Welcome to

Presentation On Steel
Melt Shop -2
1
1

SMS-2

22

Layout of Steel Melting Shop # 2

R

Q
Billet Storage Yards

L
K
Discharge Aisle

scale pit

casting / mould & tundish repair

H

3
G

Ladle distribution aisle

LF
RH2

LF2
RH 1

LF1
LF1

Sec. Metalurgy Aisle

G
WWTP

A S Ol

L P Bay
E
D
Rampl
C
B

ESP

ID FAN

argon rinsing

Charging
aisle
Torpedo
aisle
HMDP

LD controle room

FA storate
Lance Repair
WMD Pump House
Cooling Towers
Scrap
Yard
Dalian make crane

Slag Yard

Unique make crane

WMI Make crane
Mukund make crane

FACILITIES OF SMS-2

HOT METAL THROUGH TLC ONLY

2 HOT METAL CARS (AT 8.65 LEVEL)
HOT METAL DESULPHURISATION PLANT (HMDP)
SLAG YARD WITH CRANE DUMPING
LD CONVERTERS WITH OLR- 2 NOS
SECONDARY DEDUSTING AND FERRO ALLOY
DEDUSTING SYSTEM.
LADLE PREPARATION AREA
SECONDARY METALLURGY (LF & RH)
SIX STRAND BILLET-CUM-ROUND CASTER- 1NO
SIX STRAND BILLET CASTERS 2 NOS
44

HMDP
25-30 HEATS/ DAY ROUTED THROUGH HMDP
AVERAGE TREATMENT TIME 50 MINUTES
DESULPURISATION DONE BY INJECTING CALCIUM
CARBIDE & Mg BASED COMPOUND
HOT METAL SULPHUR REDUCED FROM 0.04% TO
0.005%
COMBINED CAR FOR SLAGPOT & HOT METAL
LADLE WITH HYDRAULIC TILTING.
55

LD CONVERTERS
CAPACITY-150T, H/D RATIO 1.44,
SPECIFIC VOLUME 1 M3 / ton
TOP LINING, FIXED BOTTOM
TILT DRIVE WITH EMERGENCY PNUMATIC MOTORS
BOTTOM STIRRING WITH 8 PLUGS & BATH LEVEL
MEASUREMENT
TAP TO TAP TIME 49.5 Min (avg)
LANCE WITH ROPE DRIVE & EMERGENCY
PNEUMATIC DRIVE
ON-LINE ARGON RINSING STATIONS
DOG HOUSE
SECONDARY DEDUSTING SYSTEM
HYDRAULIC SKIRT DRIVE
HYDRAULIC VENTURI SCRUBBER
66

LD CONVERTERS

continued

BLOWING TIME: 16 MINS (Max)

O2 FLOW RATE: 600 M3/MIN (Max)
INPUT: 1025kg/t
SCRAP INPUT: 50-55 kg/t
Iron ore INPUT: 20kg/t
O2 BLOWING RATE: 3.5 to 4 NM3 / T/MIN
CONVERTER OPERATION MODE: 2/2
NO OF HEATS/DAY: 56 heats (2 LDs)
NO OF HEATS/YEAR: 18760
CAPACITY: 2.80 MTPA
HEAT WT: 150T AVG
TAPPING TEMP: 1680C
SLAG FREE TAPPING WITH SLAG RETAING DEVICE
77

Materials Requirement BOF

Sl. No

Description

Unit

Hot Metal

Qty/ Heat
(SMS-2)

(SMS-1)

Ton

155

144

Scrap

Ton

12

Iron Ore

Ton

3.2

2.65

Lime

Ton

11

5.3

Calc Dolo

Ton

2.2

2.52

Raw Dolo

Ton

2.2

0.65

Pet Coke

Ton

0.68

0.28
88

Ferro alloys requirement

Sl. No

Qty/ Heat
( in Tons)

Description
(SMS-2)

(SMS-1)

Si Mn

1.6

1.9

Fe Si

0.8

0.22

HCFeMn

0.12

0.19

MCFeMn

0.032

HCFe Cr

0.1

0.57

Cu Scrap

0.012

0.045

Al Ingot

0.08

0.055

Al Wire

0.16

0.11

99

GAS CLEANING PLANT

INDEPENDENT GCP FOR EACH LD.

WET TYPE GAS CLEANING SYSTEM.
SMS-2 GCP DESIGNED M/S BAUMA-GERMANY & SUPPLIED BY SMS
DEMAG .
SMS-1 GCP DESIGNED M/S IRSID CRUESOT LOIRE -FRANCE &
SUPPLIED BY CLECIM.
SUPPRESSED COMBUSTION BY CLOSING GAP BETWEEN HOOD &
CONV WITH THE HELP OF SKIRT.
COMBUSTION AIR FACTOR (AIR FLOW INDUCED IN THE CIRCUIT/
AIR FLOW REQUIRED TO BURN ALL GAS) BELOW 0.1
GAS FLOW CONTROLLED BY HOOD PRESSURE AND VENTURI.
GAS COOLING FROM 1600 DEG TO 800 DEG ENTRY TO SCRUBBER.
GAS COOLING FROM 800 DEG TO 75 DEG IN SCRUBBER.
VVVF MOTOR FOR ID FAN FOR OPTIMUM USAGE OF POWER.
DELIVERY OF CLEANED GAS UP TO 50mg/NM3 (DUST LOAD AT ID
FAN) AND 5 mg/NM3 AFTER ESP.

10
10

LADLE PREPARATION BAY

14 NOS LADLES WITH CAPACITY 150-160T(FREE
BOARD 450MM)
2 NOS CRANES 125/25T
2 NOS LADLE HEATER (HORIZONTAL)
3 NOS LADLE DRIER (VERTICAL)
2 NOS ON LINE LADLE HEATER (VERTICAL)
TYRE MOUNTED LADLE LINING BREAK OUT
MACHINE
2 NOS LADLE TILTING STAND FOR DEBRICKING
2 NOS STEEL LADLE STAND
5 NOS STEEL LADLE RELINING STAND
1 NO HORIZONTAL STAND FOR NOZZLE
11
CLEANING
11

SECONDARY METALLURGY

LHF - 2 NOS
ALL HEATS ARE ROUTED THROUGH LHF
TWO CARS FOR EACH LHF
RH - 1 NO
21 HEATS / DAY ARE ROUTED THROUGH RH
DEGASSER
HYDROGEN REMOVAL TO LESS THAN 2.0
PPM AT RH DEGASSER
EOT CRANE FOR SHIFTING HEATS FROM
ONE CAR TO OTHER CAR
12
12

CONTINUOUS CASTING SHOP

Six-Strand BILLET CUM ROUND CASTER- 1NO

(CCM-1) Radius-10mtr.
.150 mm Square, rounds of 220mm, 280mm, 350 mm
Six-Strand BILLET CASTERS- 2NOS (CCM-2 &3)
Radius-10mtr. .150 mm , 200 mm Squares
TUBULAR MOULDS
CASTING SPEED 1.5 3.8 Mtr/Min FOR SQUARES,
0.65 1.8 M/MIN FOR ROUNDS
SLAG DETECTION DEVICE , EMS & AMLC SYSTEM
HYDRAULICALLY OPERATED MOMs
BUTTERFLY TYPE LADLE TURRET
MANIPULATORS FOR LADLE COVER AND SHROUD
13
13

CONTINUOUS CASTING SHOP

continued

RIGID DUMMY BAR WITH PARKING DEVICE

LIFT AND LATERAL TRANSFER CAR

WALKING BEAM COOLING BED

DEBURRING & MARKING MACHINES , SAMPLE COLLECTING CAR

TWO TYPES OF TUNDISHES (TYPE1 FOR M/C1 , TYPE2 FOR M/C- 2&3)

TUNDISH WITH SLIDE GATE & CNC SYSTEMS

TUNDISH DESKULLING BY TILTING EQUIPMENT

HYDRAULIC SYSTEMS FOR RUN OUT AREA, BILLET PUSHERS &

TUNDISH TILTING STANDS.
14
14

Sl
.

Location

LIST OF CRANES IN SMS-2

Bay

Qty.
(Nos
)

Capacity
(Tons)

Desulphurisati
on Aisle

A-B

250+75/20

Charging Aisle

B-C

250+75/20

F-G

250+75/20

G-H

250+75/20

A-B

100+40/20

3
4
5

Secondary
Refining Aisle
Ladle
Distribution
Slag Aisle

Charging Aisle

B-C

60+60

Ladle
Preparation

E-F

125+30

Scrap Aisle

A-B

30
(Magnet)

Casting/Tundis

75/20

Purpose

For handling Hot Metal Ladle

and other Misc. work.
For charging hot metal into
Converter and other misc.
For handling Steel Ladle and
other Misc. work.
For handling Steel Ladle and
other Misc. work.
For handling Slag Pot.
For handling Scrap Box and
charging scrap into
Converter.
For handling empty Ladle
and other Misc. work.
For handling Scrap with help
of Magnet.
15
For handling Tundishes,

Discharge
Aisle
Scale Pit of
11
Billet Caster
10

12

Converter
Aisle

Converter
Aisle
Converter
14
Aisle
Ladle
15 Preparation
Aisle
13

J-K

--

C-D

C-C/D

C-C/D

E-F

Discharge
16
Aisle

J-K

Billet Storage
17
Aisle

L-M
M-Q
Q-R

3
3
3

30/5
(Magnet)

For handling material in

Mould preparation area.
For handling and removal of
10(Grab)
scales of Billet Caster.
For handling Ferro-Alloy by
16
bottom discharging Bucket
and other Misc. work.
For handling Lance and other
50
Misc. work.
For handling Lance and other
10
Misc. work.
3 (Wall
Crane)

For handling Refractories and

other Misc. work.

20(RT)

For handling and removal of

Square as well as Round
Billets form Cooling Bed.

20(RT)

For handling and Storage of

Square as well as Round
16
Billets.

Power requirements
Max. Demand
SMS#1
SMS#2
Plant overall

34 MW
56 MW
470 MW

Reason for Higher Max Demand in SMS#2 over SMS#1

Extra facilities provided in SMS # 2 like HMDP, Dog House,
additional LHF, RH, De-dusting unit for FAFA and MHS.

17

17
17

Power Flow into SMS # 2

220 KV 2 Lines

MRS

Main Receiving Station

(AP TRANSCO)

LBSS - 6
33
KV
33 KV

11 KV

Generator Switchboard (TPP)

11 KV 1 Line

33 KV

GSB - 4

11 KV 1 Line
11 KV
2 Lines

LBSS - 7
11 KV

33 KV

LBSS- 6 Steps Down 220 KV to 33

KV and 11 KV.

33 KV LF-1 Board
ECR-1

LBSS-7 Steps Down 33 KV to 11 KV

and receives 1 no 11 KV line directly
from LBSS-6.

33 KV LF-2 Board
ECR-3

33 KV, 4-Lines

7- LBDS 4
ECR-1

11 KV Board

18

Power Flow within SMS # 2

11 KV Board in ECR-1
3 - Feeders

7- LBDS 4
ECR-1

11 / 6.6
KV T/F

6.6 KV Board in ECR1

7-4-HVLC-1
ECR-1

11 KV /
415 V T/F

6.6 / 3.3
KV T/F

11 KV /
415 V T/F

11 KV /
415 V T/F

7-4-LCSS-01 7-4-LCSS-02

6.6 KV Board in ECR-1

ECR-1

ECR-1

LC LC LC LC LC LC LC LC LC
3 5 7 8 9 10 11 12 13

7-4-LCSS-14
ECR-4

7-4-HVMCC-1
ECR-1

3.3 KV

~
6.6 KV

ID fan motors of
SECS, LF DEdusting, BMHS, FES,
etc

AC Drive
GCP ID
Fan

SECS = Seconday Emission Control System

11 KV /
690 V
T/F
FG and
GH Aisle
Cranes.

11 KV /
690 V
T/F

7-4-LCSS-04

7-4-LCSS-06

ECR-1

CCB

AB and
BC Aisle
Cranes.

Sub-Stations for Dalian Liquid

Metal Handling Cranes.

19

20
20

MAJOR TECHNOLOGICAL CHANGES in CONV SHOP

SMS-2

SMS-1

Hot metal receipt by TLC only

Hot metal receipt by open tops

and TLC

No mixer unit

Mixer units - 2 nos

HMDP

No HMDP

Slag yard pits above ground level

Slag yard pits below ground level

Slag dumping by crane

Slag dumping by Dump cars

150 cu.m LD Vessels

133 cu.m LD Vessels

Lance - Rope drive

Lance - chain drive

VVVF Drive for GCP For ID Fans

Fluid coupling drives for ID Fans

All heats are routed either through

LF or RH

Only one LF . RH not available.

21

MAJOR TECHNOLOGICAL CHANGES IN Sec Met area

SMS-2

SMS-1

2 LHF and 1 RH degasser

1 LHF and 1 IRUT

2 Hydraulically operated
Ladle tilter in LP Bay

No such facility

Platform Car for return ladles STC - 4 only for return

& Slag pots
ladles.

22

MAJOR TECHNOLOGICAL CHANGES in CCS

SMS-2

SMS-1

Emergency ladle in CCM

No such facility

Independent arms for lifting

of ladles in Turret at CCM

Single arm for both legs

Six strand Billet casters, 10

meter radius

Four strand Bloom casters,

12 meter radius

Rigid Dummy bar, bottom

insertion

Flexible Dummy bar Top

insertion

Hydraulically operated
MOMs

Electro mechanical MOMs

AMLC , EMS for moulds in

all 3 CCMs

Installed only in CCM-2

recently
23

MAJOR TECHNOLOGICAL CHANGES in CCS

SMS-2

SMS-1

Tundish slide gate, CNC

Monoblock stoppers

Cantilever Tundish car

Simply supported on Wheels

Single gas cutting pulpit for

six strands M/c

Two pulpits per M/c(each for

a pair of strands Twin Table
cars

Lateral Transfer car for each No such facility

machine
Walking Beam Cooling Beds No such facility
Every M/c has its own HFL

3 HFLs For Six M/Cs

24

MAJOR PROCESS CHANGES

SMS-2
Average heat size 150T

SMS-1
Average heat size 143T

Continuous iron ore charging No such facility provided

while blowing
400 mm Ladle free board

Very little free board

All heats through LF or RH

LF used only if time permits.

Low sulphur grades can be

made (HMDP)

No such facility provided

Degassing grades can be

made (RH Degasser)

No such facility provided

25

View from SMS-2 GCP stack

26

View from SMS-2 GCP stack

27

View Of SMS-2 CCM

28

View Of SMS-2 converter during

erection

29

View Of SMS-2 GCP Finfans

30

31