0 1.5 2.0 2.5 3.0
0
20
40
60
80
100
Comm.Pass
%,Passed
Particle Size (mm)
Figure-3: Particle Size Analysis
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Figure-4: Particle Shape Analysis
SEM analysis shown in Figure 5 reveals that these fines are not oxidized. Some small slag inclusions
were also seen in the briquetted samples.
Figure-5: SEM micrograph of Lumps (Pt1-High carbon Phase, Pt2-Low Carbon Phase) and Briquettes (Pt1-
High carbon Phase, Pt2- Slag particle)
Pt-1
Pt-2
Pt-1
Pt-2
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3.2 Briquetting Studies: Metallic fines show a different binding behavior compared to
conventional ore particles. Figure 6 shows surface of manganese ore and ferro manganese metal
particles. The ore particles usually contain small cracks and cleavages which play important role in
binder absorption and binding of the particles.
Figure-6: Surface Roughness of Mn ore and FeMn Metal Particle
Three different combination of sodium silicate were tried and it was found that the
prepared agglomerate does not attain the suitable compressive strength and it varies between 90
and 240 kgf/sample. The strength achieved by machine compaction was 700-1150 kgf/sample. The
strength of the briquettes is not suitable for handling and presence of alkalis and silicon are a
concern which prevents its use in the steel making process.
Acrylic resins and phenol based resins were then used and it was found that acrylic resins
produce an agglomerate of strength of 650-1050 kgf/sample and 720 to 1100 kgf/sample at 1 ton
and 3 ton loads, respectively.
Thermosetting resin produces the best agglomerate with minimum compressive strength of
1050 kgf/sample. Agglomerate strength varies between 1600 and 2000 kgf by machine compaction
with a 15 MPa load. This binder produces good strength with manual compaction also and strength
varies between 1050 to 1440 kgf/ sample for 5 and 10 % binder content, respectively.
A comparative analysis of maximum cold compressive strength achieved using different
binders is given in Figure-7 and it shows that phenolic resin based agglomerate achieves maximum
strength. Handling properties of these briquettes were tested and shown in Table 3 for the
briquettes produced with the most suitable binder combination. The physical characteristics of
briquettes are acceptable to existing LD steel making process.
Properties Briquette
Size & Shape Diameter : 30mm, L : 20mm
Apparent Density 5200 kg/m3
Compressive Strength 55Mpa
Tensile Strength (Load Applied in radial direction) 15Mpa
Tumbler Index (Wt 15kg, rpm 200@25) 95% (>6.3mm)
Abrasion Index (Wt: 15kg, rpm 200@25) 3%( <0.5mm)
Shatter Index (Wt : 10 kg, No of Drops : 4, Height : 2m) 98%(<5mm)
Table-3: Properties of briquettes
(a) Mn Ore Particle (b) FeMn Particle
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Figure-7: Maximum Cold Compressive Strength of Briquettes Achieved using Different Binders
3.3 Smelting Studies: Initially these briquettes were tested in laboratory and subsequently
larger trials (0.5, 10 & 100 ton) were conducted at the plant. Mixing and other operational
performance parameters were observed during the lab scale induction furnace operations. It was
observed that fines do not mix properly in the liquid steel but get trapped in the foam on top of the
liquid steel. It also generates a significant amount of slag. The slag generation was lowest for lumps
and highest for fines. Mn recovery was lowest for the fines but it was similar for lumps and
briquettes. A comparison is given in Figure 8. Mn recovery was also observed for different types of
briquettes tested for tumbling test. The best recovery was observed for the briquettes of 30mm
diameter and 20mm thickness (Weight: 65gm) and same were used for the plant trial.
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Figure-8: Comparative Analysis of Mn Recovery from Lumps, Briquettes and Fines
4. Product Validation
First phase plant trials were carried out using 500 kg of FeMn briquettes. The Plant adds
150 to 600 kg of ferro manganese in ladles of heat size of 155 tons to produce different grades of
steel. 200 kg and 300 kg ferro manganese briquettes were added in two heats. It was found that the
Mn recovery was 5 to 10% higher when using briquettes (over lumps) compensating the lower Mn
content of fines. The improved dissolution characteristic is the likely reason for improved Mn
recovery. Nitrogen level did not show any unexpected variation (and was within ~13ppm). In
second phase of plant trials, 10 ton of ferro manganese briquettes were prepared and added
manually in 20 different heats of different grades of steel in varied quantities. These trials too were
found satisfactory and in further trials 100 tons of FeMn briquettes were filled in the working chute
and added through the actual plant feeding system. These results, presented in figure 9, confirm the
results of the previous trials.
After successful implementation at the plant scale, a vendor was identified and developed
for supply of 200 tpm of ferro manganese briquettes. Later after successful lab and plant scale trials
with briquetting of silico-manganese fines, the capacity at the vendor was increased and
briquetting of silico manganese fines for use at the LD Shops(BOF Steelmaking) was commercially
undertaken. Lab scale trials have also successfully been completed using FeCr fines.
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Figure-9: Slag-Metal Analysis During Plant Trials
5. Conclusions
Ferroalloy fines cannot be used in bulk steel making processes like BOF(LD) as the small
size increases losses, reduces recovery and can act as carrier for moisture and gasses. High quality
briquettes can be produced by mixing the resin binder, compaction and by curing at 150˚ C
temperature. The process flow sheet developed for briquetting is shown in Figure-10. The
developed product was tested in the lab and commercialized after successful plant trials.
Apart from financial benefits of using ferroalloy fines, use of briquettes is environment
friendly and it can significantly reduce the amount of metallic dust and fines generated during
handling and use of ferroalloy fines in smaller furnaces.
The method of briquetting developed by Tata Steel for bulk ferroalloys (FeMn, SiMn and
FeCr) can be extended to noble ferro alloy fines and fines of manganese metal which will further
reduce costs of steel making and increase competitiveness.
Figure-10: Process flow Sheet to Agglomerate the FeMn Fines
5. Acknowledgements
The authors express their sincere thanks to Dr. D. Bhattacharjee, Director, RD&T, TATA
Steel, Mr. Rajeev Singhal, EIC, FAMD and Mr. Debashis Das Chief LD#1, Tata Steel for their keen
interest and guidance during the development of the process and its commercialization.
Metal Analysis Slag Analysis
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6. References
[1] K.D. Peaslee, D.S. Webber, S. Lekakh and B. Randall: 58th SFSA Technical and Operating
Conference, 4.1, (2005).
[2] P.G. Sismanis and S. A. Argyropoulos: Proc. of the 69th Steelmaking Conf., 69(1986), 315.
[3] Y. Lee, H Berg, B. Jensen, and J. Sandberg: Iron and Steel Society, 54(1996), 237.
[4] M. Tanaka, M. Mazumdar and R.I. L. Guthrie: Metall. Trans. B, 24B, 4, (1993), 639.
[5] H. Berg, H. Laux,, S. T. Johansen and O. S. Klevan: Ironmaking Steelmaking, 26,2, (1999),127.
[6] V Singh, S M Rao, B D Nanda and D Srinivas: International Patent Application No. 2009-
PCT/IN2009/000532.
[7] Vance, L Calbert. : United States Patent 1946-2405278.
[8] Saunders, R. Earle, Pope, L. Richard: United States Patent 1960- 2935397.
[9] L. Robert and Ranke: United States Patent 1975-3898076.
[10] J.P.Beukes, J. Nell and S. D McCullough: South Africa Patent: 2001-4091.
[11] A Ramu, P K Banerjee and B Roy Choudhury: Unpublished Report, R&D Tata Steel, India,
R&D-INV-011-96-1-13-97(1997).
7. Abbreviations
Mn Manganese
Cr Chrome
Fe Ferro / Iron
Si Silicon
C Carbon
P Phosphorus
kg Kilograms
mm Millimeters
kgf Kilogram-force
BOF/LD Basic Oxygen Furnace Processes like LD