PROJECT TRAINING REPORT
ON
STUDY OF BASIC OXYGEN FURNACE AND CONTINOUS
CASTING
Duration - 06/06/23 to 01/07/23 at Bokaro Steel Plant
Under the Guidance of
Sr. A.K Tiwari
General Manager, SMS II/CCS , BSL
By
PAWAN HANSDA 3rd Year - 6th Sem.
BSL URN - 5911312
I.D. – 20030500038
DEPARTMENT OF METALLURGICAL ENGINEERING
B.I.T SINDRI, Dhanbad
Signature of Project Supervisor with Date
TO WHOM IT MAY CONCERN
This is to certify that PAWAN HANSDA, a student of Bachelor of Technology (
Metallurgical Engineering), B.I.T Sindri, Dhanbad has successfully completed the
Project Training on the topic “ BASIC OXYGEN FURNACE (SMS II/CCS) “
from STEEL AUTHORITY OF INDIA LIMITED, BOKARO (BSL) for a period
of four weeks from 6th June 2023 to 1st July 2023 under the guidance of
Sr. A.K Tiwari , General Manager , SMS II/CCS , BSL.
HIS PERFORMANCE DURING THE TRAINING WAS EXCELLENT.
NEETA BA
GEN. MANAGER (HRD)
BOKARO STEEL PLANT
CERTIFICATE
This is to certify that PAWAN HANSDA, from B.I.T Sindri, Dhanbad has
undergone Project training at “Steel Authority of India Limited (SAIL), Bokaro
Steel Plant” for a period of four weeks from 6th June 2023 to 1st July 2023 , under
myguidance.
His performance was satisfactory so as to fulfill all the requirements for successful
completion of the training.
Date: - (Signature of Project Supervisor)
ACKNOWLEDGEMENT
I would like to express my sincere gratefulness and profound gratitude
to Steel Authority of India Limited for providing an opportunity to
undergo Project training of four weeks at “Bokaro Steel Plant, Bokaro
Steel City, and Jharkhand”
In regards to the training, I bear immense pleasure in expressing my
Special gratitude to Sr. A.K Tiwari (SMS II/CCS) as a project guide
and thanks to all the Employees of respective shops and complex for
their honest teaching, practical demonstration, guidance and suggestion
in respective shops and complex.
This training wasn't possible if Dr. B.N Roy, HOD , Department Of
Metallurgical Engineering , B.I.T Sindri wouldn't have allowed us in
the first place, so thanks to him as well.
ABSTRACT
Bokaro Steel Plant (BSL) is located in the Bokaro district of Jharkhand. It is the fourth integrated
public sector steel plant in India built with Soviet help. It was incorporated as a limited company in
1964. It was later merged with the state-owned Steel Authority of India Limited (SAIL).Currently it
houses five blast furnaces with a total capacity to produce 4.825 MT of Crude steel.
Bokaro Steel Plant is designed to produce a wide range of flat products: Hot rolled coils, Hot rolled
plates, Hot rolled sheets, Cold rolled coils (CRM), Cold rolled sheets, Tin mill black plates (TMBP) ,
Galvanized plain and corrugated (GP/GC) sheets.
In this project report, we are mainly focused on the Steel Melting Shop (SMS) and Continuous Casting
Shop (CCS) which are the backbone for the overall flourishment of the plant. Currently, in BSL there
are two Steel melting shops, SMS-New and SMS-II respectively with a Continuous casting shop each.
As on date, 100% casting is through continuous casting route only. Initially, ingots were made at steel
melting shops and were sent to the Slabbing Mill for rolling into slabs which was not at all a cost
effective route.
Replaceable Equipment Repair Shop (RERS) , under Capital Repair (Mech.) Department , is the most
active shop in BSL that repair segments of the caster every day , so as to boost the continuous casting
process . It also contains Manual and Automated Machining tools like CNC Mill, Lathe, and Open Arc
Welder etc. to accelerate the repairing process.
This Report mainly focuses on the Process involved in the Steel making shop in SMS II to produce steel
for casting.
Contents
● INTRODUCTION
❖ Introduction to Bokaro Steel Plant
❖ Process Flow Of Steel Production `
1. Steel Melting Shop And Continuous Casting Shop
1.1 Introduction to Steel Melting Shop-II
1.2 Introduction to Continuous Casting Shop
2 . Basic Oxygen Furnace (LD Converter)
3.Problems
3.1 Optimization of MgO in Steel Making Slag.
4. CONCLUSION
5. REFERENCES
INTRODUCTION
Steel Authority of India Limited is India’s
largest steel producing company and ranks 18th
in the World. It was founded in 19th January
1954 with headquarter at New Delhi. It was
incorporated to central public sector on 24
January 1973. With an annual turnover of more
than Rs.1 lakh crore, the company is among the
seven Maharatnas of the Country‟s Central
Public Sector Enterprises.
SAIL traces its origin to the formative years of an
emerging nation - India. After independence the
builders of modern India worked with a vision -
to lay the infrastructure for rapid industrialisation
of the country. The steel sector was to propel the
economic growth. Hindustan Steel Private
Limited was set up on January 19, 1954.
Hindustan Steel (HSL) was initially designed to
manage only one plant that was coming up at I would
Rourkela. For Bhilai and Durgapur Steel Plants, like to
the preliminary work was done by the Iron and Steel Ministry. From April 1957, the supervision and
express
control of these two steel plants were also transferred to Hindustan Steel. The registered office was
my to Ranchi in December
originally in New Delhi. It moved to Calcutta in July 1956, and ultimately
1959. sincere
The 1 MT phases of Bhilai and Rourkela Steel Plants were completed by the end of December 1961.
grateful
The 1 MT phase of Durgapur Steel Plant was completed in January 1962 after commissioning of the
ness
Wheel and Axle plant. The crude steel production of HSL went up from .158 MT (1959-60) to 1.6
and
MT. A newsteel company, Bokaro Steel Limited, was incorporated in January 1964 to construct and
operate the steel plant at Bokaro. profoun
The second phase of Bhilai Steel Plant was completed in September d
1967 after commissioning of the
Wire Rod Mill. The last unit of the 1.8 MT phase of Rourkela - the Tandem Mill - was
gratitud
commissioned in February 1968, and the 1.6 MT stage of Durgapur Steel Plant was completed in
e the completion
August 1969 after commissioning of the Furnace in SMS. Thus, with to of the 2.5 MT
stage at Bhilai, 1.8 MT at Rourkela and 1.6 MT at Durgapur, the totalSteel
crude steel production capacity
of HSL was raised to 3.7 MT in 1968-69 and subsequently to 4MT in 197273.
Authori
ty of
India
SAIL manufactures and sells a broad range of steel products, including hot and cold rolled sheets
and coils, galvanized sheets, electrical sheets, structural, railway products, plates, bars and rods,
stainless steel and other alloy steels. It has been possible through 5 integrated plants and 3 special
steel plants which employs over a lakh of employees and produces 13.5 million metric ton of steel
annually. Along with this there are various subsidiary and joint venture plant set up with SAIL.
SAIL has its own Research and Development Centre at Ranchi to examine and improve the quality
of steel production and update the technologies to be in par with rest of the world. Besides, SAIL has
its own in- house Centre for Engineering and Technology (CET), Management Training Institute
(MTI) and Safety Organization at Ranchi. For promoting and selling various long and flat products
produced in domestic market and abroad, SAIL has its own Central Marketing Organization with
branches spread all across the India and world. SAIL's International Trade Division ( ITD), in New
Delhi- an ISO 9001:2000 accredited unit of CMO, undertakes exports of Mild Steel products and Pig
Iron from SAIL‟s five integrated steel plants.
MAJOR UNITS OF SAIL
Steel Plant Location Major Products
Plates, Rods, Rail Tracks,
1. Bhilai Steel Plant Bhilai, (Chhattisgarh) Structurals,TMT, Merchants
Structurals, Wheels & Axles,
2. Durgapur Steel Plant Durgapur, (WB) Skelp
Rourkela,(Orrissa) Plates, Coils, Pipes, GP/GC,
3. Rourkela Steel Plant Silicon Steel
Plates, Coils, Sheets, GP/GC,
4. Bokaro Steel Plant Bokaro, (Jharkhand) TMBP
Indian Iron & Steel Burnpur, (WB) Structurals, Rails, Bars, Rods
5. Company Limited (IISCO)
INTRODUCTION TO BOKARO STEEL PLANT
Bokaro Steel Plant - the fourth integrated plant in the Public Sector - started taking shape in 1965 in
collaboration with the Soviet Union. It was originally incorporated as a limited company on 29th
January 1964, and was later merged with SAIL, first as a subsidiary and then as a unit, through the
Public Sector Iron & Steel Companies (Restructuring & Miscellaneous Provisions) Act 1978. The
construction work started on 6th April 1968.
Figure – BSL MAIN GATE
The Plant is hailed as the country‟s first Swadeshi Steel Plant, built with maximum indigenous
content in terms of equipment, material and know-how. Its first Blast Furnace started on 2nd
October 1972 and the first phase of 1.7 MT Ingot steel was completed on 26th February 1978 with
the commissioning of the third Blast Furnace. All units of 4 MT stage have already been
commissioned and the modernisation taken up in the nineties has further upgraded this to 4.65 MT
of liquid steel.
Major Landmarks in the history of Bokaro Steel Plant
Years & Month Landmarks
1966, Jan Construction work started
1972, Sept First Coke Oven Battery and Sinter Band commissioned
1972, Oct First Blast Furnace commissioned
1973, Dec Steel Melting Shop - 1 started production
1974, Dec Trial rolling of slabs in Slabbing Mill
1975, Dec Hot Strip Mill commissioned
1976, Jan Hot Rolled Coil Finishing commissioned
1977, June Cold Rolling Mill Complex - 1 commissioned
1983, June Steel Melting Shop - 2 started production
1991, Sept Cold Rolling Mill Complex - 2 commissioned
1997, Sept Continuous Casting Shop started production
Facilities
Raw Materials & Material Handling Plant
The Raw Materials and Material Handling Plant receives, blends, stores and supplies different raw
materials to Blast Furnace, Sinter Plant and Refractory Materials Plant as per their requirements. It also
maintains a buffer stock to take care of any supply interruptions.
Some 9 MT of different raw materials viz. Iron ore fines and lumps, Limestone (BFand SMS grade),
Dolomite lumps and chips, hard Coal and Manganese ore are handled here every year.
Iron ore and fluxes are sourced from the captive mines of SAIL situated at Kiriburu, Meghahataburu,
Bhawanathpur, Tulsidamar and Kuteshwar. Washed coal is supplied from different washeries at Dugda,
Kathara, Kargali and Giddi, while raw coal is obtained from Jharia coalfields.
Coke Ovens & By-product Plant
The Coke Oven Complex at Bokaro converts prime coking coal from Jharia, Dugda and Moonidih and
medium coking coal form Kargali, Kathara and Mahuda, blended with imported coal, into high quality
coke for the Blast Furnaces, recovering valuable by-products like Anthracene Oil, Benzene, Toluene,
Xylene, Light Solvent Naphtha, Ammonium Sulphate and Extra-hard Pitch in the process. Bokaro is
situated in the prime coal belt of the country.The Coke Oven battery has 8 batteries with 69 ovens each,
maintained meticulously in terms of fugitive emission control, use of phenolic water and other pollution
control measures.
Blast Furnaces
Bokaro has five 2000-cubic metre Blast Furnaces that produce molten iron - Hot Metal - for steel making.
Total hot metal production capacity of blast furnaces is 5.25MT. Bell-less Top Charging, modernised
double Cast Houses, Coal Dust Injection and Cast House Slag Granulation technologies have been
deployed in the furnaces. The process of iroin-making is automated, using PLC Charging System and
Computer Controlled Supervision System. The wastes products like Blast Furnace slag and gas are either
used directly within plant or processed for recycling / re-use.
Steel Melting Shops
Hot Metal from the Blast Furnaces is converted into steel by blowing 99.5% pure Oxygen through it in
the LD converter. Suitable alloying elements are added to produce different grades of steel.
Bokaro has two Steel Melting Shops – SMS- NEW and SMS-II. SMS-NEW has 3 LD converters of 130T
capacity each. 1 single strand caster with capacity of 1.305 MT or 33 Heats/day has been installed. It can
produce slab of width range from 850 mm to 1650 mm, the slab length will vary from 7.5 mts. to 10.5
mts. The product mix contains of low, medium, high carbon and micro alloyed steel such as LPG, API,
SAILMA etc. The facility also includes Tundish Preparation Bay, Slab Yard and mould repair section.
The new facility includes one twin LF with common arcing facility for both LF.
Steel ingot route through mould yard and Stripper yard earlier has been closed from 2nd 2021 and now all
steel is produced from LF and Caster route. It was capable of producing Rimming steel. SMS-II has 2 LD
converters, each of 300 T capacities, with suppressed combustion system and Continuous Casting facility.
It produces various Killed and Semi-Killed steels.
Continuous Casting Shop
The Continuous Casting Shop has two double-strand slab casting machines, producing high quality slabs
of width ranging from 950 mm to 1850 mm. CCS has a Ladle Furnace and a Ladle Rinsing Station for
secondary refining of the steel. The Ladle Furnace is used for homogenising the chemistry and
temperature. The concast machines have straight moulds, unique in the country, to produce internally
clean slabs.
Argon injection in the shroud and tundish nozzle prevent re-oxidation and nitrogen pick-up, maintaining
steel quality. The eddy current based automatic mould level control, unique in the country, gives better
surface quality. The air mist cooling and continuous straightening facilities keep the slabs free from
internal defects like cracks. The casters are fully automated with dynamic cooling, on-line slab cutting,
de-burring and customised marking. The shop is equipped with advanced Level-3 automation and control
systems for scheduling, monitoring and process optimisation.CCS produces steel of Drawing, Deep
Drawing, Extra Deep Drawing, Boiler and Tin plate Quality. It also produces low alloy steels like LPG,
WTCR, SAILCOR and API grade.
Slabbing Mill
Slabbing Mill transforms ingots into slabs by rolling them in its 1250 mm Universal Four-High Mill. The
rolling capacity of the Mill is 1.9 MT per annum. The shop has Hot and Cold Scarfing Machines and 2800 T
Shearing Machine. Controlled heating in Soaking Pits, close dimensional accuracy during rolling and hot
and cold scarfing help produce defect-free steel.
Hot Strip Mill
Slabs from CCS and Slabbing Mill are processed in the state-of-the-art Hot Strip Mill. The fully
automatic Hot Strip Mill with an annual capacity of 4.5 million tonnes has a wide range of products -
thickness varying from 1.2 mm to 20 mm and width from 750 mm to 1850 mm. The mill is equipped with
state-of-the- art automation and controls, using advanced systems for process optimisation with on-line
real time computer control, PLCs and technological control systems.
Walking Beam Reheating Furnaces provide uniform heating with reduction in heat losses, ensuring
consistency in thickness throughout the length. High-pressure De-scaling System helps eliminate rolled-in
scale. Edgers in the roughing group maintain width within close tolerance. The roughing group has a
roughing train of a Vertical Scale Breaker, one 2-high Roughing Stand and four 4-high Universal
Roughing Stands. The finishing group consists of a Flying Shear, Finishing Scale Breaker and seven 4-
high Finishing Stands. Hydraulic Automatic Gauge Control system in the finishing stands ensures close
thickness tolerance. The Work Roll Bending System ensures improved strip crown and flatness. The
rolling speed at the last finishing stand is between 7.5-17.5 metres per second. The Laminar Cooling
System is a unique feature to control coiling temperature over a wide range within close tolerance. The
Hydraulic Coilers maintain perfect coil shape with On-line Strapping system. On-line Robotic Marking on
the coil helps in tracking its identity.
Hot Rolled Coil Finishing
All the Hot Rolled coils from the Hot Strip Mill are received in HRCF for further distribution or despatch.
IT has an annual capacity of 1.2 MT. HR Coils rolled against direct shipment orders are sheared and
finished to customer-required sizes and despatched to customers. The material is supplied as per Indian
specifications and many international/ foreign specifications.
Cold Rolling Mill
The Cold Rolling Mill at Bokaro uses state-of-the-art technology to produce high quality sheet gauge
material, Tin Mill Black Plate and Galvanised Products. Cold rolling is done to produce thinner gauge
strips of very smooth and dense finish, with better mechanical properties than hot rolling strips. Rolling is
done well below re-crystallization temperature without any prior heating of the material. The products of
CRM are used for deep drawing purposes, automobile bodies, steel furnitures, drums and barrels, railway
coaches, other bending and shaping jobs and coated steels. The CRM complex comprises of two Pickling
Lines (including a high speed Hydrochloric Acid Pickling Line with re-generation facilities), two Tandem
Mills, an Electrolytic Cleaning Line, a Continuous Annealing Line, Bell Annealing Furnaces, two Skin-
Pass Mills, a Double Cold Reduction Mill (DCR), Shearing Lines, Slitting Lines and a packaging and
despatch section. The 5-stand Tandem Mill is capable of rolling sheet gauges upto 0.15 mm thickness. It
has sophisticated Hydraulic Automatic Gauge Control, computerised mill regulation and optimisation
control.
Hot Dip Galvanising Complex
The Hot Dip Galvanizing Complex integrated with the CRM produces zinc-coated Cold Rolled strips
resistant to atmospheric, liquid and soil corrosion. The Continuous Coil Corrugation Line in the HDGC
produces corrugated sheets and the Galvanised Sheet Shearing Line produces galvanised plain sheets for a
variety of applications. The first shop of Bokaro Steel to get the ISO-9001 certification way back in 1994,
this complex has maintained a highstandard of coating quality and its SAILJYOTI branded products enjoy a
loyal market. This complex made certain innovations for higher productivity to help re-build earthquake-
ravaged Gujarat.
Services - a valuable support network
The service departments like Traffic, Oxygen Plant, Water Management and Energy Management provide
invaluable support to this gigantic plant. Bokaro Steel has a vast networked of railway tracks and over 40
diesel locos to smoothly run its operations. The Oxygen Plant provides Oxygen, Nitrogen and Argon for
processes like steelmaking and annealing. Water Management looks after the huge water requirements of
the plant and the township, providing different grades of water and taking care of recycling needs. Energy
Management juggles the supply and demand of by-product gases and their demand as process fuel.
Maintenance Departments
Bokaro has centralised maintenance departments for large-scale electrical and mechanical
maintenance, in addition to shop-based maintenance wings for running repairs and maintenance.
These facilities are capable of executing massive capital repairs, supported by the fabrication facilities
of the auxiliary shops.
Auxiliary Shops
To meet its needs for maintenance and repairs, Bokaro has a cluster of engineering shops such as
Machine Shop, Forge Shop, Structural Shop, Steel Foundry, Ingot Mould Foundry, Cast Iron and
Non-Ferrous Foundry, Electrical Repair Shop and Power Facilities Repair Shop in addition to shop-
specific Area Repair Shops. Most of the repairs and maintainance requirements of the plant are met
in-house.
The auxiliary shops and maintenance wings of Bokaro Steel, aided by in-house design teams, have
executed a number of highly sophisticated procurement-substitution, productivity enhancement and
quality improvement jobs, saving revenues and enhancing equipment availability.
The expertise and operational scale of these departments, along with the service departments,
Makes Bokaro a truly integrated plant, housing many virtual enterprises within Bokaro Steel.
Bokaro Steel Plant is designed to produce a wide range of flat products:
Hot rolled coils
Hot rolled plates
Hot rolled sheets
Cold rolled coils (CRO)
Cold rolled sheets
Tin mill black plates (tmbp)
Galvanised plain and corrugated (gp/gc)
sheets Oxygen Gas Produced
Area of plant - 17,000 acre
Township area - 19,000 acre
⮚ Carbon content is --% in steel at Bokaro Steel Plant
Inside Bokaro Steel Plant
⮚ 300 km railway truck⮚70 loco is present.
⮚ 100 rail crossing .⮚10-12 gates are there for entry/exit in plant.
PROCESS FLOW OF STEEL PRODUCTION
Figure - PROCESS FLOW OF BSL
1. Steel Melting Shop And Continous Casting Shop
Steel is an alloy consisting mostly of Iron, with Carbon content between 0.2% and 2.1% by weight,
depending on the grade. Steelmaking is an oxidising process. It refines and oxidises the impurities in hot
metal like C, Si, Mn and removes S, P, to a desired level. Fluxes are added to form basic slag to fix S & P.
Hot metal supplies the necessary heat in BOF steelmaking
Steel at Bokaro is produced by oxygen blending (L.D) process. There are five 130 ton and two 300 ton L.D
converters in Bokaro. The converters are charged with scrap, hot metal and fluxes. Pure oxygen is blown
through water-cooled lance with multi-orifice nozzle to remove impurities by oxidation and then steel is
made. Purity of Oxygen used is 99.5 %.
Approximately 60 cu m. of oxygen is used to produce one ton of steel. The tap-to-tap time for the 130 ton
and 300 ton converters is 60 and 80 minutes respectively.
There are two steel melting shop SMS I and SMS II and a Continuous Casting Shop near SMS II which
have two casters.
In CCS Steel is further refined, chemistry and temperature are control so that the liquid is fit for casting.
Liquid steel available is converted into solid form with minimal losses for further processing in the solid
state
FLOW - CHART SMS II AND CCS
1.1. Introduction to Steel Melting Shop-II
SMS-II differs from SMS-I because of blowing process and converter gas recovery system. The
mode of combustion in SMS-II is suppressed combustion where atmosphere air is not allowed in
hood area and combustion of converter gas is suppressed which is further used as flux.
Inputs: Hot Metal from the Blast Furnace.
Outputs: Semi-Killed or Killed steel to continuous casting machine exclusively.
Shop Equipments
SMS-II
2 Converters each of 300 T capacity
2 Mixers each of 2500 T capacity
6 hole Lances
Gas Cleaning Plant
Transfer cars
EOT cranes
Sections: Major sections of SMS-II are as follows:
1. Mixer: The mixer is of 2500 T capacity and the temperature is about 1573-1593 K. The mixer
acts as a reservoir of hot metal, homogenizes it and maintains the temperature. It acts as a
buffer stock. Hot metal from mixer is supplied to converter by locos. There are two mixers in
SMS-II.
2. Converters: This converts hot metal into steel by oxidation following an exothermic reaction.
Lime, Scrap & Following hot metal are charged in a definite sequence and then oxygen lancing
is done. The lime and other addition are done during blowing through slide gate system. Lime
is added as a flux to maintain the basicity of bath. Basicity is defined as the ratio of Calcium
Oxide & Silicon Oxide and is kept between 3-3.5. There are two converters of 300 T capacities
each.
3. Steel Refining Unit: Steel Refining Unit: This unit homogenizes the temperature and comical
composition of liquid steel received from different converters. Desulphurization of steel is done
up to a Sulphur level of 0.01%. Adding prerequisite quantities of Ferro-alloys also dose
chemical correction of steel. End point temperature control of liquid steel is done by heating or
cooling the melt.
4. PIT Side
5. Magnetic Yard
6. Slag Yard
1.2. Introduction to Continuous Casting Shop
There are two double stand casting machines capable of producing slabs of 950mm to 1850mm
width (cold). Thickness can be of 200mm, 225mm or 250mm. Converter metal of SMS is further
refined in the Steel Refining Unit (SRU) and cast into slabs in the casting machine. In the process
of casting, metal is poured into tundish from the laddle and from tundish, metal flows into caster
mould. Normally it takes 60 to 65 minutes for casting 290-300 tonnes of metal in to slab.
Depending upon the slab width, the rate of pouring can be from 0.9 metres/minute to 1.8
metres/minute. The yield ratio (liquid metal to slab) in caster is 97-98% where as in earlier route
(liquid metal-ingot-slab) yield ratio is about 80%. In caster, chemical uniformity from slab to slab
is better. Now plant is producing better quality slabs at lower production cost after modernization.
Continuous Caster: It is the heart of SMS-II and has following main parts:
a. Tundish: It is refractory liquid buffer vessel designed to continuously feed liquid metal from
ladle to continuous casting mould at regulated flow rate.
b. Mould: Solidification of metal starts in the mould. Copper using primary cooling mode
generally makes it. At the beginning of casting, a dummy bar is inserted inside the mould to
avoid free fall of steel. Continuous lubrication between and steel is provided by mould
powder. It also acts as coolant.
c. Secondary Cooling Zone: The metal, after leaving the mould enters in its secondary cooling
comprising arrays of rollers and water spray nozzles. Rollers support and guide its downward
movement of strand and water spray cools the strand resulting in complete casting.
d. Straightening Rolls: These are located at the end of strand 2 where fully solidified strand is
straightened by pairs of internally water cooled rolls and made to move over horizontally
placed roller tables. After the stand has been straightened, it is cut to required length using
acetylene- cutting machine.
Shop Equipments
CCS
Two Twin strand curvilinear casters
Steel Refining Unit (SRU) with LF/LRS for treatment of steel before casting
On-line slab cutting
MgO lined Tundish of 50 T capacity
Slide Gate System
Advantages of Continuous Casting:
1. It gives higher yield.
2. Energy consumption is low.
3. Operating cast is low.
4. Role of primary mills gets eliminated.
2. Basic Oxygen Furnace (LD Converter)
Basic Oxygen Furnace (BOF) process was developed in Austria in the early 1950s at the two Austrian
steelworks at Linz and Donawitz and hence the BOF process is also called LD (first letters of the two cities)
steel making. There exist several variations on the BOF process. The main are top blowing, bottom blowing,
and a combination of the two which is known as combined blowing. In SMSII the two BOF vessels are
combined blown with suppressed gas technology and have capacity of around 300 tons.
Structure of a Basic Oxygen Furnace
The scheme of a Basic Oxygen Furnace (BOF) is
presented in the picture. The BOF vessel also
known as converter is simply a barrel shaped steel
shell with a refractory lining and supported on a
tilting mechanism. The converter shell consists of
three parts namely (i) spherical bottom, (ii)
cylindrical shell, and (iii) upper cone. The converter
shell is attached to a supporting ring equipped with
trunnions. The supporting ring provides stable
position of the converter during O2 blowing. The
converter is capable to rotate in a vertical plane
about its horizontal axis of 360 degrees on
trunnions driven by electric motors and can be held
in any position..
This rotation (tilting) is necessary for various converter operations during a heat. Only 8 % to 12 % of
the converter volume is filled with the liquid steel after a heat is made. The bath depth is about 1.2 m to
1.9 m. The capacity of BOF converter of SMS 2 is 300 tons and SMS 2 has 2 converters. The tap to tap
time for a BOF heat is around 40 – 50 minutes, of which around35 % is the O2 blowing time. This rate
of production made the process compatible with the continuous casting of liquid steels, which in turn has
an enormous beneficial impact on yields from crude steel to the shipped product, and on downstream
rolled steel quality. The SMS 2 converters are equipped with combined blown technology with O2
Lance on top and N2 and Argon tuyeres in the bottom. The lance is water cooled with a multi hole (6 in
the case of SMS 2) copper (Cu) tip. O2 flow is normally in the range of around 6 to 8 cum/min.t. The O2
pressure is usually in the range of around 12 to 18 atmosphere.
Refractory lining of a Basic Oxygen Furnace
The refractory lining of basic oxygen furnaces work in severe conditions of high temperature and oxidizing
atmosphere. The lining wear is fastest in the zone of contact with the oxidizing slag (slag line).
Refractory bricks for lining basic oxygen furnaces are made of either resin bonded magnesite or tar bonded
mixtures of magnesite (MgO) and burnt lime (CaO). The bonding material (resin, tar) is coked and turns into
a carbon network binding the refractory grains, preventing wetting by the slag and protecting the lining the
from chemical attack of the molten metal.
The following measures allow prolonging the service life of the lining:
Control of the content of aggressive oxidizing oxide FeO in the slags at low level.
Addition of MgO to the slags.
Performing “slag splashes” - projecting residual magnesia saturated slag to the lining walls
by Nitrogen blown through the lance.
Repair the damaged zones of the lining by gunning refractory materials.
Properly maintained lining may serve 20000 heats.
Functions of BOF
Removal of impurities like C, Si, Mn, and P with the help of oxygen.
Removal of C Si etc raises the melting temperature of the alloy. So temperature must be raised to
keep the product as liquid.
Oxidation leads to temperature rise and oxides like SiO2, MnO, FeO, P2O5.
Oxides must also be in liquid state. So CaO is added so that the resultant mixture called SLAG is
also liquid. So the impurities are removed through slag.
Sequence of operation in BOF
Lime / dolomite addition at
converter bottom.
Scrap charging
Hot metal charging
Oxygen blowing
Addition of fluxes in batches
during blow
After blowing oxygen lance is
lifted and converter tilted for
sample and temperature
recording
Tapping in ladle
Addition of de-oxidiser in ladle
during tapping
Charging of the converter
Scrap
Lance tip
Hot Metal
Blowing Practice
Supply of O2 at desired flow rate and pressure through a Lance.
Specific Oxygen flow rate varies from 3.0 to 4.0 NM3 per Ton per min.
O2 purity should be 99.5%.
O2 is supplied at high pressure at about 12 - 13 bar.
O2 is blown at supersonic velocity.
Oxidation is completed in 16 - 20 mins.
Entire operation is over in 40 - 50 mins.
No fuel required, as this is a heat excess process. Heat is generated by the exothermic oxidation
reactions.
Steel scrap, Iron ore, DRI is added as coolants to control final temperature to about 1650C.
Chemical and physical processes in a Basic Oxygen Furnace
Oxidation of impurities present in hot metal Change in the slag composition during the blow
vs blowing time
Working of Basic Oxygen Furnace
The primary raw materials for the BOF are generally HM (around 85 to 92 %) from the blast furnace and the
remaining steel scrap. These are charged into the BOF vessel. O2 is blown into the BOF at supersonic
velocities. It oxidises the carbon (C) and silicon (Si) contained in the HM liberating great quantities of heat
which melts the scrap. There are lesser energy contributions from the oxidation of iron (Fe), manganese
(Mn), and phosphorus (P). The flux used in this process is primarily calcined lime (with CaO content of
around 85%). This lime is produced by the calcining of limestone with low silica (SiO2) content. The post
combustion of carbon monoxide (CO) as it exits the converter also transmits heat back to the bath. The
product of the BOF is liquid steel with a specified chemical analysis at a temperature of around 1640-
1680deg C. The term ‘basic’ refers to the refractory linings of the furnace which are made of alkaline
materials (mag C bricks). Refractory linings must have specific properties to withstand high temperatures,
the corrosive action of the highly oxidised and basic slags, and abrasion during charging and blowing. Basic
slags are required to remove P and sulphur (S) from the liquid charge.
Before ignition, weighed amount of calcined lime/dolomite fluxes are dropped in the converter from
overhead bins to support the scrap burden and prevent refractory lining from mechanical shock produced
during scrape charging.These are the fluxes that form the slag. It is necessary early in the blow to form a
fluid slag, which has the function of preventing sparking, the ejection of metal from the converter due to the
impact of the O2 jet. To promote quick formation of slag, calcined lime is used. If raw limestone was used,
its calcination would absorb heat from the process. Iron ore required (to adjust temperature) is then added
with the remainder of the flux charge, whilst blowing continues. The flux charge is added within the first
few minutes of the blow.
Before the beginning of a heat in the converter the HM is weighed out, sampled for chemical analysis and
for temperature. This data, together with grade specifications, is used to calculate the amount of scrap, fluxes
and O2 required. These amounts also depend on the levels of Si., and temperature of the HM, since the heat
generated by oxidation of the impurities must balance the requirements of bringing the scrap, fluxes and hot
metal to the required temperature. SMS 2 has a computer charge model to determine the optimum
proportions of scrap and HM, flux additions, lance height and oxygen blowing time, once the HM
temperature and chemical analysis is known.
A heat begins when the converter is tilted about 45 degrees towards the charging bay and the pre weighed
scrap charge is charged into the mouth of the converter from a scrap charging box with the help of the scrap
charging crane. The HM is immediately poured directly onto the scrap from a transfer ladle by a HM
charging crane. Charging takes normally 8-9 minutes. After charging the converter is rotated to the vertical
position, the lance is lowered to around 2.5 m to 3.0 m above the bottom of the converter. Through this
lance, O2 is blown into the charge mix. The lance blows O2 on to the charge mix at high velocity and
reactions commence. Seconds later ignition occurs when the CO from the reaction burns to carbon dioxide
(CO2), producing a brilliant, luminous flame at the mouth of the converter. The amount of O2 used is
around 55 -60 cum per ton of crude steel produced. The height of the lance above the liquid metal has an
important effect on blowing characteristics and on the analysis of the steel. The operation starts with the
lance in a high blow position which is around 3 m above the metal level in the converter. After a few
minutes, after the flux is added and sufficient slag has formed, the lance is lowered to the low blow position.
As blowing begins, an ear piercing shriek is heard. This is soon muffled as silicon from the HM is oxidised
forming silica (SiO2), which reacts with the basic fluxes to form a gassy molten slag that envelops the lance.
The gas is primarily CO from the C in the HM. The rate of gas evolution is many times the volume of the
converter and it is common to see slag slopping over the lip of the converter, especially if the slag is too
viscous. Blowing continues for a predetermined time based on the metallic charge chemistry and the liquid
steel specification. This is typically 15 to 20 minutes, and the lance is generally pre-programmed to move to
different heights during the blowing period. The lance is then raised so that the converter can be turned
down towards the charging bay for sampling and taking of the temperature. Once the heat is ready for
tapping and the preheated steel ladle is positioned in the ladle car under the furnace, the converter is tilted
towards the tapping bay, and liquid steel pours through the tap hole from under the floating slag, into the
Steel Ladle below. The tap hole is located on one side in the upper cone section of the converter. In SMS 2
slag Darts are used to prevent slag entering the STL as the converter is turned down. After tapping steel into
the Steel ladle and the converter is rotated upside down for the tapping of the remaining slag into the slag
pot. Then the converter is returned to the upright position. Then slag splashing is used with the help of N2
blow to coat the refractory line with MgO as slag is very corrosive at tapping temperature. Ferro alloys are
charged from overhead bins into the STL. The common alloys are ferro-manganese, silicon manganese, and
ferro-silicon.
The BOF process uses no additional fuel. The oxidation of HM impurities (C, Si, Mn, and P) supplies the
heat. Oxidation of the molten metal and the formation of the slag is complicated process proceeding in
several stages and occurring simultaneously on the boundaries between different phases (gas-metal, gas-
slag, slag-metal). Most oxides are absorbed by the slag. Gaseous products CO and CO2 are transferred to the
atmosphere and removed by the exhaust system. Since CO has very high calorific value so it is used as a
fuel for power generation.
Changes in Slag Composition
• Fluxes are charged into the furnace early in the blow and they dissolve with the developing oxides to form
slag
• The rate of dissolution of these fluxes strongly affects the slag- metal reactions occurring during the blow.
Therefore, it is mportant to understand this at the beginning of the blow.
• The tip of the oxygen lance is kept high above the bath surface known as soft blowing, which results in the
formation of an initial slag rich with SiO2 and FeO. During this period, large amounts of burnt lime and
dolomitic lime are charged into the furnace.
• The lance is then lowered, and the slag starts to foam at around one third of the blow due to the reduction
of the FeO in the slag in conjunction with CO formation.
• The drop in the FeO content in the slag is shown in Figure. Also, as the blow progresses, the Calcium
oxide (CaO) dissolves in the slag and the active slag weight increases.
• Finally, after three quarters into the blow, the FeO content in the slag increases because of a decrease in the
rate of decarburization.
• The resulting slag at turndown have typical ranges such as 42 to 55 percent of mass of CaO, 2-8 percent of
mass (wt.%) of MgO, 10 to 30 percent of mass (wt.%) of Feo, 3 to 8 percent of mass (wt.%) of MnO, and
10-25 percent of mass (wt.%) of Si02.
MgO in Basic Oxygen Furnace
In the Basic Oxygen Furnace (BOF) steelmaking process, the composition of MgO (magnesium oxide) in
the slag can vary depending on several factors, including the raw materials used and process conditions.
Typically, the MgO content in BOF slag ranges from around 2% to 10%. During the BOF process, hot metal
(molten iron) is combined with scrap steel and fluxes, such as limestone (CaCO3) or dolomite
(CaMg(CO3)2), in the converter vessel. The fluxes serve multiple purposes, including the removal of
impurities and the formation of slag. Magnesium oxide (MgO) is usually introduced into the BOF process
through the addition of dolomite, which contains both calcium carbonate (CaCO3) and magnesium
carbonate (MgCO3). When dolomite is added to the converter, it decomposes, releasing carbon dioxide
(CO2) and forming magnesium oxide (MgO) and calcium oxide (CaO). The MgO content in the resulting
slag depends on the dolomite-to-scrap ratio and the amount of magnesium present in the dolomite. The
typical range of 2% to 10% MgO in BOF slag is a general approximation, and the actual composition may
vary depending on the specific process parameters and the desired steel quality.
It's worth noting that the presence of MgO in BOF slag can have important implications for slag properties
and subsequent uses. For example, a higher MgO content can increase the viscosity of the slag, impacting its
flow characteristics and potential applications, such as in road construction or cement production. Therefore,
steelmakers carefully control the composition of fluxes to achieve the desired slag characteristics for
efficient steelmaking operations and slag utilization.
3.Problems
3.1 Optimization of MgO in Steel Making Slag.
Optimizing the use of MgO (magnesium oxide) in steelmaking slag is an important area of research aimed at
improving the overall efficiency and quality of the steelmaking process. MgO is commonly used as a fluxing
agent in steelmaking, where it helps in controlling the sulfur content and viscosity of the slag.
Here are some research directions and approaches that have been explored to optimize the use of MgO in
steelmaking slag:
Characterization of slag composition: Understanding the chemical and mineralogical composition of
steelmaking slag is crucial for optimizing the use of MgO. Researchers analyze the slag samples to
determine the presence of various elements and compounds, including MgO, and their effect on slag
properties.
Thermodynamic modeling: Thermodynamic modeling techniques, such as FactSage and Thermo-Calc, are
used to predict the phase equilibria and slag properties as a function of MgO content. These models help
identify the optimal MgO concentration in the slag to achieve desired outcomes, such as improved
desulfurization efficiency.
Experimental investigations: Laboratory-scale experiments are conducted to evaluate the impact of different
MgO concentrations on slag properties and steelmaking performance. These experiments involve adjusting
the MgO content within a controlled range and measuring parameters like viscosity, desulfurization
efficiency, and inclusion formation.
Computational fluid dynamics (CFD) modeling: CFD simulations are employed to study the fluid flow and
heat transfer phenomena occurring in the steelmaking process. By incorporating the effect of MgO on slag
viscosity and fluid dynamics, researchers can optimize the placement and injection of MgO into the slag,
improving its distribution and efficiency.
Optimization algorithms: Mathematical optimization techniques, such as linear programming and genetic
algorithms, can be applied to optimize the MgO addition in steelmaking slag. These algorithms consider
multiple variables, including MgO content, slag composition, and process conditions, to find the optimal
combination that minimizes specific objectives, such as sulfur content or energy consumption.
Recycling and reusing MgO-rich slag: Researchers also explore ways to recycle and reuse MgO-rich slag to
reduce waste and improve cost-effectiveness. This involves investigating methods to extract and recover
MgO from the slag for use in subsequent steelmaking processes.
Overall, the optimization of MgO in steelmaking slag involves a combination of experimental
investigations, thermodynamic modeling, computational simulations, and optimization techniques. By fine-
tuning the MgO content and understanding its impact on slag properties, researchers aim to enhance the
efficiency and sustainability of steelmaking processes.
4.Conclusion
The Steel Melting Shop is a vital component of the steel production process, responsible for melting,
refining, and customizing raw materials into high-quality molten steel. With its equipment and processes,
the SMS enables flexibility, quality control, and efficiency in steelmaking. By utilizing various raw
materials and incorporating refining and alloying techniques, the SMS contributes to the production of
diverse steel grades that meet the demands of various industries.
The basic oxygen furnace is a critical component of the steelmaking process, enabling the production of
high-quality steel on a large scale. Despite its limitations, the BOF remains a widely used technology due to
its efficiency, cost-effectiveness, and versatility. However, in the context of increasing environmental
concerns, efforts are being made to develop alternative steelmaking processes with lower carbon emissions
and reduced energy consumption.
Optimization of MgO in steelmaking slag is vital for enhancing steel production efficiency, product quality,
and cost-effectiveness. By employing strategies such as raw material selection, lime addition, slag
composition control, slag reworking, process parameter optimization, and recycling/recovery techniques,
steel manufacturers can achieve significant improvements in MgO optimization.
It is essential for steel manufacturers to understand their specific steelmaking process, quality requirements,
and environmental regulations when implementing MgO optimization strategies. By fine-tuning these
strategies to suit their operations, steel manufacturers can maximize the benefits and optimize MgO content
in steelmaking slag.
Further research and development in this field are encouraged to explore innovative techniques and
technologies for MgO optimization in steelmaking slag, leading to continuous improvement and
competitiveness in the steel industry.
5. References
1. Zhu, J., Zhang, M., Zhang, H., Wei, W., & Guo, X. (2020). Optimizing the MgO content in converter
steelmaking slag. Ironmaking & Steelmaking, 47(5), 559-566.
2. Biswas, A. K. (1981). Principles of blast furnace iron making: Theory and practice. Cootha
Publishing House.
3. Rajagopal, R., & Sharma, S. K. (2014). Knowledge management practices in SAIL: A case study of
Bokaro Steel Plant. The IUP Journal of Knowledge Management, 12(1), 22-41.
4. Tupkary, R.H. and V.R. Tupkary, An Introduction to Modern Steel Making, 6th ed., Khanna
Publishers, Delhi, 1998
5. Li, J., Jiao, K., & Chen, W. (2009). Modeling and optimization of a BOF steelmaking process using
support vector regression. Journal of Iron and Steel Research International, 16(6), 43-48.
