Operating experiences at JSPL, BF-II Achieving higher performance indicators with inferior raw materials By : Hemant Upadhyay Arvind Kumar Bhagat.

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Presentation transcript:

Operating experiences at JSPL, BF-II Achieving higher performance indicators with inferior raw materials By : Hemant Upadhyay Arvind Kumar Bhagat

Copyright © 2010 Jindal Steel & Power Ltd. Sl. No. ParameterUOMBaseCurrent 1Productivityt/m3/d Coke RateKg/thm PCI RateKg/thm Fuel RateKg/thm Al2O3 In Metallic% SiO2 In Metallic% Coke Ash% Slag RateKg/thm Hot Blast Temperaturedeg C O2 enrichment% Base Case

Constraints

Copyright © 2010 Jindal Steel & Power Ltd. Raw Material Quality (SiO2) 10% increase

Copyright © 2010 Jindal Steel & Power Ltd. Raw Material Quality (Al2O3) 15% increase

Copyright © 2010 Jindal Steel & Power Ltd. Raw Material Quality (Total Gangue) 13.5% increase

Copyright © 2010 Jindal Steel & Power Ltd. Raw Material Quality (Ash) 38%

Copyright © 2010 Jindal Steel & Power Ltd. Output : Slag rate

Copyright © 2010 Jindal Steel & Power Ltd. Fuel Consumption 5%

Copyright © 2010 Jindal Steel & Power Ltd. Productivity

Enablers

Copyright © 2010 Jindal Steel & Power Ltd. Oxygen Enrichment

Copyright © 2010 Jindal Steel & Power Ltd. Productivity Correction There should be some thing else also Correcting the base productivity for all +’s & -’s, the adjusted figure is less than the actual

Copyright © 2010 Jindal Steel & Power Ltd. Burden Distribution Optimization

Copyright © 2010 Jindal Steel & Power Ltd. Burden Distribution Optimization

Copyright © 2010 Jindal Steel & Power Ltd. Sinter in Burden

Copyright © 2010 Jindal Steel & Power Ltd. Hot Blast Temperature

Copyright © 2010 Jindal Steel & Power Ltd. Optimization of coke quality with PCI

Copyright © 2010 Jindal Steel & Power Ltd. Practices followed at JSPL, Raigarh Cold strength Fines Input Consistent quality of coal for injection with medium VM Hot strength Moisture Gangue / Ash Mean size Raw Material Quality Not in Control

Copyright © 2010 Jindal Steel & Power Ltd. Metal & Slag Level in Hearth

Outcome

Copyright © 2010 Jindal Steel & Power Ltd. Uniform Hot Metal Temperature

Copyright © 2010 Jindal Steel & Power Ltd. Gas Utilization

Copyright © 2010 Jindal Steel & Power Ltd. Pulverized Coal Injection

Copyright © 2010 Jindal Steel & Power Ltd. Fuel Rate Correction - 1

Copyright © 2010 Jindal Steel & Power Ltd. Fuel Rate Correction - 2

Copyright © 2010 Jindal Steel & Power Ltd. Production cost

Copyright © 2010 Jindal Steel & Power Ltd. 1.It is possible to optimize the process to get higher performance indices with inferior raw materials also. 2.It is advisable to do a detailed cost benefit analysis before going for any such experiments. 3.On paper it may seem lucrative, but it’s always an opportunity loss to operate a furnace at higher slag rates. 4.In general it should be discouraged to charge garbage in Blast Furnace. Conclusion

THANK YOU