Winner novel agglomeration process for ferroalloy fines
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Transcript of Winner novel agglomeration process for ferroalloy fines
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Tata Innovista 2013 - Winner Novel Agglomeration Process for Novel Agglomeration Process for Ferroalloy Fines Ferroalloy Fines
Receiving the award from Mr Cyrus Receiving the award from Mr Cyrus MistryMistry, , Chairman Tata Sons, Chairman Tata Sons, MymbaiMymbai, 26, 26--AprApr--1313
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Novel Agglomeration Process for Ferroalloy Fines
for use in bulk Steel Making Processes
P509613121840 Core Process Innovation
Mr. Veerendra Singh Principal Researcher, R&D, Tata Steel Mr. Prabhash Gokarn Head, Raw Material Projects, Tata Steel Mr. Bibhu Nanda Head, FAP Joda, Tata Steel Mr. Amitabh Bhattacharjee Head, KVHS, Tata Steel Mr. Ashuosh Kumar Head, Steel making LD1, Tata Steel
Tata Innovista, Finals 25th April, 2013
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1. Ferroalloy Production Process 1 slide
2. Problems Caused by Ferroalloy Fines 1 slide
3. Challenges in Agglomeration of Fines 1 slide
4. Finding a Solution 2 slides
5. Establishing Agglomeration Flowsheet 1 slide
6. Plant Scale Trials 1 slide
7. Commercialization & Stabilization 1 slide
8. Customer Feedback 1 slide
9. Results 1 slide
P509613121840 Novel Agglomeration Process for Ferroalloy Fines
Presentation Structure
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P509613121840 Novel Agglomeration Process for Ferroalloy Fines
Background
Steel @ World Production :1.5 billion tons
@ Tata Steel production :26 million tons
Ferroalloys 30 MT produced in the world 350 kTPA produced by Tata Steel
* Bulk – FeCr(incl ChCr), FeMn, SiMn, FeSi… Noble - FeTi, FeNb, FeV, FeMo, FeB …
Ferroalloys used in steel making for deoxidation & alloying
Contributes 5 % - 30% of steelmaking cost
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P509613121840 Novel Agglomeration Process for Ferroalloy Fines
Ferroalloy Production Process
Ferroalloy Cake
Ferroalloy Casting in Pans
Ferroalloy production
Smelting-reduction (@ 1500o C)
Casting of liquid ferroalloy (1m x 2m pans)
Sizing (2m→300mm→80mm)
Packing and Despatch
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High Carbon FeMn fines Silico Manganese fines
Lumps
(10-80mm)
Bulk Steel Making Process
Fines & Chips (0-3,3-10mm) 5% to 15% generation
Lower Realization Handling Difficulties
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Fines co-generated during sizing :
Unsuitable for bulk steel making (eg LD)
Environmental hazard
Transportation & handling difficulties
Contamination during handling & storage
No technology to reduce fines generation
Can we establish agglomeration of fines ?
P509613121840 Novel Agglomeration Process for Ferroalloy Fines
Trigger
Lower Realization Rs 10,000 – 20,000
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(b) FeMn Particle
P509613121840 Novel Agglomeration Process for Ferroalloy Fines
Challenges
Size : <3mm
Challenges
C1 : Metallic fines behave differently
C2 : No existing established process
C3 : Binder Selection
• Unwanted ingredient (P, S etc)
C4 : Agglomerate quality
• High Cold Compressive Strength
• High Hot Compressive Strength
C5 : Agglomeration process should be economical
(a) Mn Ore Particle
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P509613121840 Novel Agglomeration Process for Ferroalloy Fines
Finding a Solution – Research efforts
Chemical analysis of FeMn Lumps & Fines
Size analysis of fines
Element (%) FeMn Lumps (>10mm)
FeMn Fines (0-3mm)
Mn >70 >67
Si 1.5 1.4 – 2
P 0.3 0.25
C 6-8 6 - 8
SEM analysis of FeMn Lumps & Fines
Lab Studies : Characterization of Fines
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• Molasses +Lime • Cement • Lignosulphate • Coal tar • Sodium Silicate • Resins
o Phenol-formaldehyde Resin o Acrylic Resin
Binder Selection
.
P509613121840 Novel Agglomeration Process for Ferroalloy Fines
Finding a Solution – Research efforts
Resin works as a best binder for alloy fines
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P509613121840 Novel Agglomeration Process for Ferroalloy Fines
Establishing Agglomeration Flowsheet
Key Questions : Safety Recovery Operational Performance
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Lab Studies : Product Validation
Lab Testing
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Slag Analysis
P509613121840 Novel Agglomeration Process for Ferroalloy Fines
Plant Trials
Metal Analysis
No increases in P,S and N in the steel.
Mn and C pickup in steel was similar for lumps and briquettes.
Charge Quantity remain same.
NO other operational problem was faced during the trial.
Establish for both SiMn and FeMn fines
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(a) Vendor Development (250tpm)
(b) Process for handling & addition in vessel
P509613121840 Novel Agglomeration Process for Ferroalloy Fines
Commercialization & Stabilization
Vendor Capacity being increased Vendor Capacity being increased
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P509613121840 Novel Agglomeration Process for Ferroalloy Fines
Customer Feedback
Appreciation from EIC (FA&MD)
Appreciation from Chief LD2-SC
Appreciation from Chief LD1
Appreciation from Chief BPE & KVHS
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P509613121840 Novel Agglomeration Process for Ferroalloy Fines
Impact
• Tangible (Rs)
• Rs 0.3 Crore (till now)
• Rs 1.5 Crore/ Year (current rate)
• Rs 1.8 Crore/Year (next year)
• Intangible • Reduces Environmental pollution
• Reduces storage & handling issues
• Provides jobs to ~15 semiskilled workmen (currently)
0.3
1.5 1.8
Till Date Current Rate
From Next Year
Rs Crore/year
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P509613121840 Novel Agglomeration Process for Ferroalloy Fines
Way Forward
Future • Scope to shift from manual sizing to use of crushers*
• New plants of FAMD (Joda & Gopalpur) with crushers
• Saving sizing cost by Rs 150/MT ~Rs 1.2 Crs/year
• Increase in Capacity Plan to briquette all Mn fines produced at FAMD plants as capacity increases ~Rs 3 Crs/year
• Rollout at TSKZN being explored
* Crushers generate higher fines than manual sizing - briquetting makes use of fines possible
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Projected Volume & Cost Savings With Increase of Capacity
SiMn (MT) FeMn (MT)
Cost Saved(Rs lakh)
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P509613121840 Novel Agglomeration Process for Ferroalloy Fines
Questions ?
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Thank YouThank You
KVHSKVHS
Mr. Pankaj Lochan and team
OperationsOperations Mr D Das & colleagues
at LD1
Mr JB Singh & colleagues at LD2
FerroAlloy Yard colleagues