Overview of technological breakthrough & in-house

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Overview of technological breakthrough & in-house
innovations in JSW Steel Ltd, Dolvi works
Mrigandra Singhai, Harsha V Sharma, Pradip K Patra, Alok Chandra
09/25/14
Contents
Overview of JSW Steel Dolvi Ltd.
Breakthroughs in Iron making area
Breakthroughs in CONARC furnace
Breakthroughs in CSP caster
Breakthrough in products
09/25/14
Overview of JSW Steel Dolvi Ltd.
JSW Steel Ltd, Dolvi Works
3
3
Location
JSW Steel Ltd, Dolvi Works
44
DOC- 1994
A Journey Begins at Dolvi
JETTY - 10 MTPA
DOC- 1994
SIP - 1.6 MTPA
DOC- 1998 Ph1, 2005 Ph2
DOC- 2000
DOC- 2005
BF - 2.0 MTPA
SINTER - 2.8 MTPA
DOC- 1998 Ph1, 2003 Ph2
DOC- 2013
Dec’ 2010 Setup
A Journey Begins at Dolvi
Feb-2014
Coke Oven – 1
MTPA
DOC- 1994
SIP - 1.6 MTPA
DOC- 1998 Ph1, 2005 Ph2
DOC- 1994
Feb-2014
Pellet – 4 MTPA
JETTY - 10 MTPA
DOC- 2000
DOC- 2005
BF - 2.0 MTPA
SINTER - 2.8 MTPA
Mar-2013
DOC- 1998 Ph1, 2003 Ph2
CPP – 55MW
EAF – 4.5 MTPA
CSP - 3.3 MTPA
6
6
Process Flow at Dolvi
Coal
Coke
Iron Ore & Fluxes
Pellet Plant
4 MTPA
Coke Oven
1 MTPA
Sinter Plant
2.8 MTPA
NG
LCP
2X300 TPD
Sponge Iron Plant
1.6 MTPA
Blast Furnace
2 MTPA
DRI
Cal. Lime
SMS (Con-Arc)
4.0 MTPA
LCP
600 TPD
Hot Metal
Liquid Steel
BF Gas
Iron Ore
Power Plant
55 MW
Thin Slab Caster
Two Strand
3.3 MTPA
Slab
Existing Facilities
Hot Strip Mill
3.3 MTPA
HRC
Projects Commissioned
Railway
Siding
77
Major Facilities at Dolvi
S.N.
Plant /Facility
Rated
Capacity
Year of
Special Features
Commissioni
ng
1994
450m long jetty with four unloading
cranes
1994
Gas based single module, being
modified for usages of COG
1
Captive - Jetty
10 MTPA
2
Sponge Iron
Plant
1.6 MTPA
3
Blast Furnace
2.0 MTPA
2000
10.8m hearth dia., 2 tap holes, 5MW
GET, two SGP units, Productivity 2.6
4
Sinter Plant
2.80 MTPA
2005
204m2 bed area, WHR boiler, Five
ESPs, Productivity 1.61
5
Hot Strip Mill
3.3 MTPA
Ph1-1998,
Ph2- 2003
6
Lime Cal. Plant
1200 TPD
7
Power Plant
53.5 MW
8
Railway Siding
1.0 MTPA
9
Pellet Plant
4.0 MTPA
10
Coke Oven
1.0 MTPA
Combination of CONARC & CSP, Final
strip thickness 1-20mm & width 9001550mm
2000& 2013 Three units, 2x300 from MERZ &
1X600 From Cimprogetti
Mar’2013 BF gas fired, power generation
surpassed its rated capacity
June’2013 3500 m Long Track at use for dispatch
of HR coils
Feb’2014 464m2 travel grate
Feb’2014
5.5m height, Stamp charged , 2x55
ovens & recovery type
8
Facilities at JSW Steel Dolvi
JSW Steel Ltd Dolvi is the first Asian plant having CONARC for steel making & first
Indian Plant having thin slab caster (CSP) technology for HR coils.
9
9
Technology Comparison
Route 1
BF-BOF route produces
Hot Strip
Mill
Thick Slab of 200-250 mm
Sinter
BF-BOF
Coiling
Stand
Slab
Caster
Iron Ore
Coke
Blast
Furnace
LD
(BOF)
HR Coils
Reheating
Furnace
Conventional
Routes
Roughing
Mill
Slab
Caster
DRI
Plant
High
Energy
Consumpti
on
High
Energy
Loss
Hot Strip
Mill
EAF
Pellets
DRI-EAF
Route 2
Coiling
Stand
Natura
l Gas
HR Coils
Iron
Ore
Route 3
Scrap
DRI-EAF route produces
Thick Slab of 200-250 mm
CSP Route
`
Reheating Roughing
Furnace Mill
Flexible
Pellets
JSW, Dolvi's Unique Steel Making Process
Scra
p
Twin Shell
EAF
Coke
Thin
Slab
Caste
r
High
pressure
descaler
Blast
Furnace
Iron
Ore
Natural
Gas
Energy
Efficient
Coiling
Stand
TF
Ladle
Furnace
DR Plant
Hot
Strip
Mill
Continuous process
VOD
Plant
HR Coils
CONARC – Thin Slab Casting
casts 100% continuously Thin slab
of 50-68 mm without re-heating
10
Presence of JSW
CRM II
11
Breakthroughs in Iron making area
Blast Furnace



Existing blast furnace was brought in from
Germany where it was operational for around
7 years
In 2000, installed capacity 1.8 MTPA with a
total volume of 2581m3 and working volume
2151m3
The current furnace capacity is 2.0 MTPA.
The maximum productivity achieved is 3.07
ton/m3/day
Producti Producti
Date
on
vity
30-03-2010
6607
3.07
01-05-2010
6190
2.88

Fuel
Rate
500
504
Coke
289
272
Nut
Coke
45
54
Coal
166
177
Sinter
68
80
Pellet
27
13
Ore
5
7
India’s First, NG co-injected with coal in BF
09/25/14
12
NG Injection in Blast Furnace
1.
Oxy-Coal injection was used in the year
2005
2.
In 2009 co-injection of NG along with coal
injection was introduced
3.
First in the country with complete in-house
design.
4.
It helped in reduction of carbon emissions
as well as better control of furnace
operations.
09/25/14
13
Advantages of NG
1.
2.
3.
4.
5.
6.
09/25/14
High Calorific value. Coke replacement ratio is more than 1
Ease of handling and environment friendly.
Helps in smooth operation of blast furnace due to high
concentration of hydrogen in tuyere gas.
Reduced Sulphur input to furnace.
More throughputs due to increased Oxygen input.
Lower Bosh slag basicity which helps in stable and
productive operations as gangue input is reduced.
14
Breakthroughs in CONARC furnace
Steel Making

Asia’s First CSP Plant in combination with CONARC Process

Offers operational flexibility of operating with 100% hot metal &
100% solid charge
09/25/14

Elimination of a process step with CSP

Lower operation cost

Lesser carbon footprints

Compact process and lower cycle times
15
Triple Lance in CONARC
1.
2.
3.
4.
5.
When using 100% hot metal, CONARC
is not as efficient as LD
In-house development for this
breakthrough modification in EAF by
using multiple lances instead of one
single lance
The blowing strength and the penetration
depth of the oxygen jet in CONARC is
low as compared to LD converters
CONARC has lower height to diameter
ratio typically 1, whereas it is generally in
the range of 1.5-1.7 for LD converters
This restricts the oxygen top lance flow
rate in 100% Hot Metal (HM) heats
(CONARC) to 180 Nm3/min, whereas it
is in the range of 350 - 400 Nm3/min in
LD converters.
09/25/14
16
Analysis of the Problem
The Approach Area of Metal Bath Surface is in Direct Contact with the
Oxygen Jet will leading to higher rate of Reaction between the Metal
droplets & the Slag layer, as Achieved in LD Converter.
17
17
Benifits
09/25/14
1.
By using a triple lance system in CONARC furnace, the
approach area of metal bath surface is increased, leading
to higher rate of reaction between the metal droplets and
the slag layer.
2.
It has improved %Yield, reduced cycle time, reduced
jamming of roof and elbow, and increased refractory life.
18
Contents
Brief introduction of the organization
Breakthroughs in Iron making area
Breakthroughs in CONARC furnace
Breakthroughs in CSP caster
Breakthrough in products
09/25/14
19
CSP Benchmarking
Highest steel in mould time:

A high degree of caster
utilization achieved by
minimizing the sequence
break time

Reduced Caster breakouts,
aborts

Reduced upstream and down
stream delays
09/25/14
20
High Yield
 Tundish skull reduced
 Bottom design of tundish
modified
 This allowed the maximum
liquid steel into mould and keep
the skull in tundish during tail
out procedure.

 This facilitated effective metal
slag separation thus improved
yield.
09/25/14
21
Sequence length improvement
• Reverse SEN ramping has been introduced which reduced
the SEN erosion.
• SEN ramping time has been increased step by step
• Re design of New SEN according to our casting conditions
• Mixing of different grade chemistry by proper planning to
reduce number of sequences.
09/25/14
22
Benchmarking in speed
Average casting speed
is the highest among
various CSP units.
09/25/14
23
Major initiates for high casting speed

Metallurgical length extension (7.9 to 9.4m)

Close chemistry control: A close chemistry control avoids
variation in speed which may lead to breakout

Lower Carbon values: Speed in inversely proportional to
C & S levels in steel.

Maintaining super heat in narrow range.

Optimization of casting powders & copper plate for high
casting speed
09/25/14
24
Contents
Brief introduction of the organization
Breakthroughs in Iron making area
Breakthroughs in CONARC furnace
Breakthroughs in CSP caster
Breakthrough in products
09/25/14
25
Stabilization of Boron micro-alloyed grade
steel in CSP
• B- 10-20 ppm level to improve the
work hardening index
• Boron has an adverse effect on hot
ductility
Edge crack
• Boron grades are extremely difficult
to cast in CSP
• Transverse corner cracks (Edge
cracks)
09/25/14
26
• Detailed statistical analysis
• Study of hot ductility behaviour
with boron addition was done
using Gleeble
• Parameters optimized:
– Temperature: to avoiding poor
ductility zone at bending
– Mn/S ratio
– B/N ratio to change the size &
distribution of BN precipitates
Similar optimization done for Nb microalloyed steels which is highly
prone to transverse corner cracks
09/25/14
27
Stabilization of micro-alloyed grade of steel
 CSP technology was originally developed for mass production of CG/
CR grades
 Elimination of soaking pit, lower reduction ratio and shorter ROT puts
limitations in producing value added grades
 Effective utilization of Nb, V & Ti has helped the company to cater the
demanding needs of auto customers in all the property ranges
 Apart from lower cost due to various in built technological features,
another advantage with CSP products in leaner chemistry for a given
set of property requirements.
 Lower Carbon equivalent gives this steel better weld ability and leaner
chemistry results in lower Ferro alloy cost.
09/25/14
28
Development of ALM650/ ALM700 grade
Ref Grade: EN 10149_2_2005 S650MC
Typical Application: Applications includes Truck Chassis, Dumper body, Cranes and
Earth Moving Machines
Truck Chassis
Earth Moving m/c
29
ALM650 - Specification
Chemistry
Mechanical Properties
30
Actual Chemical & mechanical Properties
Chemistry
Mechanical Properties
31
Actual Chemical & mechanical Properties
HER
Impact Properties
Impact Energy in J (Full Size)
32
Development of coil break free EDD grade with
Nb route
 Coil break is a common
problem in low C, low Mn
EDD grades
 Yield point elongation which
is caused by presence of
free Nitrogen in steel
 Addition of Boron/Ti and skin
pass are some of the
solutions
09/25/14
33
Mechanical Parameters
Coil
Breaks
Reduces
Non availability
of free
dislocations
Causes
Causes
No driving force for
generation of new
dislocations
Causes
Reduces
•Increase uncoiling
speed
•Increase tensile load
during uncoiling
Causes
Slow speed of
un-coiling
34
Inadequate
Tensile load
during uncoiling
Metallurgical Parameters
Coil
Breaks
Reduces
Yield Point
Elongation
Causes
Causes
Free Nitrogen
Causes
Reduces
•Add B or other
nitride forming
elements
•Increase CT above
640
Causes
Low Coiling
Temperature
35
Absence of Nitride
forming elements
JSW Steel, Dolvi works solved this issue with Nb
addition in small quantity (0.04-0.06%).
36
Nb- Bearing Grades - SH29
Ref Grade: IS 1079_2009 HR2/ HR3/HR5
Typical Application:
Pipes & Tubes
Hand Brake Arm
Drum Closure
Different Coupler
37
Development of API X70 up to 12 mm with DWTT
at -40C
 Limitation of reduction ratio in CSP
 Limitation in API grades for low
temperature impact properties
 Carefully designed chemistry & high
pressure compact cooling
implemented
 Developed API X70 with good DWTT
at - 40oC
09/25/14
38
Collaborative research with IIT Mumbai
39
From research at IIT to implementation in mill
40
40
Development of DP590 grade
Ref Grade: IS 1079_2009 HR5_DP590
Typical Application: Wheel Rim and Wheel Disc for Automobile
41
A short ROT of thin slab caster poses a limitation on cooling path for dual
phase microstructure development. To counter this, a two stage cooling
process was designed to give desired cooling required for microstructure
and property development.
42
42
Phase 4: Engineering modification:
BEFORE
AFTER
43
43
YS (MPa)
UTS
(MPa)
%El (in 80
mm GL)
‘n’ value
330-460
min 590
min 19
min 0.13
Results of initial
trial
385-485
>610
24
>0.17
0.62-0.70
After product
stabilization
340390*
>620
24
>0.17
0.55-0.62
Specification (as
per EN10346:2009)
YS/UTS
ratio
44
5.0 MTPA
Coal
Coke
Pellet Plant
4 MTPA
Coke Oven
1 MTPA
Sinter Plant
2.8 MTPA
Sponge Iron Plant
1.6 MTPA
NG
LCP
1200 TPD
Iron Ore & Fluxes
Blast Furnace
3.5
2 MTPA
MTPA
DRI
Cal. Lime
SMS (Con-Arc)
4.0 MTPA
5.0
Hot Metal
Liquid Steel
Billet Caster
1.5 MTPA
Thin Slab Caster
3.3 MTPA
Billet
55 MW
Power Plant
Slab
Hot Strip Mill
3.3 MTPA
Bar Mill
1.5 MTPA
Bars
2015 Setup
Sinter Plant
2.24 MTPA
BF Gas
Iron Ore
HRC
1 MTPA
Railway Siding
45
Thank You
46
46
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