Table of Contents

    • 52

    • Experience of Blowing-In and Production Ramp-Up of the Largest Blast Furnace of India

      In 2004–2005, Tata Steel committed to setting up a 6-million-ton integrated steel plant at Kalinganagar Industrial Complex, Duburi, in the Jaipur district of Odisha. The steel works was planned to be established in two modules of 3 million tons each. The first phase of integrated crude steel facility was comprised of one sinter plant of 5.75 million tons in collaboration with Outotec GmbH, one blast furnace of capacity 3.24 million tons per annum (4,330 m3) with Siemens VAI as the technology supplier, and a coke plant with 1.5 million tons per annum rated capacity with two batteries of 88 ovens designed by ACRE, China. Notable commissioning issues were presented during execution of this greenfield project along with unskilled workforce, quality and supply of raw materials in integrated start-up with coke and sinter, stabilization of the downstream units, and unavailability of locational support services. Additionally, significant equipment-related challenges included the collapse of a stove checker support during erection, dislodging of the stove’s silica refractory during heating, hot blast main failure, programmable logic controller server outage leading to forced shutdown, etc. This paper elucidates the journey in overcoming the above-mentioned challenges, engendering a successful blow-in along with measures taken to ramp production up to a rate 15% above the designed capacity.

    • 74

    • Environment Defines Productivity: Emission Con-trol System Modification Using Fluid Dynamic Study of Building Ventilation at Sinobras Meltshop, Brazil

      Fluid dynamic modeling was used to develop solutions for eliminating fugitive emissions from the meltshop building and to increase the annual liquid steel production. Secondary emission control system performance was simulated by an inverted 1:100 scale Plexiglas® model of the entire meltshop, utilizing the negative buoyancy effects of saline solution in water. Test results show that with the installation of the additional scavenger exhaust at the east side of the meltshop and an overall increase of the system capacity by 50% allows for the elimination of fugitive emissions and increase of annual production by 50%.

    • 84

    • SDI Heartland Temper Mill Stand Motor and Drive Replacement

      Steel Dynamics Inc. – Flat Roll Group Heartland Division had a problem on its temper mill. The stand bottom motor was on the verge of failure. Did it make sense to replace the DC motor with another DC motor when the drive was obsolete? Did it make sense to replace with an AC motor and drive for a mill that was all DC? What happens if a new AC motor and drive are ordered and the DC motor fails in the interim? These are the questions that were faced. The paper will address the alternatives in detail, the challenges that were encountered, and how it worked out.