Visakhapatnam Steel Plant Welcome Visakhapatnam Steel Plant Blast Furnace Dept. to

Blast Furnace Layout B H S GETS M C S T L R S GCP SGP S S Y SGP L R S Main Charging Conveyor (D2) Main Charging Conveyor (D1) T L R S BF-3 April 2012 GCP SGP S S Y SGP L R S P S Y Traffic Build A S O P C M S M S SMS

Visakhapatnam Steel Plant It has two Blast furnaces, one is Godavari and second is Krishna, both names are from important rivers of Andhra pradesh. Rated capacity of Blast furnace is 3.4 MT annually. At present both furnaces are producing at the rate of 4.0 MT annually by advancement and enhancement in the following thing Raw material quality Furnace technology and control Furnace availability by strengthening the facilities provided, skill ness and improvement in cast house technology. BF-3 is commissioned on 24th April 2012, it’s rated capacity is 2.5MT annually.

Normal Operating Parameters of V.S.P Blast Furnaces(working) Blast volume:5200Nm3/min Blast pressure:3.35 kg/cm2 Hot blast temp.:1000 0C Blast humidification 50 to 60 gms/NM3 O2 enrichment 1.65% Top pressure:2 kg/cm2 Top gas temp.:150 0C -250 0C Cast/day:12-15 Av. production:5600 ton/day

Raw Materials for Iron Making Sinter Iron Ore Coke Nut Coke Lime Stone/LD Slag Quartzite/Silica Bricks Mn Ore Iron Bearing Fuel Additives

SIMLIFIED FLOW CHART OF BLAST FURNACE IRON ORE PELLETS & FLUXES SINTER COKE AIR BLAST BLAST FURNACE FLUE DUST SLAG HOT METAL BF GAS EXCESS TO PCM TO SMS

DIFFERENT SECTIONS OF BLAST FURNACE Furnace proper including cast house Burden handling section Slag granulation plant & Slag handling conveyors Pigcasting machines Laddle repair shop Masses & Compounds shop Pig storage yard Slag storage yard

I Process Flow Diagram MCS S8 C6 S7 C5 S6 C4 Main Charging Conveyor BF Gas S6 C4 Met. Coke Sinter Main Charging Conveyor BF GAS GCP S5 C3 Dust Catcher Horizontal Conveyor S4 C2 Flue Dust S3 C1 Nut Coke Pig Storage Yard Slag Storage Yard Iron Ore S2 A3 S1 A2 Additives PCM A1 Li quid Slag Hot Blast Pigs SGP Hot Metal Granulated Slag MCS SMS

FURNACE I Some of the features: Circular cast house with cranes Four tapholes Cast house slag granulation Useful volume 3200m3 ; 12 m dia hearth PLC Controlled PW charging system Gas Expansion Turbine station for top gas recovery O2 Enrichment

Main Charging Conveyor BURDEN HANDLING SECTION I Incoming Conveyors Junction House SH-1 SH-2 Bunkers Screens BF Weigh Hoppers Main Charging Conveyor Horizontal Conveyor

Over View of Burden Handling Section b1/b2 conveyor: capacity: 2160 m3/hr Speed: 2 m/sec Width : 2000 mm D1/D2 Conveyor: Capacity: 2160 m3/hr Type: Steel cord Total No. of bins: 17 Sinter: 5 nos(2-735 m3 & 3-1165 m3) Iron Ore: 3 nos (950 m3) Coke: 6 nos (950 m3) Additives: 3 nos (400 m3) Material handled per day at BHS Coke : 6000 tons Sinter: 15000 tons Iron ore: 3900 tons Additives :150 tons

I SLAG GRNULATION PLANT Four process lines per furnace, two each on either side of the furnace PL#2/6 PL#3/7 TH#2/6 TH#3/7 BF SGP RHS SGP LHS TH#1/5 TH#4/8 PL#1/5 PL#4/8

PIG CASTING MACHINE I Four double Strand Pig casting machines with a capacity of 1700 tons/day/machine Performance Records: Highest Daily pouring : 6723 tons on 31.3.1993 Highest monthly pouring: 107463 tons for Mar’93 Water Spray Water Spray Pigs Pig Storage yard Pig Wagon Lime Spray

I LRS & TLRS Ladle fleet consists of 30 open top ladles of 140 tons capacity 16 TLCs of 300 tons capacity Lining Life: Open top 300 to 320 heats TLC 600 to 750 heats Ladle

MASSES AND COMPOUND SHOP I Products: Mudgun Mass Runner Mass Taphole frame Mass Hydrated Mass Raw materials Used: Coke Breeze Pitch Grog Silicon carbide Plastic Clay Bauxite Resin Wash oil

BLAST FURNACE PRODUCTS HOT METAL Analysis: C-4.3%, Si-0.40%, Mn-0.07%, S-0.036%, P-.09% SLAG Analysis: SiO2-35.0%, Al2O3-17.5%, CaO-36.0%, MgO-9.05%, FeO-0.39%, MnO-0.10, Basicity-1.03 To 1.04 GAS Analysis: CO-20.0 to 22.0%, CO2-19.0 to 21.0%, H2-2.0 to 3.0% Calorific value-700 to 740K.Cal/NM3

SPECIFIC CONSUMPTION PER TON OF HOT METAL SINTER - 1262Kg Iron Ore - 361Kg Fuel Coke - 493 Kg Nut Coke - 37 Kg Total Fuel- 530 Kg Air Blast - 1259cu.mts Oxygen - 20 to 23cu.mts Cost of production per ton of Hot metal till Jul’2011- Rs.20000 aprox.

I TECHNOLOGICAL IMPROVEMENTS Use of castables at Cast house runner systems Amano scope for monitoring burden profile and gas flow PLC for top charging and as well as for batching at BHS O2 Enrichment of Blast PLCs for stove automation PLCs for SGP operation

Features of BF-3

Basic data Annual rated capacity 2.5 mt Useful Volume 3814 m3 ; Working volume : 3230 m3 Hearth dia: 13 m ; No. of Tuyeres: 34

Main geometrical features Hearth diameter: 13.000 m Belly diameter: 14.770 m Throat diameter: 9.500 m Inner volume: 3814 m3 Working height: 25.9 m Working volume: 3230 m3 N° of tuyeres: 34 N° of tap holes: 4 Shaft angle 81° 24’47” Bosh angle 77° 22’17” Sump depth 2800 mm

Other Features Flat Cast house with full castable runners Copper cooling staves in high heat zone New generation parallel hopper bell less top PCI with O2 enrichment Hydraulic mudgun & Drilling machine Level -2 automation INBA slag granulation system Super micro pore carbon blocks in hearth area. Waste heat recovery Closed loop cooling system with soft water, water cooled hearth bottom. Latest instrumentation Profilometer Radar probes RTDS in cooling elements for heat flux measurement.

Thank you UTPAL KR. PARUI A.G.M(o) B.F(Works)