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VIZAG STEEL PLANT

ABSTRACT

Steel has always been the backbone of nation's economy.


From an annual production of 13 million ton in 1900, global steel production
raised to 300 million ton in 1950 and to 842 million ton in 2000. India
produces 30 million ton per annum from 9 major plants. The major steel
plants contribute 19 million tones and the rest is contributed by secondary
sector. Visakhapatnam Steel Plant is one of the 6 integrated steel plants
contributing 3.51 million ton of liquid steel per annum. It is the only steel
plant in India accredited with ISO 9001, ISO 14001, and OHSAS 18001
certificates for Quality environment and Safety aspects of the steel making
activities. With the improvement in operating performance of major units
and efficient maintenance and material handling system the plant has made
a turn around and achieved net profit of 2100 crore rupees during the
current fiscal 2004-05.

This project deals with the Design verification of critical Trunnion


ring of a process equipment LD Converter used for steel making process. The
LD converter is a steel shell lined with refractory material used for handling
the molten steel at 1650° C. The vessel is suspended on a trunnion ring with
four numbers of tie rods and rotates at 0.1-1.0 RPM by means of four hung
reducers and one special reducer with motors of 4 - 172KW DC. The trunnion
ring is box section with plates 140mm having forged end journals and the
entire assembly weighs around 147 Tons carrying 1000 Tons of vessel with
hot metal. The linear dimension of the trunnion ring will be around 14 Meters
and the straightness of the surface should be 1 mm over 1000mm span.
General norms of the life of the trunnion is around 1 0 Years but the it is to
be changed with the survey readings if the deformation exceeds the limit. In
converter No.1, the survey readings depicted around 20mm deformation and
is to be changed in a planned shutdown as the repair takes around 40 days
shutdown of the process equipment. Keeping this in mind a new trunnion
ring was imported from the Russia and is observed the changes in the design
compared to the existing trunnion in the hole sizes 0300 fTom 0180. It is
necessary to verify the design before implementation about the safety of the
system.

In this regard after visiting the site and collecting the necessary
dimensions a 3Dimensional modeling using CATIA has been done for the
existing and modified design. Also the model has been imported to ANSYS
and the von-mises stresses have been obtained by applying fixed support
constraint

and loading conditions and the stresses induced in the trunnion ring is
around 25.32 N/mm2 in the existing trunnion and 36.5 N/mm2 in the
modified trunnion ring. With the material of ASTM-A36 of the trunnion, the
existing Factor of safety is reduced fTom 11 to 8 and as per the norms for
the structural the allowed factor of safety shall be above 5. Hence the
design is safe for the operation. The data is presented with 3D model of
objects, meshed images and von-mises

stresses. The present analysis was done only in static case. This can be
further

extended to dynamics considering the rotation of the trunnion ring. As the


technological developments are taking place in steel making process there
is an

. ample scope of adopting new design Russian LD converter


trunnions with the adoption Top cone water cooling system coupled with
bottom bath agitation facilities which require bigger hole sizes in the
trunnion end journals, the designs become critical and requires thorough
analysis.

SOCIAL RESPONSIBILITY

Peripheral development and special concern for the displaced persons underling the
Visakhapatnam steel plant's commitment and concern for the social and regional development
around it. As a special gesture for the welfare of the displaced persons, Visakhapatnam steel plant
provided them with over 5,900 jobs, which constitute more than 1/3 of its total non-executive
manpower. In the recruitment policies of VSP displaced persons have been given several
concessions in the areas of educational qualifications, age and skill levels. As a part of social
responsibility VSP took a massive afforestration program has been launched in and around the
plant. Out of the total 9,200 hectares of area 3,600 hectares has been ear marked for afforestation.
Along the land boundary of VSP a green belt of half a kilometer has been delineated for
afforestation. 1.4 lakh trees have been planted in 100 hectares during 94-95 and 1.22 lakhs of trees
has been planted in 207 hectares during 95-96.3 million trees for 3MT of steel was the slogan
ofVSP.

That target also achieved. VSP has been complying with statutory standards of both
Andhra Pradesh pollution control board and central pollution control board. It has been closely
maintaining 31 major stack emissions and 8 ambient air-monitoring areas out side steel plant. I

. Mission and Core values of VISAKHAP A TNAM STE


PLANT :.

Vision:
To be a continuously growing world-class company.
We shall:

.:. Harness our growth potential and sustain profitable growth.

.:. Deliver high quality and cost competitive products and be the first
choice of the customer.

.:. Create an inspiring work environment to unleash the creative energy


of

people.

.:. Achieve excellence in enterprise management.

.:. Be a respected citizen, ensure clean and green environment and


develop vibrant communities around us.
Mission:

To attain 10 million ton liquid steel capacity through technological


up- gradation, Operational efficiency, to produce steels of international
standards of cost and quality to meet the aspirations of the stake holders.

Core-values:

.:. Commitment

.:. Customer satisfaction

.:. Continuous improvement

.:. Concern for environment

.:. Creativity and innovation


OVERVIEW TO VIZAG STEEL PLANT

GENERAL SURVEY OF IRON AND STEEL MAKING IN INDIA

India is the third largest producer of iron and steel in the common
wealth nations (surpassed only by the UK and Canada) and is 16th among
the steel producers of the world. At present, India's capacity of steel
production is nearly

1.5% of the total world production.

The Tata Iron and Steel Co., Jamshedpur (Bihar), Indian iron and steel
Co., Burnapur (West Bengal), Visveswaraya iron and steel limited, badhravali
(Karnataka) and a few electric arc furnaces were the only steel plants in India
until 1955.three new public sector plants under Hindustan steel Ltd,. Were
established in the period 1955-60 at Bhilai (MP), Rourkela (Orissa) and
Durgapur

(WB). Each of these has their own coke-ovens which supply the large amount
of coke needed for steel manufacturer. The plant at Bhilai and Durgapur
employs the basic open-hearth process of steel making. The Rourkela plant is
unique in the fact that it employs L-D process for manufacturing 75% of steel.
The output of the remainder (Le., balance of25% of steel) is by the basic
open-hearth process.

At present there are eight integrated steel plants and about 174 mini
steel plants. The integrated steel plant located at Jamshedpur (TISCO) is the
only private sector plant, and the rest are in public sector. Integrated steel
plants in public sector are:

1. Indian iron and steel Co., (IISC,), Burnapur (WB)

2. Viswesraya iron and steel Ltd,.(VISL), Badhravali (Karnataka)

3. Rourkela steel plant (RSP), Rourkela (Orissa)

4. Bhilai steel plant (BSP), bhilai (MP)

5. Bokaro steel plant (BSL), Bokaro (Bihar)

6. Durgapur steel plant (DSP), Durgapur (WB)

7. Visakhapatnam steel plant (VSP), Visakhapatnam (AP).

The visakhapatnam steel plant is designed to produce three million tons


of

liquid steel per annum to be converted to 2.656 million tons per annum of
saleable

steel. In addition, Visakhapatnam steel plant will produce annually about 5.56
lakh tons of pig iron and various by-products for sale.

LOCATION:

The plant is located in Visakhapatnam City, which is on the coast of


Bay of Bengal. Visakhapatnam city is an important commercial center of
Andhra Pradesh. It has the deepest port and is one of the principal outlets
for country's exporting Iron ore. The city has many large industries such as
the Hindustan Petroleum Refinery, Bharat Heavy Plates and Vessels ltd.,
Coromandal Fertilizers, Hindustan Zinc, Hindustan Shipyard etc. The city is
situated on the main broad gauge railway line between Calcutta and Madras
and is well connected with other major cities and state capitals by rail, road
and air. The Visakhapatnam steel plant is located 16 Kms. to the southwest
of the Visakhapatnam Port and is about 26 Ian ITom Visakhapatnam city. The
town ship and the plant have been built on an area of 27,000 acres, between
the national highway no.5 and the Bay of Bengal.

CLIMATE:

Visakhapatnam has warm and humid climate. April to June are the
warmest months of the year and December to February are the coldest
months of

the year. The city benefits ITom the Southwest monsoons (June to
September) & Northeast monsoons (October to December). The average
annual rainfall is 973.6mm and highest mean montWy maximum
temperature is 37.8 degrees centigrade.

THE DEPARTMENTS:

There are altogether 25 departments in Vizag Steel Plant. These


have been divided into two categories as Core Zone and Service Zone.
Some of them are as follows:

Core Zone: Blast Furnace, Coke Ovens, Steel Melt Shop, Mills,
Sinter Plant, and Raw Material Handling Plant.

Service Zone: Thermal Power Plant, Calcined Refractory Manufacturing


Plant

Coke Ovens & Coal Chemical


Plant:

Coking coal after selective crushing and


proper blending is subjected to destructive
distillation (heating in the absence of air) in the
Coke Ovens. After heating for nearly a period of 16-
18 hours at a temperature of about

1100°C, coke is obtained and is used as a fuel as


well as

reducing agent in the Blast Furnace. The Coke


Ovens of VSP are engineering feats by themselves.
They are the

tallest ovens constructed in the country. There are three batteries, each
having 67 ovens. Each oven is having a volume of 41.6 cu.m and can
hold 31.6 T of dry coal charge. The carbonization time is 16 hours. A
mixture of blast furnace gas and coke oven gas having a calorific value
of 1000 Kcal/NM3 supplies the heat for carbonization. Another feature is
the dry cooling of coke carried out by the inert gas nitrogen thus,
reducing pollution considerably. Besides, a bio-chemical plant
separately undertakes the treatment of effluents. By-products like
benzene, toluene, xylene, naphthalene, coal tar, creosote oil, pitch,
ammonium sulphate and benzol products are also recovered from the
coke ovens gas. VSP produces, among other by-products, pushkala a
prime fertilizer based on ammonium sulphate.
Sinter Plant:

Iron ore fines, coke breeze, limestone and


dolomite along with recycled metallurgical
wastes are converted into agglomerated
mass at the Sinter Plant, which forms 80% of
iron bearing charge in the Blast Furnace. The
Sinter Plant comprises of two sinter
machines each having

312 square metres of grate area with a total


,

production capacity of 5.256 million tons per annum. Hot sinter,


discharged ITom sintering machine at 900 degrees centigrade, is crushed
to 15mm size in a spiked single roll crusher with a 1300 X 4200 mm
rotor. Unsintered grains are liberated as sinter returns.

Blast Furnace:

VSP has two Blast Furnaces with a useful


volume of 3200 cu. m. each. Blast Furnace is
charged with coke, iron ore and sinter ITom the
top and produces about 5000 tons of molten iron
per day. Its novel circular cast house with four tap
holes ensures continuous tapping of hot metal.
There are four hot blast

stoves for each furnace with a total heating


surface of 224000 square metre. The dome is
heated to a

temperature of 1450 degrees maximum, while the waste flue


temperature is 400degrees centigrade. The stoves are capable of giving
a blast temperature up to

1300degrees centigrade. A mixture of blast furnace gas and coke oven


gas having a calorific value of 1100 KcalINM3 heats stoves. Gas mixing
station is provided to mix BF gas and coke oven gas in required
proportion and to get the necessary calorific value. Separate stations
are provided for each furnace. The annual production capacity of these
Blast Furnaces is 3.4 million tons of liquid
lron.
Steel Melt Shoo & Continuous
CastinS!:

Three topblown converters, each of


133 cu.m. Volume, produce a total of 3.51
million tons of liquid steel per annum. This
liquid steel thus produced is casted in six-4
strand bloom casters. A special feature in
energy conservation is the collection of
Converter gas to be used as a fuel in the
plant. The entire molten steel at VSP

is continuously cast at the radial type


continuous

casting machines resulting in significant energy conservation and better


quality steel. 100% Continuous casting on such a large scale has been
conceived for the first time in India.

RollinS! Mills:

The cast blooms trom continuous casting department are heated


and rolled in the three high speed and fully automated rolling mills
namely Light & Medium Merchant Mill, Wire Rod Mill and Medium
Merchant & Structural Mill, to produce various long products like
reinforcement bars, rounds, squares, flats, angles, channels, billets, wire
rods etc. Technologies adopted at Rolling Mills include world-class
Stelmor and Tempcore processes.

MODERN TECHNOLOGY:

Visakhapatnam Steel plant is the most sophisticated and modem


integrated steel plant in the country. Modem technology has been
adopted in many areas of production, some of them for the first time in
the country. Among

these are:

1. Selective crushing of coal.

2. 7 meter tall coke ovens

3. Dry quenching of coke.

4. On ground blending of Sinter base mix.

5. Conveyor charging and bell less top for blast furnace.

6. Cast house slag granulation for blast furnace.

7. 100% continuous casting of liquid steel

8. Gas expansion turbine for power generation utilizing blast


furnace

top gas pressure

9. Hot metal desulphurisation 10. Extensive treatment facilities of


effluents for ensuring proper

environmental protection. 11. Computerization for process


control 12. Sophisticated, high speed and high production rolling
mills.

MAJOR PLANT FACILITIES:

The production facilities in the Visakhapatnam steel plant are most


modem amongst the steel industry in the country. The know-how and the
technology have been acquired from different parts of the world from the
reputed and established sources.

Some of the novelties of the Visakhapatnam steel plant are:

1. 7-meter height coke ovens ofVSP are the tallest so far built
in the
country. Dry quenching of coke has been adopted which will not only
improve the quality of coke and economics of coke production, but also
contribute significantly to the reduction of environment pollution.

2. Base mix yard for sinter plant introduced for the first time in
the

country helps in excellent blending of the feed material to the sinter


machine and production of consistent good quality sinter.

3. With useful volume of 3200 cubic meters each the two blast

furnaces have bell less top charging equipment and 100% cast house
slag granulation. The granulation of the entire molten slag arising at the
furnace cast house avoids the need to transport molten slag and
optimizes utilization of slag.

4. 100% continuous casting ofliquid steel into blooms result in


less

and better quality of blooms.

5. The VSP have three sophisticated and large rolling mills with
the

latest features of automation and optimization.

6. The operations of blast furnaces, steel melting shop and rolling


mills have been entirely computerized to ensure consistent quality and
efficient performance.

The major production departments of Visakhapatnam steel plant


are the raw materials handling system, coke ovens, sinter plant, blast
furnace, and steel melting shop and rolling mills.

Extensive facilities have been provided for repair maintenance as


well as manufacturing of spare parts. There is a Central machine shop,
Structural shop, forge shop, foundry, wood working shop and loco repair
shop. Visakhapatnam steel plant has got its own Air separation plant for
production of oxygen and acetylene plant for production of acetylene
gas. A captive power plant has also been provided for power generation
with 4 units, three of 60MW generation and one 67MW capacity.

RAW MATERIAL LINKAGES:

The steel plant is getting it supply of iron ore-lumps and fines


from the Bailadilla deposits in Madhya Pradesh, blast furnace grade lime
stone from the Jaggayyapeta in Andhra Pradesh, SMS grade lime stone
from Badnapur in MP,

blast furnace grade lime stone from the Kotni-sonor deposits in MP. Most
of cocking coal requirement will be met by imports through the
Visakhapatnam harbor while the balance will come from the Bengal-Bihar
area. Coal for power generation will come from Anantha deposits of Talc
her region in Orissa. POWER SUPPLY:

Peak construction power requirements were about 12MV A This


was arranged from the Gajuwaka substation of APSEB at 33KV.

The Plant has in-plant power generation from a power plant


having 3 Nos, of 60 MW sets installed. An additional requirement of
operational power, around 150 MV A, is being met from APSEB grid.
Operational power supply is initially at 220 KV, which is subsequently
stepped down to 400 KV.

WATER SUPPLY:

Requirements of water during the peak of construction were


of the order of 4.5 mgd. This was met from the Meghadrigedda, and
Raiwada schemes of Andhra Pradesh State Government.

Operational water requirements 70 mgd of the steel plant


are being met ftom the Yeleru water supply scheme provided by the A.P.
State Government. This involved construction of a storage reservoir at
Yeleswaram and a 153 Kms. long linked canal to the plant site apart
from the Kanithi Balancing Reservoir.

Product Mix:
The product mix of

VIZAG Steel Plant

compnses

. Wire Rods

. Bars

. Angles
Channe
. ls
. Beams

. Rounds

. Billets
The Plant also produces Pig Iron, Granulated Slag and Coal Chemicals.
The rolled products find extensive usage in the Construction,
Inftastructure, Railways, Power, Oil, defense, and Transport and Ship
Building sectors. Bars and Rods are used mainly for re-inforced concrete
work for housing, construction of dams, buildings & factories,
manufacture of agricultural implements, fabrication of light engineering
components. The Wire Rods are used in Wire Drawing industry for
electrodes, transmission lines and weld ability requirements. The
structurals find application in engineering, house building, agricultural
implements, machinery, transmission towers, etc.

BRIEF ON STEEL MELTING SHOP OF


VSP

In line with international levels of operation, the levels of steel


production can be considerably higher than that what was envisaged in
the revised

DPR. Each converter with a volume of 133M3 is capable of producing 150


tons of liquid steel per heat and considering 10,000 heats annually per
operating converter, a liquid steel achievable ftom one operating
converter. Thus with the installation of

third converter in SMS the shop has the potential to produce about 3.0MT
of liquid steel. Accordingly, it is proposed to install one more converter
and two additional bloom casters in SMS-l, within the area provided for
the future expansion. As a result, SMS-2 need not be installed. To achieve
the production of3.0 MT per year the following is a must:

~ Silicon content of hot metal should not exceed 1%

~ Lime used as flux should have 90-92 %(CaO + MgO) and Si02
content

should not exceed 2.5%. This may necessitate import of high-


grade limestone.
~ Converter lining life should be 300 heats, and the relining time
should not

exceed 5 days.

~ The blowing time should not be more than 18 minutes and the
gas

cleaning system shall be adequate to meet this requirement.

~ Each bloom caster is required to cast 10 heats in sequence. The


machine

availability may have to be increased to 310 days per year.

~ The capacity of cranes, transfer cars etc. marginally increased to


handle 150 tons per heat.

FACILITIES:

The major facilities are as follows:

3.0 MT Stage

1. Production (T lye) (a) Liquid steel (b) Cast blooms

(1) 250x320 MM (2) 250x250 MM

3,000,000 1,915,000

2. Facilities 905,000

(a)
(b)Hot
L-D metal mixers
Converters 2x1300T
2x1333

(c) Continuous casting machines 3x4-strand 2x 1300-7 torpedo cars of 300T cap

3x133M3

6x4 -strand
REFRACTORIES FOR SMS:
to 1.0 Mt of HIM can be held with this lining over a year.

~ FOR CONVERTER LINING: Permanent lining is by chrome magnesite


~ High grog bricks line hot metal ladle, and medium heat duty bricks
bricks. Working lining is by pitch -bonded magnesia enriched
are used as
dolomite back-up
bricks. lining. Life
Magnesite is 500
blocks lineheats.
tap hole. Lining life is 300
heats.
~ For slide gate refTactories high alumina based material is used.

~ High alumina bricks line steel teeming ladles as working lining and
~
medium heat duty fireclay bricks as back up. Life is 15-20 heats. ~
~ Mixer lining is by high duty magnesite bricks, and back-up lining

is by mica insulation bricks. Alumino-silicate bricks line Root. Up

Fire clay and high grog bricks line Tundishes and slag boxes. Stopper rods
for tundishes are corundum graphite mono-block stopper rods, Al203
graphite nozzles. Submerged nozzle is
corundum graphite; lining life of tundishes is 10 heats for
working lining.

LAYOUT:

The LD Converter building 36m towards north end and a new scrap
aisle is provide adjacent to the charging aisle. The ladle preparation bay
is extended by the north end to facility installation of new ladle
preparation bay is extended by the north end to facilitate installation of
new ladle preparation facilities. The continuous casting department is
extended by 102m towards north end for relocation of CCM-4 and housing
the 5th and 6th bloom casters.

CONVERTERS:

The tap-to-tap cycle time


is

Timing in
min.
. Charging of scrap 3
. Charging of hot metal 4
1
. Oxygen blowing 8
. Intermediate slag off 3
Sampling, temperature
. recording etc.
5

. Steel tapping 6
. Draining of slag 2
. Preparation of converter 3
. Unforeseen days 6
Total: 50

Provision is kept for production of 59 heats per


day.
SAILENT FEATURES OF THE CONVERTERS:

· Converter capacity, tons

· Effective volume of converter M3 · Converter specific


volume, M3 rr · Mouth diameter inside lining, nun

150 145

0.95 2700

· Weight of converter lining including bottom lining,tons


455

· Thickness of working lining, mm 780

· Thickness of permanent lining, mm 230

· Weight ofline shell with trunnion ring and bottom, tons


849

· Weight of lined bottom, tons 60

· Speed of converter tilting, rpm: Max. 1.0

· Min. 0.1

· Lance movement speed, mtslsec: nominal 0.88

· Minimum 0.2

· Lance travel, mm 15000

· Oxygen working pressure 15 KSCG

· Water working pressure 12 KSCG

Suppressed combustion type gas collection, cooling and cleaning system


is provided. This system comprises of tube-bar-tube type skirt, gas
cooling hood, closed loop type gas cooling arrangement with fin-fan
cooler, gas duct, ill fan, change over valve, flare satack, gas holder,
electrostatic precipitator, booster fan etc. the gas is being recovered and
when the gas composition is acceptable.

AUTIOMATION AND CONTROL

CONVERTER CONTROL SYSTEM:

Following level hierarchical system is provided: level-l consists of

process control computer system for overall shop management, co-


ordination, and data acquisition and monitoring. Level-2: Blowing: micro
computer system for on line dynamic end point control using sub lance
and set point control and Level 3 :Distributed control systems for control
and monitoring of the process parameters, flux and Ferro alloys charging
control, main and sub lance position control etc. This works in conjunction
with electric controls including thyristor

converters and programmable logic controller for sequential and safe


operation of process equipment.

SLAG YARD:

The estimated slag arising is about 2000 kg per ton of cast bloom
and one slag pot of 16M3_18M3 is adequate for one heat. The filled slag
pot fTom the converter is transported to slag yard by self propelled slag
transfer car. Two 100+20 T EOT cranes, lime spraying unit, 10T steel ball,
slag dump car etc., are

provided. Pits are provided for dumping, cooling and crushing: Operation
of dump car provided with tilting mechanism is controlled fTom a control
post. There are four lime-spraying points. After cooling, the slag cakes are
broken by 10T steel ball by magnet crane. The steel jams are used as
plant return scrap. Broken slags are removed fTom pit by shovel, pay
loader and loaded into dumpers for disposal by road. The total area
required for slag dumping is about 9800 sq.m. In
the slag yard of about 8280 sq.m. is available. Therefore, an additional
area of about 1500 sq.m. is provided by extension of slag yard 96 M
toward end.. SCRAP PROCESSING AND STORSGE YARDS:

Plant returns scrap and purchased are stored here. There are two
yards. In yard nO.1 about 38,000 T/yr. Of steel scrap is cut to require and
has two 1ST magnet cranes. In scrap yard no.2 about 60,000 T/yr. Of
scrap is processed. This yard has four 1ST magnet cranes. The sized
purchased scrap is received by rail. This yard can store about 19 days
stock. Oxy-acetylene torches and 02 lancing do cutting of scrap. An
alligator type scrap-cutting shear is provided in each yard for preparing
scrap to be added during argon rinsing. Self-loading and unloading trucks
will be used for transport of scrap to SMS.

SKULL BREAKER:

About 52,000 T of steel and iron-scrap is processed here. A 20 t


overhead crane with detachable magnet is used for dropping a 10 T steel
ball to break the ladle skull and other pieces. A 50/20 T crane with
detachable magnet is used for lading and unloading of wagons and for
supplying and removing scrap fTom the crushing pit. Oxy-acetylene
torches do cutting.
Section through the BOF vessel during oxygen blowing.

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