60th Refractory Operating Committee Me

PERFROMANCE DATA (Refractory & Operation)

Refractory Sp.Consumption & Sp. Cost
SMS#1 SMS#2
Department/Shop Unit 2014-15 2015-16 Best 2014-15 2015-16
Specific consumption kg/tcs
RED ( Total plant excluding C/R) kg/tcs 8.03 8.57 9.06 9.19
SMS ( without operational consumables ) kg/tcs 6.45 7 8.09 8.28
SMS operation kg/tcs 0.16 0.13 0.06 0.06
BF operation kg/tcs
Total consumption (RED+ kg/tcs 8.03 7.13 9.12 9.41
SMS operation + BF operation)
Specific Cost Rs/tcs
RED Total Rs/tcs 403.04 447.33 428.20 467.34
Operation(SMS+BF) Rs/tcs 13.46 6.79 5.06
RED+Operation Total Rs/tcs 416.50 437.66 434.91 472.40
Steel Melting Shop Rs/tcs 325.07 339.10 369.44

STEEL AREA SMS-1 SMS-2

BOF Converter/EAF unit 2014-15 2015-16 Best 2014-15 2015-16
Number of Converter & Production No/MT 3.00 3.00 4 4
Converter life heats 3761 4200 13771 3250 3250
Lining weight tonne 480 480 560 690.63
Relining time Hrs 48.5 48.5 50 50
Original lining thickness in mm

W/L-700 & 600MM, S/L- 150 MM W/L-700MM W/L-700MM

Top cone mm S/L-150MM S/L-200MM
C/P(W/L)-900,S/L-150, T/P(W/L)-800MM, W/L-800MM W/L-1000MM
Chare pad& Tap Belly mm S/L-150MM S/L-150MM S/L-200MM
W/L-800MM W/L-800MM
Trunnion mm TRUNNION (W/L)-800MM, S/L-150MM S/L-150MM S/L-200MM
W/L-750-800MM W/L-900MM
Lower cone/Knuckle area mm W/L-900&950MM, S/L-200MM S/L-230MM
Left over lining thickness in c/pad, mm C/P-200-350MM
50-100 150-200
& Trunnion at the end of campaign 150-300
Refractory lining consumption kg/tcs 1.34 1.37 1.37
Gunning repair consumption kg/tcs 0.26
Taphole sleeve life heat 116 95.00 95-100
Maintenance charge pad & tap belly tonne 289
Taphole resleeve time min 60 45MIN 45MIN
Converter refractory cost Rs/tcs 72.57 69.7 71 71.6
Limiting factor on life

BOF/EAF Operational Data

Capacity Tonne 4 MT 4 MT 6 MT 6 MT
Heat weight Tonne 134.5 134.5 171.84 173.51
Avg. blow /day No 78.0 78.0 92 84
Avg. blow /day/Vessel No 26 26 23 21
Average Tap-to-tap time Minute 50 50 58 44
TMI (Total Metallic Input) Kg/tcs 992.6 992.6 1132
Reblow % 5.5 5.5 4.58 4.95
Turn down bath carbon % 0.036
Tapping temp.>1700 C % heat 0.89 0.89 1.1
Tap temp.heat between 1660-1700C %heat % heat 8.70
Converter hot metal
analysis:
Si-.75 , S : .009 , P : SI -0.54 S-0.05 P-
Hot metal analysis( Si,S,P) at SMS % 0.142 0.19
Mgo -7.3 Feo-23.5 , Mgo -9.04 Feo-
Slag analysis( MgO,FeO,Basicity) % B2-3.64 24.01 B2-4.25
Blowing details
Blow end to tap start time Minute 5 8
Slag splashing details % 92 8.5
Brick-slag setting practice Y/N N Y
Steel Ladle unit
Ladle capacity Tonne 135T 135T 175 175
Process route followed ARS/LF/RH ARS/LF/RH ARS/LF/RH ARS/LF/RH 175
M/Z : Spinel , S/Z : S/Z SPINEL
Type of bricks used in different zone MgO-C MgO-C Mgo-C M/Z MgO-C
6" MGO-C-108
132.41 140.7 HEATS
ALUMINA SPINEL- ALUMINA SPINEL-
Steel ladle life heats 148 HEATS 157.12
VAD/RH Ladle life heats
Specific consumtion in ladle(Total) kg/tcs 2.74 2.65 2.39 2.15
Working lining Tonne 21.52 21.52 36.11 36.11
Safety lining+Monolithics Tonne 10.45 10.45 25.53 25.53
Intermediate repairs in a campaign Tonne S/L- 8.75 S/L- 8.75 28.15 28.15
Total ladle Tonne 40.72 40.72 64.28 64.28
Ladle heat size Tonne 135 135 175 175
Total ladle specific cost Rs/tcs 95.25 95.25 124.48 135.3
Total cost/campaign Rs. In lakh 17.7 17.7 35 40.13
Wellblock life heats 65-70 65-70 60-65 60-65
Housing block life heats 67 67 60-65 60-65

480MM PLUG-19.61 480MM PLUG-21.57

Avg. Purging plug life heat 10.82 IPV-10.90,SIPV-19 410MM PLUG-13.30 410MM PLUG-13.57
Free opening rate % 99 99 98 98
Slide gate plate life heat 8.13 8.6 5.84 5.84
hot changing of inner nozzle/p plug Y/N YES YES YES YES
Intermediate repairs in a campaign No. 1 1 - -

Steel Ladle Operational

Total number of ladle No 23 28 30 30
Ladle in circulation No. 13+1 13 15+1 16+2
Ladle under relining,repair,heating No 10 10 14 12
Metal holding time in ladle Minutes 100 100 120 120
Ladle return time 10 10 12 12
LF/ARS treatment time Minutes 15 15 15 15
Casting time Minutes 20 20 45/55 45/55
No. of heats/day/ladle No. 6 6 7 7
Slide gate plate life heats 8.13 8.6 5.8 5.17
Slag in ladle kg/tcs 2.2 2.2 1.5 1.5
Retainer plate life Campaign 1.5 1.5 1.5 1.5
Slag analysis(ARS/LF/RH in & out) %

RH Degasser unit 2014-15 2014-15 2015-16

Refractory used in upper/lower vessel Type MAG-CHROME MAG-CHROME MAG-CHROME

INSIDE-MAG CROME BICK, OUTSIDE- 95%

Snorkel ALUMINA LOW CEMENT CASTING
Snorkel life heat 106 136 81 72
Lower vessel life heat 301 150 HEATS 150 HEATS
Upper vessel life heat 2266 2105 HEATS 2105 HEATS
Snorkel refractory cost Rs/tcs 11.86 11.86
Lower vessel refractory cost Rs/tcs
11.86 11.86
Upper vessel refractory cost Rs/tcs
Gunning/repair consumption kg/tcs 0.60 0.6 6.95 23.14
Freequency of gunning No every 3 to 4 heats every 3 to 4 heats every 3 to 4 heats every 3 to 4 heats
Gunning/repairing cost Rs/tcs 2.80 2.80 1.87 1.87

Tundish unit
Capacity Tonne 32T 32 T 34/42 34/42
Tundish for which caster SLAB CASTER SLAB CASTER SLAB & BILLET SLAB & BILLET
Refractories in working lining Type MGO-SPRAY
Insulation board+LC MGO-SPRAY
Insulation board+LC MGOInsulation
SPARY MASS MGOInsulation
SPARY MASS
For safety lining Type 70 70 board+LC 70 board+LC 70
Impact pad/TID refractories lining Torbostop Torbostop Torbostop Torbostop
Work lining life heats 8-9 HEATS 8-9 HEATS 8-10 heats 8-10 heats
Safety lining life campaign 801 HEATS 800 HEATS 900 HEATS 900 HEATS
Work lining consumption kg/tcs 1.1 1 1.36 1.36
Work lining cost Rs/tcs
Safety lining cost Rs/tcs
83 81 80.95 80.95
Tundish furniture cost Rs/tcs
Black refractory cost Rs/tcs
Tundish shell temperature o
C 350 350 150-200 150-200
SLAB-50MIN SLAB-50MIN
Casting duration Min 40 40 BILLET-50 MIN BILLET-50 MIN

IRON MAKING AREA 2014-15 2015-16 Best 2014-15 2015-16

BF/COREX operation
Nos. of Furnace 6 6 BF#1 0.9MT
Furnace wise capacity BF#2 1.3MT
HM Production /day/furnace BF#3 3.0MT
No of tap hole furnace wise BF#4 3.0MT
1450 to 1530
HM Temp. furnace wise Deg C CX#1 0.8MT
Hot blast temp. furnace wise 1130-1200Deg C CX#2 0.8MT
Blast pressure 4 bar
Top pressure 2.3 bar
Casting rate 4.5 tons/min
Casting time 40 min
No of cast/day 14
Type of lining in Hearth, Bosh, Stack
any other detail

Stove
Nos. of stoves furnace wise BF#1 3 stoves
Design of stoves BF#2 3 stoves
Type of Refractory lining with tonnage BF#3 4 stoves
BF#4 4 stoves

BF Hot metal ladle/Corex Hot metal ladle Unit 2014-15 2015-16

Ladle life heat 609 623 764
Refractory cost Rs/tcs 28.9 26.66
Refractory consumption kg/tcs 0.97 0.94
Total cost Rs/tcs 28.9 26.66
Type of refractories used in different zone Al2O3,Al2O3-SiC Al2O3,Al2O3-SiC
Working lining 33.08 30
Safety lining+Monolithics 43.64 38.8
No of intermediate repairs/campaign No 6.5 4
any other detail
Operational
Track time Hrs. 8 8
No. of heats/day/ladle No 3 3
Ladle tare weight at start & down Tonne
any other detail

Torpedo ladle details unit

Type of refractory used for lining ASC bricks/Al2O3 ASC bricks/Al2O3
Working lining 108.96 121.28
Safety lining+Monolithics 95.7 96.61
Ladle life heat 1400 1300
Refractory cost Rs/tcs 14.75 17.86
Refractory consumption kg/tcs 0.09 0.04
Total cost Rs 1.2 cr 1.09Cr
No of intermediate repairs/campaign No 2 2
any other detail
Torpedo Operational
Track time Hrs. 10hrs- 11hrs 10hrs- 11hrs
No. of heats/day/ladle No 2.2 2.2
Ladle tare weight at start & down Tonne 685 685
any other detail

BF Cast House Refractories

Trough
ALUMINA -SILCON ALUMINA -SILCON ALUMINA -SILCON ALUMINA -SILCON
Trough lining refractories Type CARBIDE CARBIDE CARBIDE CARBIDE

Tonnage of refractory used Tonne 520 520 1697 1697

HM throughput including repairs: 180000 180000 160000 160000
Main Trough Tonne 60 60 65 65
Metal Runner Tonne 15 15 25 25
Relining & repair time Hrs. 72 72 72 72
any other detail
BF Mudgun
Type of material TARBONDED TARBONDED TARBONDED TARBONDED
Tap-hole length Meter
Blast pressure kg/cm2 2.8 2.8 3.2 3.2
Top pressure kg/cm2 1.6 1.6 2.1 2.1
Casting rate Ton/minute 4 MT 4 MT 5 5
Casting time Hrs 1.3 1.3 1.3 1.3
No of cast/day No 10 10 14 14
any other detail
mmittee Meeting

Remarks
#2 SMS#3
Best 2014-15 2015-16 Best

21.55 13.64 (BOF+IRON ZONE) - (BF OPRN - SMS OPRN) - C/R

21.46 13.52
0.09 0.11

21.55 13.64

647.00 631.64 (BOF+IRON ZONE) - (BF OPRN - SMS OPRN) - C/R

4.25 1.42
651.25 633.17

SMS-3
Best
1 1
3762 394 511 648
690.63 471 478
9days 9days

80tons
 160 200 236 Multiple sleeve of different length

4hrs 4hrs
320 320

1.5mt 1.5mt
160 160
30 30

48min 48min
190/heat 190/heat

1610 1610

SI -0.54 S-0.05 P- SI -0.54 S-0.05 P-

0.19 0.19
Mgo -10-11% Feo-26 Mgo -10-11% Feo-
B2-2.2 26 B2-2.2

160 160

In slag zone, Metal zone, Bottom impact etc.

MgO-C Bricks MgO-C Bricks In slag zone, Metal zone, Bottom impact etc.

4.73 5.73
35 35
 22 22

67 67 changes in volume or tapping weight

160T 160T
185 202
24 24
40-45 40-45 Gunning in every plug change in SMS-2
40-45 40-45

average plug life of all length

480MM PLUG-25 480MM PLUG-25
410MM PLUG-18 410MM PLUG-18
98 98
5 5
YES YES
- -

10 10
4+1 4+1
2 2
120 120 Tap start to Cast finish
25 25 Cast finish to ladle preparation bay
15 15
45 45
6 6
6 6
2 2
2 2
 28 T 28 T
SLAB & BILLET SLAB & BILLET
MGO SPARY MASS
Insulation board+LC MGO SPARY MASS
Insulation
70 board+LC 70
Torbostop Torbostop
11.76 11 5.1
700heats 700heats
5.04 1.88

87.79 69.06
include all dam, turbostop, weir and chimney etc
include ladle Shroud, SEN/SES, stopper and mononozzle
105-220 105-220

BILLET-50 MIN BILLET-50 MIN

Best

2 No of tap holes
2 No of tap holes
4 No of tap holes
4 No of tap holes
2 No of tap holes
2 No of tap holes
 C blocks,SiC,Low Iron grade gunning.

M/s.Kalugin 1700 tons REF/Stove

M/s.DC Design
M/s.Siemens 3600 tons REF/Stove
M/s.Siemens 3600 tons REF/Stove
Type of refractory material used
Initial installation and during repairs in the whole campaign
throughput
 72 72 13.4
300 300 11.18
125 16.39
200 16.39
510 7.96
765 7.96
320 320 8.12
500 500 8.12
30 30 7.8
45 45 7.8

330 330 4.77

350 350 4.27
1550 1.9
2 2 1000
2.5 2.5 1000
1 0.5 1000
0.05 1000
0.3 0.3 1000
0.6 0 1000
0.15 0.15 1000
1.5 1.5 1000

105.2632
3.007519
8
 964.8 964.8
3354 3354
2048.75 0
3278 0
4059.6 0
6089.4 0
2598.4 2598.4
4060 4060
234 234
351 351
27037.95 11562.2
1574.1 1574.1
1494.5 1494.5
2945 0
2000 2000
2500 2500
1000 500
50 0
300 300
600 0
150 150
1500 1500
14113.6 10018.6

21580.8 11200000
1.866667