09/25/14

Overview of technological breakthrough & in-house innovations in JSW Steel Ltd, Dolvi works

Mrigandra Singhai, Harsha V Sharma, Pradip K Patra, Alok Chandra

Contents

09/25/14 

Overview of JSW Steel Dolvi Ltd.



Breakthroughs in Iron making area



Breakthroughs in CONARC furnace



Breakthroughs in CSP caster



Breakthrough in products

3

Overview of JSW Steel Dolvi Ltd.

JSW Steel Ltd, Dolvi Works

3

Location JSW Steel Ltd, Dolvi Works

4 4

DOC- 1994 DOC- 1994

A Journey Begins at Dolvi

JETTY 10 MTPA DOC- 2000 DOC- 2005 SIP - 1 .6 MTPA DOC- 1998 Ph1, 2005 Ph2 BF - 2.0 MTPA DOC- 1998 Ph1, 2003 Ph2 SINTER - 2.8 MTPA DOC- 2013

Dec’ 2010 Setup

EAF – 4.5 MTPA CSP - 3.3 MTPA

Feb-2014 Coke Oven – 1 MTPA DOC- 1994

A Journey Begins at Dolvi

DOC- 1994 Feb-2014 JETTY 10 MTPA DOC- 2000 Pellet – 4 MTPA DOC- 2005 SIP - 1 .6 MTPA DOC- 1998 Ph1, 2005 Ph2 BF - 2.0 MTPA DOC- 1998 Ph1, 2003 Ph2 SINTER - 2.8 MTPA Mar-2013 EAF – 4.5 MTPA CSP - 3.3 MTPA

6

CPP – 55MW

6

Iron Ore Pellet Plant 4 MTPA

Process Flow at Dolvi

Coke Oven 1 MTPA Iron Ore & Fluxes Sinter Plant 2.8 MTPA NG Sponge Iron Plant 1.6 MTPA LCP 2X300 TPD Cal. Lime DRI SMS (Con-Arc) 4.0 MTPA LCP 600 TPD Liquid Steel Thin Slab Caster Two Strand 3.3 MTPA Slab Hot Strip Mill 3.3 MTPA HRC

Projects Commissioned

Hot Metal Blast Furnace 2 MTPA Railway Siding Power Plant 55 MW

Existing Facilities

7

7

S.N.

1 2 3 4 5 6 7 8 9

Major Facilities at Dolvi

Plant /Facility Captive - Jetty Sponge Iron Plant Blast Furnace Sinter Plant Rated Capacity 10 MTPA 1.6 MTPA 2.0 MTPA 2.80 MTPA Year of Commissioni ng 1994 1994 Special Features 450m long jetty with four unloading cranes Gas based single module, being modified for usages of COG 2000 10.8m hearth dia., 2 tap holes, 5MW GET, two SGP units, Productivity 2.6

2005 204m 2 bed area, WHR boiler, Five ESPs, Productivity 1.61

Hot Strip Mill Lime Cal. Plant Power Plant Railway Siding Pellet Plant 3.3 MTPA 1200 TPD 53.5 MW 1.0 MTPA 4.0 MTPA Ph1-1998, Ph2- 2003 Combination of CONARC & CSP, Final strip thickness 1-20mm & width 900 1550mm 2000& 2013 Three units, 2x300 from MERZ & Mar’2013 1X600 From Cimprogetti BF gas fired, power generation surpassed its rated capacity June’2013 3500 m Long Track at use for dispatch Feb’2014 of HR coils 464m 2 travel grate 10 Coke Oven 1.0 MTPA 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

Indian Plant

having thin slab caster ( CSP for steel making & ) technology for HR coils.

first

9 9

Technology Comparison

` Route 1 Sinter BF-BOF Iron Ore Conventional Routes Coke Route 3 CSP Route Route 2 Iron Ore Flexible Pellets Coke Natural Gas Hot Strip Mill BF-BOF route produces Thick Slab of 200-250 mm Blast Furnace LD (BOF) Slab Caster Reheating Furnace Roughing Mill DRI Plant Coiling Stand EAF HR Coils Slab Caster Hot Strip Mill High Energy Consumpti on High Energy Loss DRI-EAF Pellets Iron Ore Natura l Gas Coiling Stand HR Coils Scrap Reheating Roughing Furnace Mill DRI-EAF route produces Thick Slab of 200-250 mm JSW, Dolvi's Unique Steel Making Process Scra p Blast Furnace DR Plant Twin Shell EAF Thin Slab Caste r Ladle Furnace High pressure descaler Coiling Stand TF Hot Strip Mill Continuous process VOD Plant Energy Efficient HR Coils CONARC – Thin Slab Casting casts 100% continuously Thin slab of 50-68 mm without re-heating

10 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 Date 30-03-2010 01-05-2010 Producti on 6607 6190 Producti vity 3.07

2.88

 Fuel Rate 500 504 Coke 289 272 Nut Coke 45 54 India’s First, NG co-injected with coal in BF 09/25/14 Coal 166 177 Sinter 68 80 Pellet 27 13 12 Ore 5 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. 09/25/14 13

09/25/14

Advantages of NG

1.

2.

3.

4.

5.

6.

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 basicit

y which helps in stable and productive operations as gangue input is reduced.

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09/25/14

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 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.

09/25/14 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 .

16

17

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

09/25/14

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.

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09/25/14

Contents

Brief introduction of the organization Breakthroughs in Iron making area Breakthroughs in CONARC furnace

Breakthroughs in CSP caster

Breakthrough in products 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

09/25/14

Contents

Brief introduction of the organization Breakthroughs in Iron making area Breakthroughs in CONARC furnace Breakthroughs in CSP caster

Breakthrough in products

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 • Boron grades are extremely difficult to cast in CSP

Edge crack

• 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:

A pplications includes Truck Chassis, Dumper body, Cranes and Earth Moving Machines Truck Chassis Earth Moving m/c 29

Chemistry ALM650 - Specification Mechanical Properties

30

Actual Chemical & mechanical Properties Chemistry Mechanical Properties

31

HER Actual Chemical & mechanical Properties 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

Non availability of free dislocations Causes Causes No driving force for generation of new dislocations Reduces Reduces • Increase uncoiling speed • Increase tensile load during uncoiling Causes Slow speed of un-coiling 34 Causes Inadequate Tensile load during uncoiling

Metallurgical Parameters

Yield Point Elongation

Coil Breaks

Causes Causes Free Nitrogen Reduces Reduces • Add B or other nitride forming elements • Increase CT above 640 Causes Low Coiling Temperature 35 Causes 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:

Drum Closure Hand Brake Arm 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 - 40 o C 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) Specification ( as per EN10346:2009) 330-460 min 590 %El (in 80 mm GL) min 19 ‘n’ value min 0.13

Results of initial trial After product stabilization 385-485 340 390* >610 >620 24 24 >0.17

>0.17

YS/UTS ratio 0.62-0.70

0.55-0.62

44

Iron Ore Pellet Plant 4 MTPA

5.0 MTPA

Coke Oven 1 MTPA LCP 1200 TPD NG Cal. Lime Sponge Iron Plant 1.6 MTPA DRI Hot Metal Billet Bars

2015 Setup

Billet Caster 1.5 MTPA Bar Mill 1.5 MTPA 1 MTPA Railway Siding Liquid Steel Thin Slab Caster 3.3 MTPA Hot Strip Mill 3.3 MTPA Slab HRC Iron Ore & Fluxes Sinter Plant 2.8 MTPA Sinter Plant 2.24 MTPA 55 MW Power Plant

Thank You

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