TABLE 1 : FEATURES OF LD1 AND LD2 SHOPS OF TATA STEEL |
| Sl. No. |
Parameters |
LD1 shop |
LD2 shop |
| 1. |
Year of
Installation |
1983 |
1994 |
| 2. |
Crude Steel
Capacity |
1.3 mtpa cast billets* |
2.7 mtpa cast
slabs |
| 3. |
Actual
Production(02-03) |
1.23 mtpa cast billets and 0.07 mtpa cast ingots |
2.8 mtpa cast
slabs |
| 4. |
Hot Metal
Pretreatment |
One De-S station |
Two De-S
stations |
| 5. |
Hot Metal
Handling |
Open-top ladles/mixer for storage |
Torpedo cars |
| 6. |
LD Vessels |
Two (1/2 vessel operations) |
Three ( 2/3
vessel operations) |
| 7. |
Heat Size |
130 tonnes |
127 tonnes
(original)
136 tonnes (current) |
| 8. |
Specific
Volume |
~1.1m3/tonne |
~1.1m3/tonne |
| 9. |
Secondary
Steelmaking Facilities |
On-line tap purging station attached to each vessel
One Ladle Furnace
One VADR unit |
On-line
purging station attached to each vessel
Two Ladle Furnaces
One RH-Degasser |
| 10. |
Casters |
Two-six-strand billet casters (100, 127, 130 mm sq billets) |
Three-single-strand
curved mould slab casters |
| 11. |
Casting speed
|
3m/min (avg) for CC1
2.65 m/min (avg) for CC2 |
1.02 m/min
(average) |
| 12. |
Vessel Life
(No. of heats per campaign) |
~1635 heats average FY-03) with tar dolo (and zoning with MgO-C) |
~1500 heats
average with tar dolo (and zoning with MgO-C) |
| 13. |
Ladle Life
(No. of heats/lining) |
70.7 (FY-03) |
~83 (FY-03) |
| 14. |
Heats/day |
27.5 (average FY-03)
43 (maximum) |
56 (annual
average)
68 (maximum) |
| *Note : Ingot
casting eliminated from April 2003 |
TABLE 2 : HOT METAL BALANCE -- CURRENT AND FUTURE
AFTER 1.0 MILLION TONNE EXPANSION |
| Hot
Metal |
Current
(BASE) |
After
1 mtpa
Expansion |
| “A”
to “F” Furnaces |
3.20 mtpa |
3.50 mtpa |
| “G”
Furnace |
1.20 mtpa |
1.80 mtpa |
| Total |
4.40 mtpa |
5.30 mtpa |
For the increased hot metal requirement,
it was considered necessary to enhance capacity of G Blast Furnace by ~50% to 1.8 mtpa.
Additionally, with improvements in ironmaking process, an increase of 0.3 mtpa of hot
metal was also anticipated at the older A-F furnaces. Thus, the total hot metal capacity
was set at ~5.3 mtpa as shown in Table 2, to meet the additional requirement for the 1.0
mtpa expansion of crude steel production.
At the moment, hot metal is supplied to
LD 1 in open-top ladles while LD 2 gets all its supply in 220 tonne torpedos. After the
1.0 mtpa expansion, LD 1 shop will also receive hot metal in torpedos.
The key parameters of hot metal are
expected to be as follows :
Sulphur 0.070% (same as now)
Phosphorus 0.250% (same as now)
Silicon 0.80% (lower than current)
Temperature 13400C (marginally higher than
current)
It is expected that variability in hot metal
composition would improve as compared to the current scenario.
Increasing Crude Steel Production -
Basic Issues
The basic enablers that are normally to be
adopted for increasing crude steel production at any steelmelting shop are as follows and
the same are applicable to the two steelmelting shops of Tata Steel :
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