bsl angul units

8/6/2019 BSL Angul Units

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Technology

Capacity MPTA 0.85

No. of battery Nos. 2

Nos.

Oven length mm 13500Oven Width mm 490 / 510

Oven height mm 4300

Oven temperature 1250 1300

Type of coal charging

MT 2332

Useful volume M3 26.68 41.6

Day

Cycle time Hrs. 18 22.5

Coke cooling

Combustion technology Underjet firing system

Oven pressure

MT 1.4

Stamp charging 2

Pusher car Nos. 2

Guide car Nos. 2

Quenching car Nos. 2Quenching time Sec 90

Coke cutter MT/hr 280 300

Coal silo Nos. 16 x 500

Coal bunker Nos. 4 x 400

Coal tower MT 2754

Coke conveyor MT / hr 250 300

NM3 480

3.2 mBtu/3.36 GJ

By-products like benzene, toluene, xylene, napthalene, coal tar, creosote oil, pitch, ammonium sulphate and benzol pro

By product12500 gallon/day

By product recoverytype / Non recovery/heat recovery type

No. of Oven in each

0C

Stamp charging/ topcharging

Qty. of coal charged peroven

Oven availability per

Wet (water) / Dry (Inertn2 gas)

Coal consumption (Neton dry basis)per ton of Coke

Coke oven gas / MT of

Input energyreconciliation (Coal)

68% as coke, 12% cokeoven gas, 8% oil, 4%chemical, 8% waste

heatEnergy consumption perton of Coke

Light oil(Benzene,toluene,Xylene)



Heavy oil (Napthalene)

Coal tar 29000 gallon /day

Pitch

Amonium sulphate 12 t/day

Benzol

Coke specification

Mean Min Max

Average Coke Size (mm) mm 52 25 60

Plus 4" (% by weight) % 1 4

Minus 1"(% by weight) % 8 11

Stability Minute 60 58

Minute 65 61 68

CRI 22 27

M 10 7 10

M 40 75 80

Physical: (% by weight)

Ash % 8 12

Moisture % 2.5 7

Fixed carbon % 86

Sulfur % 0.65 0.82

Volatile Matter % 0.5 1.5

% 0.25 0.4

Phosphorus % 0.02 0.33

Raw material specification (Coking coal) Coking coal Bitu

Ash % 9.7

Volatile Matter % 18 38

Total moisture % 10

Moisture (IM) % 1

Phosphorus % 0.04

Sulfur % 0.58MMR % 1.15 1.3

Fluidity ddpm 400 1600

Fixed carbon

LAMC Low ash metallurgical coke

Coke Size

Foundry coke mm >75

Physical: (measured at theblast furnace)

Coke strength after reactionwith CO2 (CSR)

Alkali (K2O+Na

2O)



BF grade coke mm 25-75

Nut coke mm 15-25

Pearl coke mm Jun-15

Coke breeze mm 0-6

Input

Coal

Output

Coke

CO gas

Heavy oil (Napthalene)

Coal tar

Pitch

Amonium sulphateBenzol

Light oil(Benzene,toluene,Xylene)



ucts are also recovered from the coke ovens gas.



inus Lignite

25 4

25 51

10 17

0.6 0.3

50 45



Technology Grate Kiln technology

Capacity

Grate area Sqm 768

Thermal energy /ton GJ 0.63 0.96

Electrical energy / ton KWh 78 84

InputIron ore less than 325 mesh (45 micron)

Limestone,dolomite

Bentonite

Output

Iron ore pellet

Iron ore pellet specification

Grade % Tolerance

Fe 65 Minimum

FeO 0.3 Maximum

5 Maximum

CaO 0.03 ± 0.01

MgO 0.06 ± 0.01

Basicity 65 Maximum

Phosphorus 0.05 Maximum

Physical Properties Value Tolerance

Bulk Density 2.2 T/m3 ± 0.2

Tumbler Index 93% Minimum

Abrasion Index 3% Min ± 0.5 %

Cold Crushing Strength (Avg) 250 Kg/P Minimum

Size Analysis

8 - 16 mm 94% Minimum

-5 mm 2 % Maximum

+16 mm 4 % Maximum

Metallurgical Properties

Porosity 18% Minimum

Reducibility 62% Minimum

Particular Chemical (ON DRYBASIS)

SiO2 + Al2O3



Capacity MTPA 0.15 6.5

Travelling Grate area Sqm 36 600

Machine width Mtr 2 5

Availability Day/year 330 345

45

MJ 1250 1400

KWh 28 32

Thermal energy /tpn GJ 0.06

M3 0.03 0.05

Nos. 16 20

CO2 generation /ton Kg 5

Bed height mm 500 730

Suction m bar 130 190

Return fine rate % 18 25

% 75 80

RDI (-3 mm) max % 28 32

FeO (max) % 5 8

Basicity CaO/SiO2 1.2 2.9

Input

Iron ore fine kg 850 100 mesh-10mmCoke breeze kg 70 0~6mm

Limestone kg 120 0~3 mm

Dunite / pyroxenite (mkg 40

Lime fine kg 30

Solid waste kg 80

Sinter

0.15 mm <10%+10 mm 70%

- 5 mm 6%

Fe

CaO

MgO

Advantage of Sinter

Specific production MT/m2/24

Solid and gaseous

fuel per ton of sinterElectrical energy / ton

Process water per tonof sinter

Manpower ( 4 shiftbasis) pera day

ISO strength (+6.3



Technology

Capacity TPD

Combustion system

Fuel consumption

Thermal energy /ton GJ 3.47Electrical energy / ton KWh 30 40

Input

Output

Loading / chargingsystem



Technology Cryogenic /Non cryogenic

Capacity TPD

Purity of oxygen

Product Nitrogen, oxygen, argon

Start up time Hr 72 96

Air filter

Multi stage cenrifugal air compressor

Chilling and air washing unit

Air purifier

Cold box

Air expansion unit

Liquid oxygen extraction syatem

Liquid oxygen storage tank

Gas oxygen compressorGas oxygen storage tank

Cooling tower

Circulating water pump house



Technology Gas based (Midrex , HYL) ; Coal base (SL/RN, ACCAR)

Capacity TPD

Kiln size

0C 900 1100

0CWaste heat recovary

GJ 20 27 2.6Gcal/mt

KWh 60 70

Metalization % 92

Feed Iron ore lump (60%), pellet

Properties of sponge iron

Size mm 5 20

Fe metallic % 82 84

Fe total % 91 92

Metalization % 89 93

Density gm/cc

Crushing strength

Weather resistanceCarbon content % 0.06 0.2

Sulphur % 0.02 0.04

Phosphorus % 0.05 0.08

Non metallic % 1 2

Input requirement

Pellet / lump Mt 1.43 1.45

Coal (Fixed carbon) Kg 380 400

Electricity KWh 80 100

Water m3 2.5 3.5

Manpower Man-H 0.35 0.6

Plant availability % 90 92

Iron ore spec for DRI

Fe total % 67.4

Sio2 % 1.5

Al203 % 1

CaO % 0.05

Operating temp(reduction zone)

Operating temp (pre

heating zone)

Energy consumption(Thermal) / Ton of sponge of

Energy consumption(electrical) / Ton of sponge of



Mgo % 0.05

Tio2 % 0.01

P % 0.03

Size mm 5-15



Useful volume m3 35 5775

Capacity MTPA 0.08 4

Productivity MT/m3/day 1.7 2.54

Coke rate Kg/ THM 500 756

Charge

Blast temperature 0C

Top pressure Kgf/cm2 2.5

Tap hole Nos.Hearth dia mtr 13.8

Slag granulation

Top feeding arrangement

Coal injection rate Kg/ THM 160 200

KWh 106 214

GJ 33

BF gas / ton of hot metal MT / m3 2.5 3.5

Specific energy consumption in europe 17.1 GJ/Ton of crude steel

Energy consumption / ton of DRI 10.8 GJ

Input

Iron ore lump (Iron bearing material)

Sinter

Iron ore pellet

Coke (Fuel & reductant)

Lime stone (Flux) mm 25-60

Output

Hot metal

Slag basicity 0.9~1.0 with MgO content 8~11%

BF gas

Top gas pr. recovery

Energy consumption(electrical)

Energy consumption(thermal)/TCS



Technology

Capacity



Technology

Heat size MT 340

No. of heat per day

LD gas /TCS Nm3 100

Input

Energy consumption(Electrical) / TCS

Energy consumption(Thermal) / TCS



Technology

Capacity

Heat size MT 180

No. of heat /day Nos. 16

Tap to tap time Min

Nm3

Carbon injection

Door lance

EBT lance

Continuous DRI charging

Electrode consumption / ton

Cooling water / ton

KWh 650 800

Input

Hot metal

Scrap

DRI

Lime

Dolomite

Coal

Pulvarized coal

Oxygen

Nitrogen/argon

Out put

Crude steel

Rmoval of

Phosporus

Sulphur

silicon

ManganeseAluminium

Carbon

Nitrogen

Hydrogen

OX consumption / heat

(100%hot metal)

Energy consumption(Electrical) / Ton of steel



KWh 550 800

GJ 2

KWh 300


Energy consumption(Thermal) / Ton of steel

Theoritical Energyconsumption(Electrical) / Ton of scrap



KWh 3000 4000

GJ 16

Electrical energy / Ton of ferroalloy

Thermal energy / Ton of steel



Capacity MPTA 1.2

No. of strand Nos. 1 2

Thickness mm 230 350

Width mm 800 2600

Length Mtr

ladle size MT 60 300

Machine length Mtr 19Machine radius Mtr 8

No. of segment 10 19

Mould oscillator

Tundish capacity



Capacity MPTA 2 5

Width mm 1850

Thickness 1.2 25

Descaling

Rougher Nos

Finishing stand

Coil boxLaminar cooling

Down coiler Nos

Thermal energy /ton GJ 1.3

Electrical energy / toKWh



Capacity

Thickness

Width mm 1500 4900



KWh 260

GJ 3


Energy consumption(Thermal) / Ton of steel



Reheating furnace

roughing stand

Intermediate stand

finishing stand

Hot shear

Progressive cooling

Finishing and packaging



McNally Bharat Engineering company Limited

Unit Technology partner Country

Sinter plant Tyazhpromexport (TPE) Russia

Sinter plant China Metallurgical Group Corporation (MCChina

Coke oven by product DMT Germany

Continuous caster Simens VAI Germany



EAF steel making cost -2010

Factor Unit Unit cost Fixed Variable Total

1.13 t 315 356.58 356.58 74.35

1.13 t 5 5.66 5.66 1.18

0 t 395 0 0 0.00

0 t 40 0 0 0.00

Oxygen 14 m 3 0.08 1.12 1.12 0.23

0.01 t 1400 19.6 19.6 4.09

Fluxes 0.04 t 30 1.29 1.29 0.27

0 t 8900 13.35 13.35 2.78

0.01 t 600 3 3 0.63

1.33 GJ 12.5 16.63 16.63 3.47

Electricity 0.34 MWhr 90 4.59 26.01 30.6 6.38

Labour 0.35 Man hr 35 3.07 9.21 12.29 2.56

1 8 8 1.67

Interest 1 11.5 11.5 2.40

Total 27.16 452.45 479.61 100.00

Blast furnace route steel making cost

Factor Unit Unit cost Fixed Variable Total

Iron ore 1.44 t 62 88.97 88.97

1.44 t 20 28.7 28.7

0.52 t 128.5 66.69 66.69

0.52 t 19.5 10.12 10.12

0.16 t 325 52.65 52.65

0.16 t 5 0.81 0.81

Oxygen 80 m 3 0.08 6.4 6.4

Item$/unitSteelscrapScrapdeliveryPig iron /

DRIPig iron /DRIdelivery

Ferroalloys

ElectrodesRefractoriesThermalenergy

Depreciation

Item$/unit

Iron oretransport

Cokingcoal

Cokingcoal

transport

Steelscrap

Scrapdelivery



0.01 t 1400 19.6 19.6

Fluxes 0.52 t 30 15.63 15.63

0.01 t 600 6.6 6.6

1 13 3.25 9.75 13

-20 -20

-2.68 GJ 12.5 -33.5 -33.5

0.12 MWh 150 2.75 15.56 18.3

Labour 0.64 Man hr 35 5.6 16.8 22.4

40 40

Interest 44 44

Total 95.6 284.78 380.37

Therm Coal Iron Ore Electric

$/tonne $/ton C/dmtu $/000m3 C/KwH

2008 M1 98.3

106.1

140.6 369.7 385-400 6.39

2008 M2 141.4 140.6 369.7 390-405 6.38

2008 M3 126.7 140.6 369.7 490-510 6.54

2008 M4 131.8

113.9

140.6 428.4 510-530 6.64

2008 M5 142.7 140.6 428.4 570-580 6.8

2008 M6 171.2 140.6 428.4 635-660 7.4

2008 M7 192.9

122

140.6 517 630-640 7.78

2008 M8 169.7 140.6 517 385-390 7.63

2008 M9 160.7 140.6 517 240-245 7.35

2008 M10 115.7

129.1

140.6 576.7 220-225 7.23

2008 M11 98.8 140.6 576.7 205-210 7.04

2008 M12 84.3 140.6 576.7 230-235 6.88

2009 M1 85.7

137.1

101 576.7 270-275 6.9

2009 M2 80.8 101 520.9 200-205 6.98

2009 M3 65.4 101 412.9 195-200 6.84

2009 M4 68.1

143.4

101 309.6 220-230 6.78

2009 M5 69.1 101 309.6 220-225 6.89

2009 M6 76.5 101 309.6 230-235 7.18

2009 M7 79.1

151

101 244.4 245-250 7.11

2009 M8 77.7 101 222.5 320-325 7.17

2009 M9 72.5 101 222.5 285-290 6.99

2009 M10 76.1 101 232.2 260-265 6.67

Ferroalloys

Refractories

Othercosts

By-productcredits

Thermalenergy,net

Electricity

Depreciation

Year/Month

CokingCoal

NaturalGas

SteelScrap$/tonne



2009 M11 84.4

142.2

101 232.2 290-300 6.44

2009 M12 89 101 232.2 340-350 6.52

2010 M1 103.9

n/a

101 273.2 335-345 6.54

2010 M2 100.9 101 273.2 325-335 6.55

2010 M3 101.1 101 273.2 435-440 6.5

2010 M4 107.3 n/a 167 300.6 415-420 n/a

2010 M5 107.3 n/a 167 283.3 n/a n/a

Hot metal cost

Raw material 86%

Saleble steel

raw material cost 57.70%



Iron ore lump

Iron ore fines

Iron ore concentrate

Non coking coal

Coking coal

Natural gas

LPG

LDOHFO

Lime



Capacity MTPA 0.01 0.36



Capacity MPTA

Coil width mm

Coil ID mm

Coil wt MT

Line speed mpm

Thickness mm

Coil car

Decoiler

Entry support device

Width adjustor device

Straightening machineGauge table

Shearing machine

Run off table

Pneumatic discharge and stacker device

Unloading table

Pueumatic system

Electrical system with computer PLC program control

Hydraulic system



Uncoiler

Double cut shear

Bridle roll

Side trimmerFine masher

Entry loop tower

Deflector roll

Vulcan annealing furnace

Water cooling

Galvanizing equipment

Steering

X ray thickness measuring

Skin pass mill

Tension levellerChromate tank

Dryer

Marking machine

Exit loop tower

Flaw detector

Exit shear

EPC unit

Recoiler



Uncoiler

Press joining machine

Entry loop tower

Degreasing unit

Scotch bite unit

Grain refining unit

Drier

Back coater 1&2

Oven1Prime coater 1&2

Oven2

Drier 3

Top coater 1&2

Printer 172

Oven3

Drier4

Exit loop tower

Tension roll

Guard film laminatorShear



Pay off real

Scale breakingEntry shear

Welder

Bridle roller

Entry looper car

Hot water dip tank

Acid pickling

Cascade rinse

Drier

Exit looper

Side trimmerBridle roll

Drier

Exit shear

Mill housing

Coiler



Welder

Hot alkali dip cleaningElectrolytic cleaning

Hot water tank drier

Bridle roll

Shear

Skin pass mill

Pinch roll

Flattner

Shear

Slitter

Looping deviceBatch annealing furnace

Rewind



India World

Per capita consumption of steel in (2009) kg 47 190

Steel industry (directly and indirectly) CO2 emission 6%

Jan-07

1857

Steel industry was delicensed in 1991 1991

Steel industry was decontrolled in 1992 1992

India's Tata Steel made a successful$11.3 billion offer to buy European steelmaker Corus Group PLC.

Bulk production of steel began afterdevelopment of Bessemer converter byHenry Bessemer's in 1857.



1. Next to Aluminum, Iron is the most widely distributed and abundant metal, consist

2. The essential iron minerals which are commercially exploited are MAGNETITE (F

3. In addition certain important iron ores are composed to some extent of Hydrous ir

4. Even though the iron content (Fe) of the mineral is a important factor, an equally i

5. Specific energy consumption/ TCS -6.5Gcal

The averag

Among the elements composing the crust of the earth, iron

Continuous casting accounts for 95% of steel production in t

Continuous casting technology started in late 1950s

During mining of iron ores run of mine (ROM) is crushed an



ing about 4.6% of the Earth’s crust.

e3O4) containing 72.4% Fe, HAEMATITE (Fe2O3) containing 70% Fe, Goethite [FeO(OH)] containing 68.5% Fe, LIMONITE a

on silicates, such as Chamosite, Thuringite, Greenalite and Glauconite.

mportant issue is type and proportion of gangue material present in the said mineral which may influence the metallurgical ope

Fe) exists in the largest quantity next to oxygen (O), silicon (Si), and aluminium (Al).

he world

screened for sizing, producing both iron ore fines (IOF, size minus 10 mm) as well as cali



nd the carbonates namely SIDERITE, CHALYBITE or SPATHIC IRON ORE, containing 48.3% Fe. Less important ores are th

rations because of process of fluxing involved in separation of Iron metal from the gangue in the furnaces.

rated lump ore (CLO, size 10-30 mm).



e Sulphides, Pyrite, (FeS2), Pyrrhotite (Fe1-nS) and the complex oxide like Franklinite (FeZnMn) (FeMn)2O4.



Process unit Function

Pickling line

Skin Pass Mill

Temper Mill

CR Slitter

To inspect the coil aginst any defect.

Sl.No.

To remove the oxides and mill scalefrom strip surface to enable furtherreduction of thickness to desired levelin cold rolling mill.

Cold RollingMill

To reduce the thickness of the pickledhot rolled coil to desired level.

ElectrolyticCleaning line

To remove the oil from the surface of the cold rolled coil to produce brightand corrossion free steel

BatchAnnealingFurnace

To obtain desired properties in thefinished cold rolled coil.

ContinuousannealingLine

To obtain desired properties in thefinished cold rolled coil.

To obtain desired surface finish andimprove flatness and suppresses theyield point elongation

To enhance the physical propertiesthrough cold forming of the steelproduct in the bite of the work roll

To cut the CR coil length wise and toremove side trims to obtain uniformwidth throughout the coil as perrequirement.

Cut ToLength

To cut the slitted coil to desired lengthas per requirement

CoilInspectionLine



Galvalume

Plate Mill

Hot Strip Mill

Skelp Mill

Section mill

Hot DipGalvanizingLine

To provide protective zinc coating tothe cold rolled coil.

To provide protective zinc andaluminium coating to the cold rolledcoil.

ColourCoating Line

To provide protective colour coating tothe cold rolled coil.

Electrolytictin &Chromiumplating Line

To provide protective tin or chromiumcoating to the cold rolled coil.

To produce plate of varying thicknessby hot rolling of slab.

To produce strip of varying thickness inthe form of coil by hot rolling of slab.

To produce strip of varying thicknessand narrow width in the form of coil by

hot rolling of billet.Merchantmill

To produce plain or TMT rebar for billetby hot rolling

To produce joist,channel,angle frombloom by hot rolling



SMS-II 2 mt

SMS-III 4 mt

bsl angul units

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