Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Charging
5min
Oxygen blowing
20min
8min
5min
Tapping
Total
5min
7min
50min
MIXTURE SECTION:
metal (pig iron) to the converter at a fairly uniform temperature & composition, in
required quantity whenever demanded. The mixture acts as buffer between Blast
Furnace and Converters.
There are two mixture of 1300 T capacity each. The pig iron reaches mixture
in ladle of 100 T capacities. Burners are provided in the mixture to maintain the
temperature of hot metal. Hot metal from mixture is supplied to the converter as per
demand.
SCRAP YARD:
Scrap yard receives the scraps generated from all over the plant in
wagons and truck. Two magnet cranes do the unloading / loading of scraps. Scraps
are supplied to the converters, which is melt with hot metal.
Lime and calcined dolomite are used as fluxes, iron ore and limestone are
used as coolants. Coke is used for preheating the converter and coating. These
materials are and charged into the converter. Very sophisticated microprocessor
based system, of weighing and then charging of bulk material into converter, is
installed in the main control pulpit.
Casting Bay
Ladle Furnace
RH Degasser
Discharge Bay
Tundish car
Stroud
Stopper
Stopper mechanism
Nozzle (submersed)
Mould
Dummy bar
Roll table
Hydraulic system
BREAKDOWN MAINTENACE: Break own maintenance is a process of maintaining the machine component and
equipment as soon as it is detected. It is done so because due to failure of that
machine component or equipment caster operation will be directly affected and
It may be the case that cooling of machine is not require for maintaining
Then the water supply is stopped and takes full shut down of the machine.
Next step in integral inspection of machine. All pinch roll are kept in lifted
position. Inspector goes inside the machine and check for bearings and rollers and
breakdown & minor defect list is prepared
spare one.
1. Tundish car (Hoist drive) : Limit switch was by passed thereby damaging the locking nut of bolts reducer.
2. Pinch rolls (Pinch roll stand) : Pinch roll no 03 roller broken.
3. Dummy bar unit (dummy bar unit) : -
JOB
PARENT EQUIPMENT:
GENERAL:
PARENT EQUIPMENT:
GENERAL:
HOIST DRIVE:
Check hoist reducer oil leakage & oil level &bottom cover bolts
Check hoist brake drum coupling brakes & intermediate shaft coupling
Check for the smooth running of mechanism for any abnormal sound
PARENT EQUIPMENT:
Check top frame fixing firm locking, condition of spindle locking & slide
blocks
These are mainly set of rollers and there failure criterion is different thus
maintenance procedure is different.
A)
FAILURE CRITERION: Following are the main failure criterion for five & eight
roll set:
1.
Roller bending
2.
Bearing failure
3.
Misalignment
POSSIBLE CAUSES:
1.
Low temperature of metal from ladle and stoppage of strand in the rollers
and low bending strength of the rollers may lead to the permanent bending of
rollers.
3.
REPARE PROCESS:
1.
2.
All the rollers are removed form the strand and are fully opened.
3.
There are two bearing in each side of roller, which is removed by removing
Bearings are checked if any problem is found bearing is removed & spar
bearing is placed.
5.
Spar rollers are placed on the frame & tighten through bolts.
6.
In case of five roll set bottom set is bigger radius this set is first maintained.
7.
First and last row of rollers are maintained at a height of 310mm from
Above the reference plane plate of different thickness based on cross section
required
9.
Then upper or smaller radius at the op is placed & is locked with bottom
Now rollers gap is maintained using tiller gauge & taking correction factor
GAP (mm)
201.70
201.58
201.45
201.33
201.20
GAP (mm)
201.20
201.13
201.06
200.99
200.92
200.85
200.77
200.70
11.
Only different fire roll & eight roll repair is that in eight roll set is small
Bearing failure
Roller breakage
POSSIBLE CAUSEC:
1. Bearing failure may be due to improper lubrication bending of roll bulging of
strand etc.
2. Roller bending may be due to improper cooling of rolls bulged strand and
stoppage of standing the roll due to stoppage of process.
3.
Fire cracks due to composition of roller material & was not detect earlier.
REPAIR PROCESS:
To make the blended rollers concentric rollers are turned on lathe to make
concentric.
Bearing failure is maintained by replacing break bearing by spare one &
damaged one is sent for repair.
Roller rejected.
From pinch rolls is used in roll table set where cutting by oxyacetylene is done
Breakage of rolls.
b)
Excessive wear of rolls due to molten metal facing and cutting flame
Repair process:
Repair process of mould consist of following steps be followed:
Dismantling of mould
Assembly of mould
Blast Furnace
2.
Furnace section
3.
Auxiliary section
1.
Fine ore
85,000
tones
2.
1,80,000 tones
3.
Limestone
40,000
tones
4.
Mn.Ore
11,000
tones
5.
Quartzite
3,000
tones
Furnace Section:
Blast Furnace is a vertical shaft furnace, enclose in a welded shell, lined with fireclay bricks of high alumina content. The hearth bottom, hearth, bosh and the
cylinder part of the bosh are cooled by means of plate coolers. In the shaft, there are
cantilever cooler. The walls of the furnace top are protected by steel refractory lined
plates. In BF#7 for cooling the shaft, there are inverted L shapes cooler.
CHARGING PROGRAMME
To facilitate smooth working of furnaces, the following charging programme
is normally practiced.
A. Programme COC / COOCC / CCOOC
B. Programme CCOO
Each charging cycle consist of 3 programmes of A & B exclusively or in
combination depending on peripheral conditions. Generally in Bell-less Top
Furnace the programme selected is B i.e. CCOO, C=COKE; O=NON-COKE i.e.
ore, sinter, Mn ore, lime atone or quartzite.
STOVES
Form bottom of the furnace the hot blast is blown into the furnace through
tuyers with the help of turbo-blowers & hot blast stove.
There are 3-4 stoves for each furnace. Each stove consists of a combustion
chamber and a regenerative chamber. Stoves are kept on blast for 2 hrs. the
following are the provision in a stove : cold blast valves (1) , Hot blast valve (2) ,
Chimney valve (2) , By-pass chimney valve (3) , gas butter fly valve (1) , Gas
burner (1) , Air fan (1).
Blast of Air reaches as follows:
Cold blast
CB Main
Tuyer stock Furnace
Stoves
Gooseneck pipe
The liquid product of smelting namely pig iron and accumulator in the hearth. Slag
floats on the Pig Iron because of difference in density.
Iron Ore
min
Chemical Analysis
10-40 mm
SiO2
2.5+-0.5%
P
Al2O3 / SiO2
Fe
0.1 % max
0.88 % max
Specification
64.2 %
_____________________________________________
Limestone
CaO
39.5 % 0.1
6-50 mm
SiO2
6.5 +- 0.25 %
MgO
8.5 +- 0.5 %
_____________________________________________
Mn. Ore
Mn
30 % min
SiO2
25-80 mm
30 % min
Al2O3
5 % min
0.30 % max
Iron Ore
2.
Lime Stone
Nandini Mines
3.
Manganese
Balaghat Mines
4.
Sinter
5.
Coke
6.
Converter Slag
SMS l l
Iron Ore
459 Kg
Lime Stone
Manganese
Sinter
35 Kg
Coke
08 Kg
Converter Slag
30 Kg
Steam
Kg
120
Compressed Air
25 M3
Air Blast
Electricity
2600 M3
33.7 Kwh
Water
40 M3
Slag
435 Kg
Flue Dust
25 Kg
BF Gas
Ref:
http://www.123eng.com/projects/steel_melting.html