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New JSW Blast Furnace Features Siemens VAI Cyclone Separator

02/23/2009 - Siemens VAI Metals Technologies reports the successful commissioning of JSW Steel’s Blast Furnace No. 3 at Toranagallu Steelworks, which features the first application of a Siemens-developed cyclone separator in the gas cleaning system.

Siemens VAI Metals Technologies reported the recent successful commissioning of JSW Steel’s Blast Furnace No. 3 at the company’s Toranagallu steelworks.
 
Equipped by Siemens VAI, the new blast furnace—JSW Steel’s third Blast Furnace at Vijayanagar Works—has a 4,019-m3+ internal volume and a nominal annual capacity of 2.8 million tonnes of iron, making it the largest blast furnace existing in India today. The new blast furnace increases the Vijayanagar Works’ production capacity to around seven million tonnes of steel per year.
 
Siemens VAI’s scope of supply and services included plant engineering and the supply of diverse core components, including hot-blast stoves and environment control systems such as top gas recovery, waste gas cleaning, and dedusting of the casthouse and stockhouse. Siemens also provided slag granulation, furnace cooling and pulverized coal injection equipment, as well as casthouse equipment including all hydraulic tap-hole drills and clay guns. Siemens also supplied its Simetal BF VAiron process control system, which will work with associated process optimization systems to optimize furnace operation and fuel rates.
 
The new Blast Furnace No. 3 employs a state-of-the-art gas cleaning system that features the first application of a Siemens-developed cyclone separator. The two-stage gas cleaning plant will allow the top gas to be utilized for heating purposes in other parts of the integrated steelworks. In the unit’s first stage, the cyclone removes dust containing iron (which can then be re-used for iron production), enabling the recovery of up to ten tonnes of iron-laden dust per hour. Siemens’ new cyclone enables flexible control of the dedusting process, optimizing iron recovery and preventing successive concentration of heavy metals such as zinc, which can reduce the useful life of the refractory lining.
 
This project is the latest in a series of orders JSW Steel has awarded to Siemens for its Toranagallu location. Previously awarded projects have included two Corex plants, a continuous caster and the expansion of a hot strip mill.
 
JSW Steel Ltd., belonging to JSW group, is part of the US $ 8 billion O P Jindal Group, one of the lowest-cost steel producers in the world. The group has diversified interests in Mining, Carbon Steel, Power, Industrial gases, Port facilities, Aluminum, Cement, and Information Technology. JSW Steel Limited is engaged in the manufacture of flat and long products, including hot and cold rolled coils, galvanized products, and auto-grade / white goods-grade CRCA Steel, Bars and Rods.
 
Incorporated in 1994, it has grown to US $ 3 billion in little over a decade. JSW Steel Limited has the largest galvanizing and color coating production capacity in the country and is the largest exporter of galvanized products with presence in over 74 countries across five continents.
 
The Siemens Industry Sector (Erlangen, Germany) is a leading international supplier of production, transportation, building and lighting technologies. The Sector consists of six Divisions: Building Technologies, Drive Technologies, Industry Automation, Industry Solutions, Mobility and Osram. With around 222,000 employees worldwide Siemens Industry posted in fiscal year 2008 a profit of EUR3.86 billion with revenues totaling EUR38 billion.
 
With the business activities of Siemens VAI Metal Technologies (Linz, Austria), Siemens Water Technologies (Warrendale, Pa.), and Industry Technologies (Erlangen, Germany), the Siemens Industry Solutions Division (Erlangen, Germany) is one of the world's leading solution and service providers for industrial and infrastructure facilities. Using its own products, systems and process technologies, Industry Solutions develops and builds plants for end customers, commissions them and provides support during their entire life cycle. With around 31,000 employees worldwide Siemens Industry Solutions achieved an order intake of EUR 8.4 billon in fiscal year 2008 (preliminary and unaudited).