BLAST FURNACE IRDNMAKING

Transcription

1 BLAST FURNACE IRDNMAKING Based on lectures delivered in the Advanced Course on "Blast Furnace Ironmaking' held at Jamshedpur February TATA STEEL EDITED BY S S GUPTA AND AMIT CHATTERJEE

2 Contents PREFACE 1. IRON ORE RESOURCES OF TATA STEEL AND ITS QUALITY CONTROL A W Pradhan, Tata Steel, Jamshedpur Introduction 1 History 2 Genesis 2 Proving the Deposit o j*^»*» Reserves 2 Quality 2 Petrography of Iron Ores 3 Comparison between Noamundi and Joda Deposits 4 Ore Preparation 4 Future Planning 6 Conclusions 6 2. BENEFICIATION OF IRON ORES Ch V G K Murty and R Sripriya, Tata Steel, Jamshedpur 2.1 Introduction 2.2 Mineralogical Aspects 2.3 Beneficiation Methods 2.4 Iron Ore Beneficiation at Tata Steel COKING COAL : ORIGIN, MINING AND QUALITY CONTROL S K Lonial, Tata Steel, Jamshedpur Introduction 17 Origin and Characteristic Features of Indian Coals 17 Tata Steel's Coking Coal Captive Sources 18 Quality Control 18 Quality of Coal Despatched Imported Coal and its Quality Conclusions COAL BENEFICIATION R Sripriya and V G. K Murty, Tata Steel, Jamshedpur 4.1 Introduction 4.2 Laboratory Sink-Float Tests 4.3 ' Washability Curves 4.4 Coal Washing Coarse Coal 4.5 Coal Washing Fine Coal 4.6 Scenario at Tata Steel 4.7 Conclusions

3 5. TECHNIQUES OF COAL PRE-CARBONISATION : A REVIEW Amit Chatterjee, Tata Steel, Jamshedpur 5.1 Introduction Preheating of Coal Briquette-Blending of Coal Selective Crushing of Coal ; Binderless Briquetting of Coal Stamp-Charging of Coal Conclusions EXPERIENCES IN THE STAMP-CHARGED BATTERY AT TATA STEEL B K Singh, K C Banerjee and A S Dhillon, Tata Steel, Jamshedpur 6.1 Introduction Stamped-Charged Battery- Learning Period Performance of Stamp- Charged Battery Appropriate Technology under Indian Conditions Conclusions SINTERING TECHNOLOGY IN TATA STEEL S G Bapat, Tata Steel, Jamshedpur 7.1 Introduction Operation at Ore Curshing and Sintering Plant Present Capacity Bedding and Blending Plant Sinter Plant No Future Trends Conclusions TESTING OF IRON OXIDES AND THEIR SELECTION FOR DIFFERENT APPLICATIONS IN IRONMAKING A K Jouhari, R K Sahoo and H S Ray, Regional Research Laboratory, Bhubaneswar 8.1 Introduction The Iron Blast Furnace Physical Tests.: Chemical Tests Mineralogical Characterisation Thermal Analysis Metallurgical Tests Discrepancy in Tests and Correlation Some Examples Conclusions.'. 80

4 9. TESTING AND CHARACTERISATION OF SINTER FOR BLAST FURNACES K N Gupta, National Metallurgical Laboratory, Jamshedpur 9.1 Introduction Desirable Qualities of Sinter Conclusions BLAST FURNACE IRONMAKING AT TATA STEEL L M Chatterjee, Tata Steel, Jamshedpur 10.1 Introduction The Eighties a Decade of Progress Burden Quality the First Step Design and Equipment Modifications Operating Philosophy Maintenance Coal Injection Instrumentation and Models Future Trends at Tata Steel Conclusions RAW MATERIALS FOR BLAST FURNACES : IMPLICATIONS AND OPPORTUNITIES FOR TATA STEEL Ashok Kumar and T Mukherjee, Tata Steel, Jamshedpur 11.0 Introduction Impact of Raw Material Quality Objectives for Ironmaking Facilities Uniformity an Opportunity : Coal Iron-Bearing Materials Fluxes and Alkali Loading..' Conclusions HIGH TEMPERATURE PROPERTIES OF IRON BEARING MATERIALS AND THEIR INFLUENCE ON BLAST FURNACE PERFORMANCE P K Roy, U N Mishra and S Pal, Research and Development Centre for Iron and Steel, SAIL, Ranch! 12.1 Introduction Softening and Melting Phenomena Ill 12.3 Application of Test Results : Effect of Different Factors on Softening and Melting Properties Practical Application of Test Results in Blast Furnace Operation Work Done at RDCIS, SAIL Application of Laboratory Findings Conclusions 119

5 13. BLAST FURNACE BURDEN DISTRIBUTION : MODEL STUDIES Anjan De, Tata Steel, Jamshedpur 13.1 Introduction Model Studies with Movable Throat Armour Development of Mathematical Model to Estimate Burden Distribution Model Study for'g'blast Furnace with PW-BLT Charging System Conclusions MANAGING THE ALKALI PROBLEM A K Das, Tata Steel, Jamshedpur 14.1 Introduction : The Alkali Cycle Inside a Blast Furnace Properties of Raw Materials Affected by Alkali Adsorption Fundamentals of Alkali Management Steps Taken at Tata Steel, Results Achieved Conclusions OPTIMISATION OF BLAST FURNACE SLAG REGIME S S Gupta, Tata Steel, Jamshedpur 15.1 Introduction Basic Requirements of Slag for Normal Operation of a Blast Furnace Liquidus Temperature Viscosity of Slag : Desulphurisation Capacity of Slags Alkali Removal Capacity of Slags Slag Alumina Conclusions COAL INJECTION IN BLAST FURNACES : THEORETICAL CONSIDERATIONS B D Pandey, Tata Steel, Jamshedpur 16.1 Introduction Coal Quality Coal Combustion Coal Injection Mode-Position of Coal Lance in the Blow Pipe Rate of Coal Injection Heat Compensation Surplus Oxygen Coefficient Replacement Ratio Effect of Coal Injection Considerations at Tata Steel 155

6 16.11 Ultra High Rates of Coal Injection Conclusions, COAL INJECTION INTO BLAST FURNACES : INJECTION EQUIPMENT G K Taneja, Tata Steel, Jamshedpur 17.1 Introduction PCI System at Tata Steel Safety Precautions Other Coal Injection Systems Conclusions :! MODEL STUDY OF HEARTH DRAINAGE IN A BLAST FURNACE A K Roy, S Govindarajan and Amit Chatterjee, Tata Steel, Jamshedpur 18.1 Introduction Study of the Drainage Phenomenon Objectives of the Tata Steel Study Experimental Observations Results and Discussion.' Conclusions STUDY OF HOT METAL DRAINAGE IN THE HEARTH OF AN OPERATING BLAST FURNACE USING RADIOTRACERS A S Prasad, Tata Steel, Jamshedpur 19.1 Introduction : 1 /I 19.2 Theoretical Considerations Experimental Details Discussion Conclusions MATHEMATICAL MODELS OF BLAST FURNACES S K Ajmani and S S Gupta, Tata Steel, Jamshedpur 20.1 Introduction Model for Determination of Top Gas Analysis Model for Prediction of Coke Rate, Blast Rate and Top Gas Rate -. : Burden Distribution Model Conclusions BLAST FURNACE HOT METAL QUALITY : MECHANISM, PREDICTION AND CONTROL B N Singh, Indian Iron and Steel Company Limited, Burnpur and Amit Chatterjee, Tata Steel, Jamshedpur 21.1 Introduction Silicon Content in Hot Metal : Manganese Content in Hot Metal.-., Control of Sulphur in Hot Metal : Conclusions 190

7 22. PRETREATMENT OF HOT METAL A S Venkatadri, R & D Centre for Iron & Steel, Steel Authority of India Limited, Ranchi 22.1 Introduction Objectives of Pretreatment Need for Hot Metal Pretreatment Physico-Chemical Aspects Desiliconisation Pretreatment Processes Refractories Status of Hot Metal Pretreatment India A Strategy for India : Future Tasks and Prospects IRONMAKING THROUGH TATA KORF'S MINI BLAST FURNACE P Jayaram, V K Lakshmanan and P K Date, Tata Korf, Jamshedpur 23.1 Introduction Mini Blast Furnace Process! Significance of Mini Blast Furnaces in India Tata Korf Mini Blast Furnaces: Basic Plant and Equipment ' The Tata Korf MBF Compared to the Conventional Blast Furnace Performace of the MBF Economics of the MBF : Low-Energy Input Achieved by Coke Economy High-Energy Utilisation MBF as the Basis of a Mini Steel Plant 216