JSPL Coal Gasfcn Mission Energy2019 PPT - GASIFICATION INDIA
JSPL Patratu - rmoc.tksranchi.inrmoc.tksranchi.in/rmoc52/Presentations/JSPL-Patratu.pdf · jspl...
Transcript of JSPL Patratu - rmoc.tksranchi.inrmoc.tksranchi.in/rmoc52/Presentations/JSPL-Patratu.pdf · jspl...
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JSPL Patratu
13 February, 2019 PresenterV1
Agenda
1. Overview of JSPL Patratu Unit
2. Improvements & challenges -
(i) Finding solution for seam lines in wire rod specially CHQ grade and improving product quality
(ii) Controlling full decarburisation in Spring steel
(iii) Controlling GBC formation in High carbon steel
(iv) successful production of high seismic resistant TMT bar-Fe500S
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(iv) successful production of high seismic resistant TMT bar-Fe500S
13 February 2019 PresenterV1
JSPL Patratu Process Overview
WRMJSPL RAIGARH
Billets via
WR/
TMT
Cust
omer
s ac
ross
In
dia
JSPL PATRATU
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BRM
RSCJSPL ANGUL
via Rail / Road
WR/
TMT
Cust
omer
s ac
ross
In
dia
Other supporting Infra
JSPL Patratu Process Overview contd..
BRM, WRM & RSC
HFO
PRODUCER GAS
ROAD LOGISTICS
INFRA
ELECTRIFIED RAILWAY
SIDING
ELECTRICITY
IOCL DAMODAR VALLEY CORP.FINSISHED GOODS DISPATCH
FINSINSHED GOODS DISPATCH
FINISHED GOODS
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BRM, WRM & RSCGAS SIDING
CENTRAL STORES
CENTRAL UTILITIESWATER
PRODUCER GAS PLANT
PATRATU DAM (PTPS) COMPRESSED AIR, PROCESSED WATER AND
OTHER UTILITIES
STORES AND SPARES SUPPLY
OTHER SUPPORTING DEPARTMENTS: FINANCE, PURCHASE, PPC & MARKETING COORDINATION, HR & ADMIN, CIVIL, LAND, EMD
FINSINSHED GOODS DISPATCH
RAW MATERIAL
Wire Rod Mill Overview
Capacity 0.6 MTPA
Technology partners Siemens (Morgan), Fives Stein for Furnace
Type of Mill Single Strand Continuous mill with NTM and RSM
Special Features • Reducing and Sizing Mill with round-round rolling gives final ovality of 0.1mm.
• Breakdown mill for high speed roughing rolling. • Warm rolling with intermediate water cooling facility to achieve
thermo mechanical rolling. This improves quality in all alloy steels.• Ring distributor to reduce coil height and shape for better packing.
Online compactor for tight packing with straps.
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• Online compactor for tight packing with straps.
Reheating Furnace Walking Beam type furnace, 160 t/hr(cold charge)
Feed Billet Size • High reduction ratio due to bigger size of billet 165mmx165mm-this improves grain structure and ensures no internal defects in wire rods.
Highest Rolling Speed 110 m/s
Stelmore Technology 100m stelmore conveyor to control all cooling parameters for online annealed wire rods and force cooling for high carbon grades.
Product Range • Wire rods (Ranging from 5.2 mm to 22.3mm in 0.5mm increments, 23.2mm, 24mm, 25mm), Re-Bars in coil form (6mm, 8mm, 10mm, 12mm)
13 February 2019 PresenterV1
Wire Rod Product Application : Sector-wise
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Bar Mill Overview
Capacity 1 MTPA
Technology partners Siemens (Morgan), Fives Stein for Furnace
Type of Mill Single Strand Continuous mill with slit line and NTM ensuring higher surface finish
Special Features • Stands in Horizontal and vertical configuration which prevents twisting of Material.
• 230 Bar Descaler to remove the Scale and ensure surface finish.• Online Water boxes for Thermo Mechanical Treatment.• 90 m Long Cooling Bed.• High Speed Rotary Entry System 90m long.
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Source: ....
13 February 2019 PresenterV1
• High Speed Rotary Entry System 90m long.• Customized online Cut lengths ( 6-12 m )with Adjustable Gauge Beam and
Cold Shear.
Reheating Furnace Walking Beam type furnace, 160 t/hr (cold charge)
Feed Billet Size 165 x 165/ 160 x 160/ 150 x 150 x 12000 mm
Highest Rolling Speed 38 m/s
TMT Process HYQST Technology(High Yield Quenched Self Tempered Steel)
Product Range TMT of 8mm to 40mm, Angles 50x50, 60x60, 75x75 and 90X90mm, PlainRounds of 20 mm to 63 mm and RCS of 40 mm to 63 mm
Rebar Service Center Overview
Products and Capacities at Rebar Service Center
Capacity 198600 MTPA
Technology partners MEP, Italy
Type of Mill Cut & Bend and Weldmesh
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Products Capacity
Cut and Bend 60000
Weldmesh 3600
U Bend 120000
Coil Straightening 12000
Binding wire 3000 (Through Conversion Agent)
Products and Capacities at Rebar Service Center
Bar Mill and Rebar Service Center Products
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• Finding solution for seam lines in wire rod specially CHQ grade and improving product quality• Controlling full decarburization in Spring steel• Controlling GBC formation in High carbon steel• Successful production of high seismic resistant TMT bar-Fe 500S
Improvements & challenges
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Generation of seam lines in finished wire rod coils
Seam lines :- These are lines in finished coils that are visible only after acid pickling. These lines are generated when material picking up scratches in rolling lines and afterwards it gets rolled.
Sources of generation:-These lines are generated when ever material is • Getting rubbed continuously/discontinuously in rolling line.
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• Getting rubbed continuously/discontinuously in rolling line.• It is passing through a groove• Fin generated in upstream stands getting rolled.• Material rubbing against jammed rolls/chips accumulated/ any hard surface
Impact of Scratch in finished Wire rodsØApplication - These material are used in manufacturing fasteners.
ØWhile drawing and upsetting operation metal opens because of the scratch mark.
ØAlloy steel grades are soft material, so any scratch or damage is not allowed.
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Corrective actions taken:1. Maintaining stock so that fin generations at any stand is abolished.2. To find out sources of scratch generation up stream .3. To provide minimal contact with troughs when material travels.
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Looper is there in between PFM and NTM to regulate tension. It pushes the metal and support it on the bed forming a parabolic
shape.
looper bed
Material passing through looper 6
Looper
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Looper bed
Generation of seam lines
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PROBLEM
• In long course bed gets wear out and depression and sharp edges formson the bed.
• When material passes over it scratches are formed on the wire rod andafter further rolling in ahead stands seam lines are generated.
• These seam lines are not visible in black condition, only after acidpickling it comes out and wire rod is failed in upset test.
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pickling it comes out and wire rod is failed in upset test.
• Due to this we have to discard more rings at trimming station resultingin yield losses and delays.
• Even after this we face problem of coil rejection and customercomplaints.
ANALYSISOnce the problem was identified we worked on the possiblesolutions.1. Looper bed is made of cast iron, we have the option to weld
the bed and grind it to maintain the surface condition.
Results:- During shutdown in May,16 we welded the looperbed. It works fairer but welded parts once again get wear outrapidly after few days.
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2. Replace the bed with harder material so that rubbing effectis nullified.
Decision :- we decided to replace the looper bed with SS 310material.
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Most damaged portion
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SS 310 plate 1850X395 mm
Delivery Turndown pipe
Point of Pinch Roll 10º
Layout of Turndown pipe & Intelligent Pinch Roll
Entry Turndown pipePinch RollLaying
Head
Metal Entering
Metal Entering
Metal Entering
Before Modification
Entry
PIPE PIPE
DeliveryEntry Turn-Down Pipe
ASSEMBLYASSEMBLY
DeliveryTurn-Down Pipe
BASE
PIPE ASSEMBLY
• In first modification roller was placed in top position of the pipe but problem was not completelyresolved
After 1st Modification
DELIVERY TURNDOWN PIPE
ENTRY TURNDOWN PIPE
PIPE ASSEMBLY
• Groove mark was actually found in two places in pipe in ‘U’ shape.
• When pipe was cut in two halves, scratch mark was observed at bottom position also but atdifferent location. So, we decided to fix roller at bottom position also.
Observation after 1st Modification
AB
Top Groove
AB
B-B Section view of pipe with Scratch mark(When metal enters the Pipe)
BottomGroove
A-A Section view of pipe with Scratch mark(When metal enters the Laying head)
Turndown Pipe
Wire Rod
Metal enters Laying head
After 2nd Modification
ENTRY TURNDOWN PIPE
DELIVERY TURNDOWN PIPE
v Scratch marks in Finished Wire rods
Problems in Wire rods
As Rolled Coil
Acid Etching
Sample of Coil after ModificationAfter Modification – Scratch free wire rod
As Rolled Coil Acid Etching
Delay due to line coming in coil
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Customer complaints due to seam lines
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OBSERVATION
We replaced it during mill shutdown• When mill started no seam lines were observed in wire rods
and delay due to this has reduced drastically up to nil.• Rings discarded at trimming station is nominal.• Number of customer complaints regarding seam lines has
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• Number of customer complaints regarding seam lines hasreduced considerably.
• Wear out rate of replaced plate is very slow and no scratchesbeing generated.
BENEFITS
• No customer complaints is being received of upset failure, seam lines, black linesespecially in boron grade.
• Lesser rings are discarded at trimming station helping in improving yield and preventingdelay due to slow trimming.
• Improvement in mill productivity as down time due to scratches has been eliminated.
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• Handling of lesser rings at trimming station has improved safety incidences and workplace pleasure.
COST SAVING
Total delay due to this problem = 3977 min
Considering average production of 100 MT per hourTotal production in 3977 min = 6288.33 MT
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Total production in 3977 min = 6288.33 MT
Total saving in conversion cost = 6288.33X Rs 3000 = Rs 19885000
Total saving in profit realization = 6288.33 X Rs 4000 = Rs 26513333
Total saving = Rs 46398333
Tangible
Sl No. Description Disadvantages of previous design Advantages after Modifications
1 Defects in Coil
• Continuous or discontinuous scratch marks and sometimes through out the coils
• Leading to Non Prime & Rejection of Coils
• Zero Scratch• Zero Non Prime • Zero Rejections
Pipe • 1 entry & 1 delivery pipe per
Tangible & Intangible Benefits
2Pipe Consumption
• 4 Entry & 4 delivery pipes per day• 1 entry & 1 delivery pipe per
day
Intangible
3 DelayDelay in• Searching scratch in coils• Sample checking
• Zero delay
4Production Loss
• More production loss due to more delay
• Zero loss
Grade % C % Mn % S % P % Si % Al % Cr
SAE 9254 0.51-0.59 0.60-0.80 0.015 Max 0.020 Max 1.20-1.60 0.025 Max 0.60-0.80
Controlling Full decarburization in Spring Steel(SAE9254)
Application – Suspension spring in automobile industry
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Full Decarb image- Complete loss of carbon due to decarburization . It makes lesser the
surface strength/hardness
Testing – Fatigue test upto 2000000 Cycle, Requirement-Zero Full decarbTo reduce/ eliminate different combination of element al change, coating , reducing oxygen level , process parameter were used. Element addition but it will increase the cost .less Oxygen level in Furnace – It has reduced FD but not eliminated completely
Now wire rod in different sizes are being produced free from full decarburization with the help of high cooling rate.
Controlling GBC formation in High carbon steel
What is GBC –How it develops - In which grades it generally it comes and why ?
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Grain Boundary Cementite
• Effect of GBC- Burst/breakage in wire drawing, spring making or different other application .
Challenge– Still we are working on it to remove it completely
. How can we remove ? – By increasing the cooling rate significantly above eutectoid temp ?
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Any other way to minimize it ?
Successful production of high seismic resistant TMT bar-Fe 500S
Fe500S – Seismic Resistant Rebar . Challenge – Maintaining High UTS/ YS ratio 1.25 which will increase its toughness First commercial production of 3000 MT
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Fe500D Fe500S
Thank You !
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