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

2. Copyright © 2010 Jindal Steel & Power Ltd. Sl. No. ParameterUOMBaseCurrent 1Productivityt/m3/d2.532.97 2Coke RateKg/thm343364 3PCI RateKg/thm154138 4Fuel RateKg/thm511526 5Al2O3 In Metallic%2.653.01 6SiO2 In Metallic%4.384.54 7Coke Ash%12.316.31 8Slag RateKg/thm298350 9Hot Blast Temperaturedeg C11741147 10O2 enrichment%3.987.45 Base Case

3. Constraints

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

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

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

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

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

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

10. Copyright © 2010 Jindal Steel & Power Ltd. Productivity

11. Enablers

12. Copyright © 2010 Jindal Steel & Power Ltd. Oxygen Enrichment

13. 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

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

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

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

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

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

19. 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

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

21. Outcome

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

23. Copyright © 2010 Jindal Steel & Power Ltd. Gas Utilization

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

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

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

27. Copyright © 2010 Jindal Steel & Power Ltd. Production cost

28. 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

29. THANK YOU