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Last updated on : 05/05/2008
Results obtained from the R&D activities carried out with partial financial assitance from Steel Development Fund(SDF) & their availability for implmentation:
The objectives of the above study were as follows:
To suggest reduction and optimisation in energy consumption or conservation of electrical power, solid/liquid/gaseous fuels, electrodes, etc. through
- Improvement in operating practice
- Introduction of energy efficient technologies
- Installation of energy efficient equipment
- To identify various technologies/equipment available in the world for secondary steel sector and responsible for energy saving/conservation;
- To suggest implementation of technologies and or equipment relevant for each of the units under study with cost benefit analyses;
- Short listing of few units for implementation of Energy Conservation Opportunities (ECOs) which are relevant to many plants with the aim to help these plants to work as model plants.
MECON studied 15 mini steel plants (10 Electric Arc Furnace and 5 Induction Arc Furnace based). They identified ECOS in such plants as follows:
- Reduction in no. of bucket charging
- Effective utilization of free space post combustion
- Scrap pre-heating system
- Use of hot runner and riser
- Insulated pit for hot empty ladles
- Converting spout tapping to submerged tapping
- Hot metal usage in EAF
- Replacement of existing 14 MVA transformer by higher temperature of 17 MVA
- Blowing of lime fires in to EAF
- Use of supersonic oxygen blowing
- Slide gate system in EAF tap hole
- Placement of ladle hood in LF station
- Continuous DRI/HBI charging
- Post combustion system
- Insulating pit for hot empty ladle
- Modification of ladle cover & reduction in cover height
- Submerged tap hole
- Hot metal usage
- Modification of ladle cover for on line wire feeding
- Change mix optimisation
- Ladle in circulation
- Ladle preheating system
- Evacuating system
- Post combustion technology
- Foamy slag practice
- Use of lime as flux
- Measurement of finished bath temperature
- Use of crucible & riser
By implementation of some of the energy conservation opportunities(ECOs), some selected Electric Arc Furnace and Induction Furnaces based steel plants have reported reduction in energy consumption. The recommendations of the MECON have been circulated to the concerned associations.
For futher details Chairman-cum-Managing Director MECON P.O. Hinoo, Ranchi - 834002 (wesite www.meconlimited.com) may be contacted.
Theadditives developed by RRL, Jorhat could reduce alumina by 4% from iron ore slimes containing 10% alumina. For further details, Director, Regional Research Laboratory (RRL),Jorhat (E-mail matsci@csir.res.in) may be contacted.
IIT, Delhi completed laboratory scale research resulting in the
formation of coke button from non-coking coal. For further details
Director, Indian Institute of Technology (IIT),
Hauz Khas, Delhi (Fax No.
91-11-26862037, 91-11-26855227) may be contacted.
In order to develop indigenously on line expert system for continuously
cast products, an 'Expert System Shell Software' has been developed which is
useful for correcting operating parameters during casting to ensure quality product. For
further details Chairman-cum-Managing Director, P.O. Hinoo,
MECON Ltd, Ranchi 834002. (website www.meconlimited.com)
may be contacted.
The project has been successfully completed by RDCIS, SAIL, Ranchi. The first trial based on zonal lining has been completed in the 300 ton BOF at SMS-II, BSL which has increased lining life from Avg. 1100 heats to 1201 and 1878 heats with the inputs from the project work. This corresponds to a specific consumption of refractory for BOF to 1.58 kg/tcs in the Ist trial and to 1.2 kg/tcs in the next campaign against a target of 2.1 kg/tcs.
For further details, Director, Research & Development Centre for Iron & Steel (RDCIS), SAIL, Ranchi - 834002, Fax No. 0651 501310 (website www.rdcis.sail.com) may be contacted.
The research work has been completed and lean alloys (as
substitute to conventional costly high alloy steel) have been developed. One alloy
has been commercially exploited at Rourkela Steel Plant.
The results are very encouraging resulting in the savings in the production cost of high
strength low alloy steel plates to the tune of Rs 12000 per tonne.
For further details, Director, Research & Development Centre for
Iron & Steel, SAIL, Ranchi - 834002, Fax No. 0651 501310 (website www.rdcis.sail.com) may be contacted.
The project has been completed by Jadavpur University. The development of gas shielding
mixture would be able to reduce welding time of the fabrication and will be beneficial for
the automobile and fabrication industry.
For further details, Head, Department of Metallurgical Engineering, Jadavpur University, Kolkata 700 032 , Fax No. 033 24146317 (website www.t_k_pal@yahoo.com) may be contacted.
IIT, Kharagpur has developed a lean chemistry steel with to replace costlier cast and forged steel material being used in the automobile parts.The research results would be useful for the auto spare parts manufacturing industries.
For further details, Head, Deptt. of Metallurgical & Materials Engineering, Indian Institute of Technology (IIT), Kharagpur 721 302 ( 91-11-26862037, 91-11-26855227) may be contacted.
By introduction of Electro magnetic stirrer & submerged entry nozzle technology, they have been able to produce large variety of steel products through continuous casting route resulting in substantial saving in energy, increase in yield etc.
For further details, Director, Research & Development Centre for Iron
& Steel, SAIL, Ranchi - 834002, Fax No. 0651 501310 (website www.rdcis.sail.com) or Director, Research &
Development Tata Iron & Steel Co. Ltd. Jamshedpur - 831 001 Jharkhand ( Fax No.
0657 - 424098) may be contacted.
The research work carried out at IIT, Delhi could reduce sulphur content of Assam coal from 3.07% - 1.60%. The coal with the reduced sulphur mentioned above might have application for some end users.
For further details Centre for Energy Studies, Indian Institute of Technology, (IIT) Hauz Khas , New Delhi- 110016 (Fax No: 91-11-26862037, 91-11-26855227) may be contacted
11. Teaching Package on Structural Steel Design for Department of Civil/Structural Engineering by Institute for Steel Development & Growth (INSDAG), Ispat Niketan (1st floor), 52/1A, Ballygunge Circular Road, Kolkata-700019.
The teaching package in civil engineering institutions has been developed and these are to be utilized in actual practice to improve knowledge and competence of fresh civil/structural engineers so that they can correctly and confidently specify usage of structural steel in construction corporating the modern development with the ultimate goal of increasing steel intensive construction in India.
For further
detail of the package, Institute for Steel
Development & Growth (INSDAG), Ispat
Niketan,1st
floor,52/1A Ballygunge Circular Road, Kolkata-700019(website www.steel-insdag.org)
may be contacted.
12. Utilisation of solid waste materials generated at Steel plants : by physical beneficiation techniques by Regional Research Laboratory, Bhubaneshwar 751 013.
The research results obtained at lab scale and large scale work would help to Integrated steel plants to utilize wastes during the production of iron and steel and thereby reduce the cost of production.
For further details, Director, Mineral Processing Technology Deptt., Regional Research Laboratory (RRL), Bhubaneswar-751013 Orissa (E-mail: drbdasrrl@yahoo.com) may be contacted.
13. Macromodeling of heat transfer and inclusion management in continuous and ingot casting of steel by Department of Metallurgical & Material Engineering, IIT, Kharagpur - 721 302
The mathematical model developed by IIT, Kharaghpur would benefit in pushing/engulfment of inclusions in the continuous casting process during steel casting.or further details, Director, Department of Metallurgical & Material Engineering, IIT, Kharagpur 721 302 . (E-mail: hod@metal.iitkgp.ernet.in) may be contacted.
14. Cold Briquetting of Iron Oxide : by Ispat Metallics India Ltd.
Ispat industries Ltd. have been able to utilize the fines/wastes generated during production of pig iron in Blast Furnace.
For further details, Director, Ispat Metallics India Ltd., CASABLANCA, Sector-11, C.B.D - Belapur, Navi Mumbai - 400614 may be contacted.
15. Damge assessment and integrity of welded components : by Jadavpur University, Kolkatta 700 032.
By completion of this project the user industries would be able to assess the effects of welding parameters and Post Weld Heat Treatment (PWHT) on the Hydrogen Induced Cracking (HIC) susceptibility and predictively develop welding procedure for improved HIC susceptibility.
For further details, Head, Department of Metallurgical Engineering, Jadavpur University, Kolkata 700 032 , Fax No. 033 24146317 (website www.t_k_pal@yahoo.com) may be contacted.
16. Development of Micro Alloyed Steel Structural products in Secondary steel sector through Induction Furnace and Controlled Rolling Route: by National Institute of Secondary Steel Technology (NISST) and All India Induction Furnace Association (AIIFA).
NISST and AIIFA have developed Micro alloyed steels an alternate to the conventional TMT steel through induction melting furnace and controlled rolling route used for construction purposes.
For complete details Director, National Institute of Secondary Steel Technology, Post Box No. 92, G.T. Road, Sirhind Side, Mandi Gobindgarh-147301 Punjab (Fax No. 0512 2590260/2597505) or Executive Director, All India Induction Furnace Association, 209-MG House Community Center, Wazirpur Industrial Area, New Delhi 110052 Fax No. 7245178 may be contacted.