Overview of technological breakthrough & in-house innovations in JSW Steel Ltd, Dolvi works Mrigandra Singhai, Harsha V Sharma, Pradip K Patra, Alok Chandra

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

3 3

JSW Steel Ltd, JSW Steel Ltd, Dolvi WorksDolvi Works

Overview of JSW Steel Dolvi Ltd.

4 4

JSW Steel Ltd, Dolvi WorksJSW Steel Ltd, Dolvi Works

Location

A Journey Begins at Dolvi

EAF – 4.5 MTPAEAF – 4.5 MTPA

SIP - 1.6 MTPASIP - 1.6 MTPA BF - 2.0 MTPABF - 2.0 MTPA SINTER - 2.8 MTPASINTER - 2.8 MTPA

JETTY - 10 MTPAJETTY - 10 MTPA

DOC- 1994 DOC- 2000 DOC- 2005

DOC- 1998 Ph1, 2005 Ph2

DOC- 1994

CSP - 3.3 MTPACSP - 3.3 MTPA

DOC- 1998 Ph1, 2003 Ph2

DOC- 2013

Dec’ 2010 SetupDec’ 2010 SetupDec’ 2010 SetupDec’ 2010 Setup

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A Journey Begins at Dolvi

EAF – 4.5 MTPAEAF – 4.5 MTPA

SIP - 1.6 MTPASIP - 1.6 MTPA BF - 2.0 MTPABF - 2.0 MTPA SINTER - 2.8 MTPASINTER - 2.8 MTPA

JETTY - 10 MTPAJETTY - 10 MTPA

DOC- 1994 DOC- 2000 DOC- 2005

DOC- 1998 Ph1, 2005 Ph2

DOC- 1994

CSP - 3.3 MTPACSP - 3.3 MTPA

DOC- 1998 Ph1, 2003 Ph2

Feb-2014

Coke Oven – 1 MTPA

Feb-2014

Coke Oven – 1 MTPA

Feb-2014

Pellet – 4 MTPA

Feb-2014

Pellet – 4 MTPA

Mar-2013

CPP – 55MW

Mar-2013

CPP – 55MW

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Sinter PlantSinter Plant2.8 MTPA2.8 MTPA


Blast FurnaceBlast Furnace2 MTPA2 MTPA


Sponge Iron PlantSponge Iron Plant1.6 MTPA1.6 MTPA


SMS (Con-Arc)SMS (Con-Arc)4.0 MTPA4.0 MTPA


Thin Slab CasterThin Slab CasterTwo StrandTwo Strand3.3 MTPA3.3 MTPA

Thin Slab CasterThin Slab CasterTwo StrandTwo Strand3.3 MTPA3.3 MTPA

Hot Strip MillHot Strip Mill3.3 MTPA3.3 MTPA


Iron Ore Iron Ore & Fluxes

NG

DRI

Hot Metal

Process Flow at Dolvi

LCPLCP2X300 TPD2X300 TPD

LCPLCP2X300 TPD2X300 TPD

LCPLCP600 TPD600 TPD


Cal. Lime

Liquid Steel

Slab

HRC

Projects CommissionedProjects CommissionedProjects CommissionedProjects Commissioned

Existing Facilities Existing Facilities Existing Facilities Existing Facilities

Pellet PlantPellet Plant4 MTPA4 MTPA


Coke

8

S.N. Plant /Facility Rated Capacity

Year of Commissioning

Special Features

1 Captive - Jetty 10 MTPA 1994 450m long jetty with four unloading cranes

2 Sponge Iron Plant

1.6 MTPA 1994 Gas based single module, being modified for usages of COG

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

Combination of CONARC & CSP, Final strip thickness 1-20mm & width 900-1550mm

6 Lime Cal. Plant 1200 TPD 2000& 2013 Three units, 2x300 from MERZ & 1X600 From Cimprogetti

7 Power Plant 53.5 MW Mar’2013 BF gas fired, power generation surpassed its rated capacity

8 Railway Siding 1.0 MTPA June’2013 3500 m Long Track at use for dispatch of HR coils

9 Pellet Plant 4.0 MTPA Feb’2014 464m2 travel grate

10 Coke Oven 1.0 MTPA Feb’2014 5.5m height, Stamp charged , 2x55 ovens & recovery type

Major Facilities at Dolvi

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Facilities at JSW Steel Dolvi

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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.

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JSW, Dolvi's Unique Steel Making Process

Thin Slab Caster

BF-BOF

HR Coils

CoilingStand

Coke

Sinter

Iron OreBlast Furnace

Slab Caster

LD (BOF)

Hot Strip Mill

Roughing Mill

Reheating Furnace

Pellets

Iron Ore

Natural Gas

DRI Plant

HR Coils

Slab Caster Hot Strip

Mill

Roughing Mill

Reheating Furnace

DRI-EAF

EAF

HR Coils

High pressure descaler

TF

Continuous process

Pellets

Iron Ore

Natural Gas

Coke

Twin Shell EAF

Blast Furnace

Ladle Furnace

DR Plant

VOD Plant

Hot Strip Mill

CoilingStand

CoilingStand

Scrap

Scrap

BF-BOF route produces

Thick Slab of 200-250 mm

DRI-EAF route produces Thick Slab of 200-250 mm

CONARC – Thin Slab Casting

casts 100% continuously Thin slab

of 50-68 mm without re-heating

High Energy Loss

High Energy Loss

High Energy Consumption

High Energy Consumption

Energy Efficient

Conventional Routes

FlexibleCSP Route

Route 3

Route 1

Route 2

Technology Comparison

11

Presence of JSW

CRM II


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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

India’s First, NG co-injected with coal in BF

DateProducti

onProducti

vityFuel Rate Coke

Nut Coke Coal Sinter Pellet Ore

30-03-2010 6607 3.07 500 289 45 166 68 27 501-05-2010 6190 2.88 504 272 54 177 80 13 7

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.

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Advantages of NG

1. High Calorific value. Coke replacement ratio is more than 1

2. Ease of handling and environment friendly.

3. Helps in smooth operation of blast furnace due to high concentration of hydrogen in tuyere gas.

4. Reduced Sulphur input to furnace.

5. More throughputs due to increased Oxygen input.

6. Lower Bosh slag basicity which helps in stable and productive operations as gangue input is reduced.

14 09/25/14

Steel Making

Asia’s First CSP Plant in combination with CONARC Process

Offers operational flexibility of operating with 100% hot metal &

100% solid charge

Elimination of a process step with CSP

Lower operation cost

Lesser carbon footprints

Compact process and lower cycle times

15 09/25/14


Triple Lance in CONARC

1. When using 100% hot metal, CONARC is not as efficient as LD

2. In-house development for this breakthrough modification in EAF by using multiple lances instead of one single lance

3. The blowing strength and the penetration depth of the oxygen jet in CONARC is low as compared to LD converters

4. CONARC has lower height to diameter ratio typically 1, whereas it is generally in the range of 1.5-1.7 for LD converters

5. 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.

16 09/25/14

Analysis of the Problem

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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.

Benifits

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 09/25/14

Contents

Brief introduction of the organization



Breakthroughs in CSP casterBreakthrough in products

09/25/14 19

20 09/25/14

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

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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.

High Yield

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• 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.

Sequence length improvement

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Benchmarking in speed

Average casting speed is the highest among various CSP units.

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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

25 09/25/14

Contents

Brief introduction of the organization



Breakthroughs in CSP caster

Breakthrough in products

26 09/25/14

• B- 10-20 ppm level to improve the work hardening index

• Boron has an adverse effect on hot ductility

• Boron grades are extremely difficult to cast in CSP

• Transverse corner cracks (Edge cracks)

Stabilization of Boron micro-alloyed grade steel in CSP

Edge crack

27 09/25/14

• 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

28 09/25/14

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.

Stabilization of micro-alloyed grade of steel

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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

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ALM650 - Specification

Chemistry

Mechanical Properties

31

Actual Chemical & mechanical Properties

Chemistry

Mechanical Properties

32

Actual Chemical & mechanical Properties

HER

Impact Properties

Impact Energy in J (Full Size)

33 09/25/14

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

Development of coil break free EDD grade with Nb route

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Coil Breaks

Coil Breaks

Non availability of free

dislocations

Non availability of free

dislocations

CausesCauses

No driving force for generation of new

dislocations

No driving force for generation of new

dislocations

Causes Causes

Causes Causes

Inadequate Tensile load

during uncoiling

Inadequate Tensile load

during uncoiling

Causes Causes

Slow speed of un-coiling

Slow speed of un-coiling

•Increase uncoiling speed

•Increase tensile load during uncoiling

•Increase uncoiling speed

•Increase tensile load during uncoiling

Reduces Reduces Reduces

Reduces

Mechanical Parameters

35

Coil Breaks

Coil Breaks

Yield Point ElongationYield Point Elongation

CausesCauses

Free Nitrogen Free Nitrogen

Causes Causes

Causes Causes

Absence of Nitride forming elementsAbsence of Nitride forming elementsCauses Causes

Low Coiling TemperatureLow Coiling Temperature

•Add B or other nitride forming elements

•Increase CT above 640

•Add B or other nitride forming elements

•Increase CT above 640

Reduces Reduces Reduces

Reduces

Metallurgical Parameters

36

JSW Steel, Dolvi works solved this issue with Nb addition in small quantity (0.04-0.06%).

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Nb- Bearing Grades - SH29

Ref Grade: IS 1079_2009 HR2/ HR3/HR5Typical Application:

Pipes & Tubes Drum ClosurePipes & Tubes

Hand Brake Arm Different Coupler

38 09/25/14

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

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Collaborative research with IIT MumbaiCollaborative research with IIT Mumbai

40

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From research at IIT to implementation in mill

41

Development of DP590 grade

Ref Grade: IS 1079_2009 HR5_DP590

Typical Application: Wheel Rim and Wheel Disc for Automobile

42

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.

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Phase 4: Engineering modification:

BEFORE

AFTER

44

YS (MPa)UTS

(MPa)%El (in 80 mm GL)

‘n’ valueYS/UTS

ratio

Specification (as per EN10346:2009) 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

340-390*

>620 24 >0.17 0.55-0.62

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Thin Slab CasterThin Slab Caster3.3 MTPA3.3 MTPA

Thin Slab CasterThin Slab Caster3.3 MTPA3.3 MTPA



Iron Ore Iron Ore & Fluxes

NG

DRI

Hot Metal

5.0 MTPA



Cal. Lime

Liquid Steel

Slab

HRC



Coke

Coke OvenCoke Oven1 MTPA1 MTPA

Coke OvenCoke Oven1 MTPA1 MTPA

Coal

1 MTPA1 MTPARailway SidingRailway Siding

1 MTPA1 MTPARailway SidingRailway Siding

BF

Gas

55 MW 55 MW Power PlantPower Plant

55 MW 55 MW Power PlantPower Plant

Blast FurnaceBlast Furnace3.5 MTPA3.5 MTPA

Blast FurnaceBlast Furnace3.5 MTPA3.5 MTPA

Sinter PlantSinter Plant2.24 MTPA2.24 MTPASinter PlantSinter Plant2.24 MTPA2.24 MTPA



Billet CasterBillet Caster1.5 MTPA1.5 MTPA

Billet CasterBillet Caster1.5 MTPA1.5 MTPA

Billet

Bar MillBar Mill1.5 MTPA1.5 MTPA

Bar MillBar Mill1.5 MTPA1.5 MTPA

Bars

2015 Setup2015 Setup2015 Setup2015 Setup

46 46

Thank You

Documents

Overview of technological breakthrough & in-house innovations in JSW Steel Ltd, Dolvi works Mrigandra Singhai, Harsha V Sharma, Pradip K Patra, Alok Chandra