Operation Practices of SMS-1,Converter Shop

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Steel Melting Shop-1

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ANNUAL PRODUCTION ANNUAL PRODUCTION PLAN/ACTUAL PRODUCTIONPLAN/ACTUAL PRODUCTION

YEARYEAR SMS-1SMS-1APPAPP

SMS-1SMS-1ACTUALACTUAL

SMS-2SMS-2APPAPP

SMS-2SMS-2ACTUAACTUALL

2006-20072006-2007 2.372.37 2.412.41

2007-20082007-2008 2.432.43 2.512.51

2008-2008-2009(HALF 2009(HALF YEARLY)YEARLY)

1.911.91 1.951.95

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BHILAI STEEL PLANT

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Main Facilities of S M S-1• 4 Nos. Twin Hearth Furnaces• Bulk charge yard• Ferro Alloy yard• Mould yard• Slag yard• Stripper yard• Magnetic yard• 2 Nos. Mixers(1300 ton each)

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FURNACESFURNACES

Shop has 4 Twin Hearth Furnaces of Shop has 4 Twin Hearth Furnaces of which 3 Furnaces are operational at which 3 Furnaces are operational at any moment and 1 Furnaces may be any moment and 1 Furnaces may be under hot reserve or refractory lining.under hot reserve or refractory lining.

The capacity of the Furnaces is 250 t The capacity of the Furnaces is 250 t x2.x2.

Furnaces are of negative draft type.Furnaces are of negative draft type.

Average lining life of Furnaces is around Average lining life of Furnaces is around 500 heats. 500 heats.

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Hot metal received from blast furnace is Hot metal received from blast furnace is converted to steel by removing carbon converted to steel by removing carbon and other elements present. A typical and other elements present. A typical analysis of hot metal received from analysis of hot metal received from blast furnace is:--blast furnace is:--

c-c- 3.5-4.0%3.5-4.0%si-si- 0.6-1.0%0.6-1.0%Mn-Mn- 0.6-1.0%0.6-1.0%

S 0.05% maxS 0.05% max P 0.10% maxP 0.10% max

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1.1. First of all 50 tons scrap is added in First of all 50 tons scrap is added in the bottom of Furnacethe bottom of Furnace

2.2. 10 tons limestone is added.10 tons limestone is added.

3.3. 200 tons of hot-metal is charged 200 tons of hot-metal is charged

from charging side through chute.from charging side through chute.

4.4. Then OThen O2 2 is blown through lance.is blown through lance.

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5.5. Blow is finished after 1hr-45 min of Blow is finished after 1hr-45 min of blowing, with 1650ºC and bath carbon blowing, with 1650ºC and bath carbon below 0.10below 0.10

6.6. After taking sample and temperature, After taking sample and temperature,

re-blowing is done for chemistry and re-blowing is done for chemistry and

temperature.temperature.

7.7. Metal is tapped in the preheated ladle Metal is tapped in the preheated ladle provided by pit side.provided by pit side.

8.8. Ferro Alloys are added as per Ferro Alloys are added as per requirement with the help of cranerequirement with the help of crane

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9.9. Final sample and temperature is Final sample and temperature is taken.taken.

10.10.Then ready metal is tapped in the pre-Then ready metal is tapped in the pre-

heated ladle provided by pit side.heated ladle provided by pit side.

11.11.Steel is sent to pit side for teeming Steel is sent to pit side for teeming

into moulds.into moulds.

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BasicityBasicity 2.5-3.02.5-3.0

MgOMgO >8.0>8.0

FeOFeO <20<20

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GradeGrade   

CONFIGURACONFIGURATIONTION                   ADDITIONADDITION         

   C'C' Mn'Mn' P'P' S'S' Si'Si' FeMnFeMn SiMnSiMn SiSi CokeCoke AlAl NbNb TEMPTEMP

         S+P≥0.065S+P≥0.065                           

GROUP'B' GR-1GROUP'B' GR-1 0.05--0.100.05--0.10 0.30--0.500.30--0.50 0.040.04 0.0350.035 0.050--0.0800.050--0.080 150150 12001200 APRAPR 00 00 00 1650±101650±10

GROUP'B' GR-2GROUP'B' GR-2 0.06--0.120.06--0.12 0.30--0.600.30--0.60 0.040.04 0.0350.035 0.050--0.0800.050--0.080 150150 12001200 APRAPR 00 00 00 1650±101650±10

CR HEATCR HEAT <0.10<0.10 0.45 MAX0.45 MAX 0.040.04 0.0350.035 0.050--0.0800.050--0.080 150150 11001100    00 00 00 1650±101650±10

2062 C+Mn/4≥322062 C+Mn/4≥32 0.12-0.200.12-0.20 0.82--1.400.82--1.40 0.0450.045 0.0450.045 0.015--0.0400.015--0.040 1800±1001800±100 550550 APRAPR 00 00 00 1660±101660±10

SLAG POT HEATSLAG POT HEAT 0.25--0.300.25--0.30 1.0--1.21.0--1.2 0.040.04 0.040.04 0.30--0.350.30--0.35 00 2700--28002700--2800 250KG250KG 350KG350KG 150KG=8NOS150KG=8NOS 00 1700±101700±10

SAIL RIM IIISAIL RIM III 0.06MAX0.06MAX 0.30--0.400.30--0.40 0.040.04 0.0450.045 0.060MAX0.060MAX 00 12801280 APRAPR 00 00 00 1650±101650±10

SAILMA 350SAILMA 350 0.15--0.180.15--0.18 0.110--0.1210.110--0.121 0.040.04 0.040.04 0.015--0.0250.015--0.025 23002300 300300    00 00 60KG60KG 1650±101650±10

GR III SKGR III SK <1.60<1.60 0.82--1.400.82--1.40 0.040.04 0.040.04 0.030--0.0500.030--0.050 1600±501600±50 550550 APRAPR 00 00 00 1650±101650±10

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The pit side work can be divided in 2 The pit side work can be divided in 2 main parts---main parts---

a.-Teeminga.-Teeming b.-ladle preparationb.-ladle preparation

TEEMINGTEEMING• After tapping the ladle is After tapping the ladle is

transferred to the teeming bay transferred to the teeming bay by means of craneby means of crane

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• The teeming ladle is equipped with slide gate The teeming ladle is equipped with slide gate mechanism which facilitates the opening and mechanism which facilitates the opening and closing of the ladle nozzles for teeming.closing of the ladle nozzles for teeming.

• The ingot mould filling time is normally 50-60 The ingot mould filling time is normally 50-60 seconds.seconds.

Capacity of Moulds 8 t .Capacity of Moulds 8 t .

SAFETY MEASURESSAFETY MEASURESSAFETY OF MAN AND MACHINES IS GIVEN SAFETY OF MAN AND MACHINES IS GIVEN UTMOST PRIORITY IN ANY STEEL UTMOST PRIORITY IN ANY STEEL PLANT.FOLLOWING MEASURES SAFETY PLANT.FOLLOWING MEASURES SAFETY MEASURES ARE TAKEN PERIODICALLY.MEASURES ARE TAKEN PERIODICALLY.

Safety meetings on weekly basis.

Safety discussion on daily basis.

Calibration of all interlocks weekly.

Calibration of lance daily once.

CONCLUSIONCONCLUSION

In order to sustain & grow in steel In order to sustain & grow in steel market we have to reduce:market we have to reduce:

– The production cost.The production cost.

– Operating expenses.Operating expenses.

– Go for Modernization.Go for Modernization.

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