Introduction To Steel Making Division

A House of Engineering Excellence
MECON LIMITED
INTRODUCTION TO STEEL
MAKING DIVISION
Concept To
Commissioning
MECON LIMITED
MECON LIMITED
Back ground
In 323rd meeting, SAIL Board on 03-04-2007
had accorded inprinciple approval for the
proposal for modernisation and expansion of
Bhilai Steel Plant.
Under this modernisation and expansion plan it
is proposed to install one new BOF Shop of
Capacity: 4.13 MTPA of Liquid Steel in new
SMS # 3 Complex in its existing integrated steel
plant at Bhilai, Chattisgarh.
MECON LIMITED
Mile stone
Inprinciple Approval
Draft TS received
25 th April 2007
Final TS Received
7 th June 2007
NIT issued on
Bidders Conference
23 rd July 2007
1st Corrigendum
11 th Aug 2007
2nd Corrigendum
5 th Sep 2007
3rd Corrigendum
21 st Sep 2007
Offers received on
1st round discussions
2nd round discussions
3rd round discussions
Price bid opened on
3 rd April 2007
30 th June 2007
15th November 2007

18 th Dec to 20th Dec 2007
25 th Jan to 26th Jan 2008
28 th Mar to 29th Mar 2008
9 th April 2008
SMS 3 Layout
MECON LIMITED
Torpedo Car
MECON LIMITED
MECON LIMITED
HM/torpedo bay, DE Bay
MECON LIMITED
Torpedo ladle receipt DE bay (2 tracks)

and EF bay (1 track)
Size 171 x 26.5 x 43 mtr.
2 no of EOT cranes of 300+80/25T
(HEC)
There is provision of Hot metal mixer with
EOT crane which is under consideration.
MECON LIMITED
Hot metal receipt (torpedo bay)DE

Bay
Hot metal is received from Blast furnaces

in torpedo (350T) ladle car in torpedo
bay(DE or EF bay) and poured into Hot
metal charging ladle kept in ladle transfer
car in reladling pit(2nos). from there
either Heat is taken to hot metal
desulphurization unit or directly poured
into BOF depending upon Hot metal
chemical analysis.
MECON LIMITED
Desulphurisation Station
MECON LIMITED
Operating Features of HMDS
Desulphurisation process
Co-injection based process
The same system will be capable enough to operate under mono-injection

Reagents considered
I) Calcium
Carbide
compound
II) Mg-based compound
Typical injection rate, kg/min
I) For CaC2 : 30-60Kg/min

II) For Mg : 6-20 Kg/min
Injection time
9-12 min
Allowable temperature drop during

25 C (max)
entire operation
Typical drop in temperature during
1. Deg/min
injection
based
MECON LIMITED
Conveying medium of reagents

Deslagging operation
Lifting and tilting mechanism of car
Slag pot
Dry Nitrogen
By tilting of Hot Metal ladle into the slag
pot & with slag skimmer
By hydraulic power pack system
Slag pot will be placed on the same HM
treatment car
MECON LIMITED
Final
in
Hot
Metal
after
desulphurization (for special grades)
0.002% (max.)
Capacity of storage silo for CaC2
for 10 days
Capacity of storage silo for Mg
for 10 days
Hot Metal Ladle

MECON LIMITED
Teeming ladle
MECON LIMITED
Teeming ladle
MECON LIMITED
Capacity-165/180T,free board-400mm for 180 t,

and480mm for 165t, upper dia-3700mm,Ht with
feet-5250mm,Ht with lifting lugs5580mm,trunion
gauge-5000mm
Plate material-ASTM 516gd60,porousplug-2no.
Consists of :-slide gate, ladle transfer car with
auto coupling device for purging,
Total no.of teeming ladles are-29 nos.
Charging Bay ( EF )
MECON LIMITED
Size 456 x 28 x 43 mtr

2 nos of EOT cranes of 300+80/25t
(HEC) for Hot metal charging, 2 nos of
semi portal cranes 65+65 t (HEC)for
scrap charging.
MECON LIMITED
STEELMAKING
BASIC OXYGEN FURNACE

ELECTRIC ARC FURNACE
INDUCTION FURNACE
MECON LIMITED
BOF Consumption Figures

BOF Consumption Figures

Nominal Heat Size 160 t & 100% scrap as coolant
Target
Low c
Medium C
High C
Hot Metal
137.8t
141.9t
143.3t
Scrap
36.6t
30.7t
28.7t
Lime
8.3t
8.7t
8.8t
Dolomite
2.6t
2.2t
2.1t
15.9 min
15.6 min
15.1 min
Blowing Time
Blow O2
Average Blow
8737 Nm3 8388 Nm3 8294 Nm3

550Nm3/mi 550Nm3/mi 550Nm3/mi
n
n
n
Temperature
1576 C
1574 C
1563 C
Blow end C
0.02%
0.06%
0.10%
MECON LIMITED
MECON LIMITED
Hot metal charging in BOF
MECON LIMITED
BOF SHOP
SMS-III
Bhilai Steel Plant
(Pkg # 025)
Salient features
No. of BOF Converters
Production of Liquid Steel

Specific Volume
H/D Ratio (new lining)

Average Tap-to-Tap time
Daily production Potential
One Conv (with avg. TTT time)
Two Conv (with avg. TTT time)
Three Conv (with avg. TTT time)
Converter Lining life
Relining time
MECON LIMITED
3
4.13 mtpa
1.13 cub.m./t for 160t nom. Heat
1.0 cub.m./t for 180t max heat sizes
1.36
50 minutes
Per Converter- Max. 30 heats
-28.8 heats
-56.6 heats
-73.2 heats
8000 hts minimum
7 days
Salient features
Specific Energy Consumption- 0.25 Gcal. / t of Liq. Steel
Pollution Control Measures like

ESP based Secondary De-dusting system.
Bag House based Material Handling De-dusting systems
State of art Electrics, Instr. & Automation system.

Combined blowing technology
Nitrogen slag splashing technology
Converter shell and top cone.
Advanced BOF suspension system.
Automatic pneumatic slag stopper during tapping.
Quick lance exchange system.
MECON LIMITED
Salient features
MECON LIMITED
State of the art Primary Wet type scrubbing system WDS Cone quencher system
Secondary emission control system (dog house) with ESP.
Separate Bag Filter based dedusting system for the material Handling system for
Converter and the SRUs.
Tap hole maintenance machine
Automatic Gunning Machine
Automatic Temperature & Sampling manipulator for the converter
On line Dust measurement in GCP
Automatic gas coupling for the ladles and transfer cars
Converter lining profile measuring system
Radar based bath height measurement system
MECON LIMITED
Converter with Dog House
Converter dog house
MECON LIMITED
Dog house is used to enclose the converter in

order to protect the operator, steel structure
and adjacent equipments against excessive
heat radiation, slopping and fumes
Both at charging and tapping side two winged
laterally driven shift able doors are provided for
access to charging of hot metal & scrap and
free access to repairs and cleaning.
MECON LIMITED
Ladle Preparation Bay GH
Diamension-432x27x56 mtr
EOT cranes 3no 120+50/25T
Facilities:- Both the ends of Bay there are Ladle
lining Wrecking stands-2no each . ladle cooling
stand with cooling blower -4no, ladle relining
pits -6no, vertical ladle dryer-8no, vertical ladle
stand with pedastals-4no,horizontal ladle stand
with pedestals/covers -4no,ladle tilting stand
with moveable Ld covers-4no,Wall crane ladle
relining, Steel ladle dryer, Slide gate assembly
fixing platform.
Scrap yard CD bay
MECON LIMITED
Receipt of scrap by railway wagon/ trucks to scrap preparation

yard.
Facility-RLY wagons/trucks/scrap pits/cranes/weighing
equipments/scrap shears/press/torch cutting device
Yard size-159mtrx36mtrx25mtr
Unloading of scrap by 3 nos. cranes of 20+20 t EOT crane with
magnet and grab attaching facility.
Size-3500mmx4000mmx3500mm
Capacity of scrap box-25m3
Total scrap boxes-8nos
Slag disposal AB bay
MECON LIMITED
After tapping of steel, remaining slag is tapped

in slag pots and taken back to AB bay and slag
dumped in slag pits and quenched with water
spray, after cleaning the lime is coated for
circulation for next cycle.
Bay is 225x 35.5 mtr, 3 nos. of 120+50t cranes
with grab &ball hammer attachment.
7 nos slag pits with water spray facility.
No of slag pots are-25 of 20 Cu mtr each.
MECON LIMITED
SECONDARY METALLURGY
Ar / N2 RINSING unit
LADLE FURNACE
RH DEGASSER
.
MECON LIMITED
Secondary Refining Bay H-I
MECON LIMITED
Bay Size L-336mtr/W-27mtr/H-33mtr

Cranes- 2 nos of 300+80/25T (HEC) and 1 no of
100/30T rotating hook (Mukund Ltd.)
Argon rinsing/Ladle furnace/RH degasser
Function of Argon rinsing of liquid steel for
homogenizing temperature and chemical composition.
Function of LF for raising temperature of liquid steel by
Arcing.
Function of RH degasser is removal of dissolved gases
of liquid steel.
MECON LIMITED
SECONDARY REFINING LADLE FURNACE
KEY TECHNOLOGICAL AREA

1)
2)
3)
4)
5)
6)
ELECTRODE SYSTEM
ROOF GANTRY
INJECTION SYSTEM
ALLOY ADDITION SYSTEM
DEDUSTING SYSTEM
CONTROLS AND AUTOMATION
MECON LIMITED
Secondary refining Bay HI BAY
MECON LIMITED
WISDRI CHINA
Argon rinsing unit online :-3nos
Ladle furnaces
-3nos
RH degasser
1nos
EOT cranes
2 nos of 300+80/25t.
1no of 100/30t.
MECON LIMITED
Ladle Furnace
MECON LIMITED
MECON LIMITED
Ladle furnaces
MECON LIMITED
No of ladle furnaces-3nos,annual
treatment/lf-1500000t/yr,no of heats to
treated/day-28(36-max),avg heat size165t,max-180t, Transformer capcity35mva heating,rate>5/min, treatment
time-36min, ladle free board-500mm.
MECON LIMITED
Ladle furnace (LF) process
Better temperature control by electric heating

Homogenization by Ar purging
Alloy addition
Inclusion control & better cleanness of steel
Deoxidation & Desulphurisation
Acts as a buffer station before continuous casting
MECON LIMITED
RH Degasser
Degassing (Vacuum removal of H2, N2, O2)

Natural & Forced Decarburization
Accurate composition adjustment
Temperature adjustment
Improving cleanliness of liquid steel
MECON LIMITED
RH Degasser
RH Degasser
MECON LIMITED
The two steel pipes are the inlet and the outlet snorkels.
Liquid steel is raised through the inlet snorkel and falls
back into the steel ladle after degassing through the
outlet snorkel.
Before snorkel immersion the injection of inert gas,
usually argon, is started in the gas pipe of the inlet
snorkel.
The reaction vessel is evacuated by means of a vacuum
pump system which is connected to the reaction vessel
through off take duct (exhaust).
RH process is based on the exchange of liquid steel
between the steel ladle and the RH vessel.
RH degasser
MECON LIMITED
Heat size-165t, max-180t,It is a refractory

lined vaccume vessel equipped with
tworefractory lined snorkels attached to
bottom of vessel, lifting/lowering of vessel
is by winch system,vaccume sys-steam
ejector,inert gas purging in one of snorkels
Steel recieculationrate-120t/min, h2 level
after treatment <1.3ppm for rail steel,Alloy
addition can be done in RH degasser.
Ladle handling Bay(I-J)
MECON LIMITED
Bay size L-336mtr/W-30mtr/Ht-33mtr

The ladle turrets of billet casters and Billet-cum-Bloom
caster shall be located in this bay. Ladle turret of beam
blank caster shall be located Perpendicular to the CCP
shop at one end of the ladle handing bay. The Beam
blank caster is laid in this bay in linear fashion (casting
direction parallel to the bay).Emergency steel ladle shall
be placed in this bay below the ladle turret towards J
row during emergency.
Cranes 3 nos of 300+80/25T (HEC) and 1 no of 100/30
rotating trolley.
Ladle Handling Bay IJ
MECON LIMITED
Function is to lift the heat, dispatched from SRU bay and

place it on Ladle turret of Casters CK1,CK2,CV1orCV2,
and dump the leftover slag of ladle into Slag pot.
Placement of heat dispatch from ARU to extended track
of LF,RH to IJ bay for treatment in LF or RH in case of
non availability of cranes in HI bay
Cranes -2nos of 300+80/25t and 1no of 100/30t capacity.
MECON LIMITED
Casting bay/Tundish preparation bay(J-K)
Bay Size L-393mtr/W-36mtr/H-47.9mtr

The bay accommodate casting platform,
tundish cars, mould, mould oscillator segments,
Torch cutting machine and dummy bar storage.
The bay consists mould cooling system, main
electrical control rooms, hydraulic room, caster
control rooms, tundish preparation area for
CK1,CK2 and CV1.
Cranes 3nos of 100/30T including 1 rotating
trolley and 3 nos of 7.5T S/portal for tundish
preparation.
Billet casting overview
MECON LIMITED
MECON LIMITED
Technical detail of billet casters

Machine typeNumber of machines/strandsMachine radiusstrand center distanceMachine speed
-Max restranding speed-Max. speed run out roller tableMetallurgical machine lengthCasting mode
-
MECON LIMITED
SIEMENs VAI High Performance caster with curved mould.

2 machines with 6 strand each
9000m
1200m
approx 6.0 m/min
40m/min
approx. 27m.
open stream casting with oil lubricant
submerge nozzle casting with stopper rod and casting powder
Ladle accommodation
Ladle turret (Butterfly type)
Cutting deviceTorch cutting machine
Dummy Bar systemRigid dummy bar
Discharge equipment
Roller table, Billet lifting device. Cross transfer car ,Turnover cooling
bed.
Machine design range100*100mm to 160*160mm
Cold section to be cast 105*105mm,150*150mm
Cold cut length
6,12m
Level of casting platformapprox +9900mm
Level of roller tableapprox +900mm
Level of transfer roller table for cold charging- +800mm
Technical detail of Billet cum Bloom caster
MECON LIMITED
Design of Billet cum Bloom caster- Bow-type caster with plate mold for bloom and tube mold for
billet, segmented strand containment continues
straightening of strand according to the SVAI
patented straightening process.
Ladle size165 t average (future 180t)
No. of machines1
No of strands per machine
6
Bow radius
12000mm
Strand center distance
1500mm
Machine length (strand length from mold level to start torch cutting machine)approx 35m
Support length (from meniscus up to last roller of segment no -1)
approx 5m
Caster equipped for section cold
-Blooms 350*300mm (Width*Thickness)
-Billets
150*150mm
Max. casting speed design range of the machine- Operation with submerged casting only.
-Blooms - max. 1,2 m/min
-Billets - max. 2.8 m/min
Cold cut product length 6m,12m
Dummy bar system Bottom feeding system.
MECON LIMITED
Technical detail of Beam Blank Caster
Design of beam blank caster-Bow type caster with plate mould, segmented strand
containment, continuous straightening of strand
according to the SVAI patented straightening process.
Ladle size 165 t average (future 180 t)
No. of machines 1
No of strand per machine- 3
Bow radius- 12000m
Strand center distance-3000m
Machine length(Strand length from mould level to start approx 30mm
touch cutting machine )
Supported length (from meniscus up to last roller web of segment no.2)- approx 9m
Caster equipped for
Beam blank 1- 405*285*90mm(517kg)
Beam blank 2- 620*440*100mm(1052kg)
Beam blank 3-1023.8*390*90mm1261kg)
Max. casting length
Segment 1+2 dep. On size (exchange component)
Segment 3- approx. 1200mm
Straightening area- approx 1100mm
Discharge area- 1200mm
Long products
MECON LIMITED
MECON LIMITED
MECON LIMITED
Casting platform and related equipment
Ladle turret different types
MECON LIMITED
MECON LIMITED
Ladle support - Different solutions
Tundish support - Different solutions
MECON LIMITED
Tundish
MECON LIMITED
SIMETAL LevCon Actuator

Tundish flow control systems
MECON LIMITED
SIMETAL LevCon Actuator
MECON LIMITED
Tundish nozzle changer
MECON LIMITED
MECON LIMITED
Ladle Turret
Tundish preheating
MECON LIMITED
Machine head features
MECON LIMITED
MECON LIMITED
SIMETAL DynaFlex hydraulic oscillator
MECON LIMITED
SIMETAL DynaFlex oscillator, different solutions
Mold - tube type

MECON LIMITED
Mold cooling
MECON LIMITED
Electromagnetical stirrer
MECON LIMITED
SIMETAL DiaMold - mold geometry
MECON LIMITED
Mold stirrer (MEMS)

MECON LIMITED
Strand guide
MECON LIMITED
Secondary cooling system
MECON LIMITED
Secondary cooling typical arrangement
MECON LIMITED
Secondary cooling
MECON LIMITED
Dummy bar and withdrawal unit
MECON LIMITED
MECON LIMITED
Withdrawal and straightening unit (rocker type)
MECON LIMITED
Withdrawal and straightening unit (frame type)
Dummy bar and dummy bar storage
MECON LIMITED
Billet cutting and evacuation area
MECON LIMITED
Cutting equipment
MECON LIMITED
Run-out roller table - multi-strand roller
MECON LIMITED
Billet lifting device
MECON LIMITED
Cross transfer car and discharge area
MECON LIMITED
Turnover cooling bed
MECON LIMITED
MECON LIMITED
Mould & Segment preparation bay (K-L)
Bay Size L-393mtr/W-27mtr/H-44.9mtr

This bay is envisaged for storage,
alignment, assembly, and maintenance of
moulds and segments & Caster roller
table for 2*6 strand billet casters and 1*6
strand billet cum-bloom caster and
Beam Blank Caster.
Cranes 2 nos-40/10T (Mukund Ltd.)
Storage bay(L-M and M-N bays)
MECON LIMITED
Bay Size LM bay L-393mtr/W-36mtr/H-35.7mtr

MN bay L-393mtr/W-33mtr/H-32.7mtr
These bay consists of remaining part of the
discharge roller tables, cross transfer
mechanism, cooling beds, end stops, marking
machines, auxiliary beds, transfer roller table
for transfer to existing rolling mills and billet and
bloom storage yard. A control room for transfer
and storage of billet located in this bay.
Cranes 3 nos 35/10T with magnet in LM bay
and 2 nos 35/10T with magnet in MN bay.
Dispatch bay(N-P)
MECON LIMITED
Bay Size L-393mtr/W-24mtr/H-28mtr

The bay accommodate roller table
with pushers and collecting beds for
blooms. Rail wagons are positioned
in this bay for transfer of blooms to
the new Rail mill.
Beam Blank storage bay A-B and B-C
MECON LIMITED
These bays are provided for the 1*3

strands beam blank caster. These bays
shall accommodate discharge roller
tables, collecting bed, fixed stops,
disappearing stops, cross transfer,
pushers.
MECON LIMITED
The sampling and temperature measuring

device is arranged on one of dog house doors
in front of converter and serves for automatic
temperature/sampling of steel bath.
LOMAS(lowmaintanancegasanalysing sys)
for controlling and monitoring of gas
concentration for converter gas analyzing
system with mass spectrometer for the
componentsCO,CO2,H2,N2.
MECON LIMITED
Primary waste gas treatment ET31
Primary waste gas treatment consists- converter

primary waste gas treatment, cooling stack
system, hot water circuit, water aux sys,1st&2nd
stage wet scrubber ,slurry treatment, uncooled
duct fan, gas analysis system,silencer&stack
system,switch over station,and gas holder
ID fan suction capacity-270000m3/hr
MECON LIMITED
Secondary dedusting system ET32
ET 32:--ET 32 station is secondary dedusting system for collection

of dust fumes generated during different processes like BOF
charging fume suction, Steel tapping fume suction, During reladeling
fume suction ladle refractory wrecking fume suction, Argon rinsing
station fume suction , AND Ladle furnace treatment fumes suction.
The dust fumes from the various sources are conveyed to mixing
duct from mixing duct goes to dust cleaning equipment , the dust
falls down to the dust hopper than collected dust is discharged to
dust silo through dust conveying system
The generated gasses are cleaned in electro static precipitator
The I D fan capacity of dedusting system is 1000,000 Acumtr/hr.
there are three no of such ID fans.
MECON LIMITED
Converter Material handling dedusting system ET71
ET- 71:-ET 71 is material handling dedusting

system for convertor charging material from
shuttle conveyor to bunkers and than to
intermediate bunkers
Total Capacity of the dedusting system for
convertor material handling is appx 115000cu
mtr/hr, no of ID fans are 2 nos, design capacity
is 115000 cu mtr/hr.
Material handling dedusting sys for sec metallurgy
MECON LIMITED
ET-72 :- is material handling dedusting system for

secondary metallurgy, this includes dedusting of
material handling system for ladle furnace 3 nos and
dedusting of material handling system for Argon rinsing
station 3nos
Total capacity of dedusting system for secondary
metallurgy is 292000cumtr/hr
No of ID fans are --2 nos, design capacity is apprx
292000cumtr/hr.
MECON LIMITED
CONTINUOUS CASTING
Billet CASTER
BLOOM CASTER
Beam blank CASTER
MECON LIMITED
MECON LIMITED
Billet Caster
MECON LIMITED
Ladle Turret
MECON LIMITED
Mould & Oscillation Unit
MECON LIMITED
Mould
MECON LIMITED
Strand Guide System
MECON LIMITED
Withdrawal &Straightening with Pinch Roll Unit
MECON LIMITED
Dummy Bar Storage
MECON LIMITED
Torch Cutting Machine
MECON LIMITED
Discharge Equipment
MECON LIMITED
Billet caster Consumption Figure

Billet Caster Consumption Figures
Designation
Unit
Quantity
Electric Power
kWh/t
5-Mar
with EMS
kWh/t
7-Apr
Refractory
kg/t
5-Mar
Tundish Covering Powder
kg/t
0.4
set/sequence
l/t
0.2
Mould Powder
kg/t
0.4
Lubricating Grease
g/t
10-May
Tundish Nozzles
Mould Lubrication Oil
MECON LIMITED
CONTINUOUS CASTING machine
LEGEND
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
LADLE
LADLE TURRET
TUNDISH
MOULD
R SEGMENTS
HYDRAULIC OSCILLATOR
BENDING UNIT
DUMMY BAR
WITHDRAWAL UNIT
MECON LIMITED
MECON LIMITED
THANK YOU

Introduction To Steel Making Division

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Introduction To Steel Making Division

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A House of Engineering Excellence

A House of Engineering Excellence

1st round discussions

2nd round discussions

3rd round discussions

Price bid opened on

A House of Engineering Excellence

15th November 2007

A House of Engineering Excellence

A House of Engineering Excellence

A House of Engineering Excellence

A House of Engineering Excellence

HM/torpedo bay, DE Bay

Torpedo ladle receipt DE bay (2 tracks)

A House of Engineering Excellence

Hot metal receipt (torpedo bay)DE

Hot metal is received from Blast furnaces

A House of Engineering Excellence

Operating Features of HMDS

A House of Engineering Excellence

Co-injection based process

The same system will be capable enough to operate under mono-injection

Typical injection rate, kg/min

I) For CaC2 : 30-60Kg/min

Allowable temperature drop during

Operating Features of HMDS

A House of Engineering Excellence

Conveying medium of reagents

A House of Engineering Excellence

Operating Features of HMDS

desulphurization (for special grades)

Capacity of storage silo for CaC2

Capacity of storage silo for Mg

A House of Engineering Excellence

Hot Metal Ladle

A House of Engineering Excellence

A House of Engineering Excellence

Capacity-165/180T,free board-400mm for 180 t,

A House of Engineering Excellence

Size 456 x 28 x 43 mtr

A House of Engineering Excellence

BASIC OXYGEN FURNACE

BOF Consumption Figures

BOF Consumption Figures

8737 Nm3 8388 Nm3 8294 Nm3

A House of Engineering Excellence

A House of Engineering Excellence

Hot metal charging in BOF

A House of Engineering Excellence

A House of Engineering Excellence

No. of BOF Converters

Production of Liquid Steel

H/D Ratio (new lining)

A House of Engineering Excellence

Specific Energy Consumption- 0.25 Gcal. / t of Liq. Steel

Pollution Control Measures like

State of art Electrics, Instr. & Automation system.

A House of Engineering Excellence

Secondary emission control system (dog house) with ESP.

Tap hole maintenance machine

Automatic Gunning Machine

Automatic Temperature & Sampling manipulator for the converter

On line Dust measurement in GCP