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TATA INNOVISTA 2013 - Regional Round Winner
Silent Sizing of Ferroalloy Cake
Silent Sizing of Ferroalloy Cake using a chemical additive
D67213121840 Dare To Try
Mr. Veerendra Singh Principal Researcher, R&D, Tata Steel Mr. Prabhash Gokarn Head, Raw Material Projects, Tata Steel Mr. Chandan Singh Sr Manager, KVHS, Tata Steel Mr. Ganesh Sahu Head, FAP Bamnipal, Tata Steel Mr. Subhakant Sarangi Manager, FAP Bamnipal, Tata Steel
Tata Innovista, Finals 25th April, 2013
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1. Background - Ferroalloy Production Process 2 slides
2. Trigger – eliminate/reduce manual sizing 1 slide
3. An Unlikely Source of Inspiration 1 slide
4. Construction Site Demolition Using Chemicals 1 slide
5. Concept Testing & Projected Benefits 1 slide
6. Plant Trials 3 slides
7. Failure and its Analysis 2 slide
8. Raring to Go - Why we will be Back 1 slide
D67213121840 Silent Sizing of Ferroalloy Cake
Presentation Structure
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D67213121840 Silent Sizing of Ferroalloy Cake
Background Business Ferroalloys* are used to produce almost all quality steels
~ 80 % of Ferroalloys used in steel making – deoxidation & alloying
Ferroalloys contribute 5 % - 30% of steelmaking cost
World Ferroalloy production - 30 mTPA in 2012.
India among top 5 Ferroalloy producers of the world
Tata Steel produces ~350kTPA Ferroalloys (FeCr, FeMn, SiMn) -
6th largest producer of FeCr, largest ferroalloy player in India
* Bulk – FeCr(incl ChCr), FeMn, SiMn, FeSi… Noble - FeTi, FeNb, FeV, FeMo, FeB … FeMn FeCr SiMn
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D67213121840 Silent Sizing of Ferroalloy Cake
Ferroalloy Production Process
Submerged Arc Furnace
Liquid Metal Cast in Pans
Metal Cakes Need to Be Sized
Sizing
Ferroalloy Production
Smelting-reduction (@ 1700o C)
Casting of liquid ferroalloy
Sizing (2m→300mm→80mm)
Packing and Despatch
Sized Lumps
Fines
Steel Making
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Crushing Machine
High generation of fines
D67213121840 Silent Sizing of Ferroalloy Cake
Trigger – eliminate/reduce manual sizing
Search for Alternates to Manual Sizing Pig Caster
Low Yield X Blasting
Unsafe X X
Manual Sizing :
- Large number of unskilled labour
- Direct & Indirect cost of high labour
- Safety Concerns
- Periodic IR Issues
- Rising aspirations of people – cost, availability
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D67213121840 Silent Sizing of Ferroalloy Cake
An Unlikely Source of Inspiration
Use of chemicals for Ferroalloy Sizing
Search for Comminution additives …
Bursting of water pipeline in cold ?
Silent demolition agents
(Construction Industry)
• CaO Based Powder • Cost Rs 20/Kg • Pressure : 100MPa
Water Ice
Rock
4% vol
Ettringite crystal
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D67213121840 Silent Sizing of Ferroalloy Cake
Construction Site Demolition Using Chemicals
Demolition of a Concrete Structure using a Chemical Reagent
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D67213121840 Silent Sizing of Ferroalloy Cake
Concept & Lab Testing
Procedure Step -1 : Making holes in cake step -2 : Filling additive slurry Step -3 : Allow expansion (2-12 hours) Step -4 : Optimize process variables (time and hole spacing)
Lab Testing
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D67213121840 Silent Sizing of Ferroalloy Cake
Potential Benefits
1. Economic • Current cost of sizing : Rs 300/ton • Cost after the process developed : Rs 150/ton • Total Saving for all the plants (FeCr, ChCr, SiMn, FeMn) (Rs):
= 350,000*150 = Rs 5,250,000 = Rs 5.2 Crore/year
2. Environmental • Lower dust generation • Reduced noise pollution • Energy used in mechanical crushing saved
3. Social • Improved process safety • Lowers unskilled manual labor • Productivity (specially hot summer, rains, festivals)
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D67213121840 Silent Sizing of Ferroalloy Cake
Plant Trials – Challenges Faced
Challenges
C-1: Making the holes C-2: Safe handling of cake
from casting bed to handing yard.
C-3: Avoiding possibilities
of flying broken pieces
Yes, now problems are solved
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D67213121840 Silent Sizing of Ferroalloy Cake
Research: Plant Trials
Trial -1
(a) Use refractory pipes during casting
(b) Cake removed and quenched
(c) Hole Cleaned and slurry filled
ProcedureProcedure
• One single crack generated passing trough the hole.
• Differential cooling and brittleness of material is main reason of this
ResultResult
Single crack …….
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D67213121840 Silent Sizing of Ferroalloy Cake
Research: Plant Trials
Trial -2
(a) Made ridge in bed
(b) Cake removed and quenched
(c) Openings cleaned and slurry filled
ProcedureProcedure
• Improper fragmentation • Brittleness of material is main
reason of this
ResultResult
Poor Fragmentation…….
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D67213121840 Silent Sizing of Ferroalloy Cake
Failure Analysis.....
Poor fragmentation
• Only one/few cracks formed
• Inadequate help to sizing
Not overcome despite many combinations of holes & slurry
composition.
Safety Limitation
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D67213121840 Silent Sizing of Ferroalloy Cake
Failure Analysis.....
Poor Fragmentation…….
Single crack …….
(a) Ferroalloy Sample (b) Rock Sample
Material properties are main reason of failure
a) Brittleness
b) No micro- cracks
c) Slow rate of loading
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D67213121840 Silent Sizing of Ferroalloy Cake
Management Encouragement Made Us ……
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D67213121840 Silent Sizing of Ferroalloy Cake
........Raring to Go – Why We Will Be Back
Explore • Use at Dolomite and Manganese mines (Explosive , Safety , Yield )
• Use in fragmenting high Silica FeCr chunks
Dolomite boulders broken using Split AG
Current Status : Successful Plant Trials at Gomardih Process Development Trials in Progress
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Silent Sizing of Ferroalloy Cake
Questions
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Thank You
KVHS
Mr. Pankaj Lochan Mr. A Bhattacharjee