Post on 10-May-2018
TATA STEEL, India
Upgrade of Blast Furnace “G”2005
Blast Furnace Constructions, Rebuilds & Relines
Introduction
During the 12 years’ life of its first cam-paign, BF “G” produced 14 million tons of hot metal. The upgrading work was undertaken to enhance the capacity of the furnace to 1.8 MTPA and a projected minimum life of 15 years, using state-of-the-art technology.
Tata Steel chose Paul Wurth as technologi-cal supplier in association with L&T for the upgrade of BF “G”.
Project Realisation
To achieve a cost effective upgrade, a critical study of existing and proposed new facilities, and striking a judicious balance between old and new facilities, was carried out. In addition to capacity enhancement, the upgraded “G” furnace has been equipped with a sophisti-cated monitoring and control system and an up-to-date automation system to enable the furnace to produce high quality hot metal at the lowest cost.
To minimize the shutdown period, a project monitoring system comparable to the world’s best practices was put in place to execute the project in optimum time. A substantial quantity of work was completed during the pre-shutdown period while the furnace was in operation. Areas of concerns were: Safety hazards of BF gas, space constraint, working at heights.
Project Description
Supermicropore hearth carbon blocks
Gas cleaning plant Blow-in
Project Data
Project overall duration (from order placement to blow-in) : 24 months
Pre-shutdown activities : 15 months
BF shutdown activities : 125 days
Blow-in date : 6 April 2005
Major Technical Reline Objectives
` increase of working volume from 1 581 m3 to 2 308 m3
` improve BF cooling by introduction of copper staves and 5 closed loop cooling circuits
` provision of a new 2nd casthouse
` extension of cooled surface area
` hearth geometry/materials quality upgrade
Services
` Basic engineering and detail engineering for selected items
` Supervision of detail engineering developed in India (for critical items)
` Supervision and testing of critical items manufactured in India
` Supervision of erection, commissioning and performance tests
Supplies
` Raw material preparation
y Upgrade of existing stockhouse equipment
y Remote flow control for ore and sinter
` Furnace top equipment
y Expansion of hopper volume
y New bleeder valves
y Increased length of rotating chute
` Furnace body
y Introduction of stave coolers (copper & cast iron)
y Profilemeter for improvement in burden distribution *
y Introduction of supermicropore carbon in hearth
` Coal injection
y Enhancement of coal injection capacity up to 200 kg/tHM
y Installation of one new additional coal mill (15 tph)
` Stoves
y Hydraulic actuation of stove valves
` Cooling system
y Demin water system for stave coolers
y Five separate closed cooling circuits
` Casthouse equipment *
y New powerful hydraulic drill machines & mud gun
y Splash cover manipulator
y Provision of a new 2nd casthouse
` Gas Cleaning Plant
y Introduction of ceramic tiles in cyclone
y Improvement in venturi scrubber
y Addition of external demister
Paul Wurth Reline Scope
Phases of shell erection
Bustle pipe gunniting
Major Technical Reline Objectives
` increase of working volume from 1 581 m3 to 2 308 m3
` improve BF cooling by introduction of copper staves and 5 closed loop cooling circuits
` provision of a new 2nd casthouse
` extension of cooled surface area
` hearth geometry/materials quality upgrade
Blast Furnace Data
Daily Production : 5 150 tHM
Hearth Diameter : 11.05 m
BF working volume : 2 308 m3
BF inner volume : 2 648 m3
Top pressure : 1.5 bar g
Tuyeres : 30
Number of tapholes : 2
Tuyere injection : PCI
International presence:Brazil, Chile, Czech Republic, Germany, India, Italy, Japan, Korea, Mexico, P.R. China, Russia, South Africa, Taiwan, Ukraine, U.S.A., Vietnam
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Non Contractual Data: Paul Wurth believes that the data contained in this folder are correct and accurate, but cannot guarantee same or better performances for any specific site without a detailed quote. Patents and Patents pending. — Paul Wurth equipment and processes are protected in many countries by patents.
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Technical Highlights
Paul Wurth S.A.32, rue d’AlsaceL-1122 LuxembourgPhone: (+352) 4970-1Fax: (+352) 4970-2209paulwurth@paulwurth.comwww.paulwurth.com
* TMT – Tapping Measuring Technology, a joint company of Dango & Dienenthal and Paul Wurth.
Bell Less Top®
Copper staves
Casthouse *Furnace shell lifting by crane
Blast furnace “G” Hot stoves & blast furnace