Empowered Committee on Research & Development:

 Ministry of Steel and Mines, Ministry of Steel has constituted on 24.2.98 an Empowered Committee under the Chairmanship of Secretary to the Govt. of India, Ministry of Steel and with Members drawn from Ministry of Science & Technology, National Laboratories, Steel plants, consultants, etc. This committee will sanction research and technology development projects with the money available from the interest proceeds of the Steel Development Fund (SDF).

 Research & Technology Mission which is to serve as the Secretariat of the Empowered Committee is under formulation. During 1998-99 (till December 1998) the Empowered Committee has met once and approved the following R & D projects.

  ( Rupees in crores )

Besides Rs. 0.9 crores has been spent ( till December, 1998) from SDF on different Science & Technology ( S&T) activities.

Research & Development Activities by Iron and Steel producers

 Iron and Steel producers, both in the public and private sector, continued to pursue their research and development activities to deal with their plant specific problems, assimilate and innovate newer technologies, utilise Indian minerals and raw materials in larger proportion, reduce pollution, conserve energy and reduce cost of production.

Total amount of money spent on Research and Development by iron & steel plants and other related industries during last 3 years were as follows:

(Rs. in Crores)

Performance of individual/undertakings during 1998-99 are reported to have been as follows:

STEEL AUTHORITY OF INDIA LIMITED (SAIL)

 Research and Development Centre for Iron and Steel, SAIL, Ranchi is trying to meet challanges in technological expertise and competence to fulfil the need of SAIL steel plants and customers.

 Significant achievement:

 New technology/Process: 1997-98:  

• An increase in specific productivity by 20% has been achieved in Sinter Machine # 1 of DSP through improved suction and uniformity of sintering process. Productivity of Blast Furnace #4 of RSP has been increased to 1600 t/day by optimising the tuyere parameters and drainage practice.
• One emulsion burner has been designed, fabricated and tested in both old and new boilers of BSP using Pitch Creosote Mixture (PCM). In proper mixing of air for combustion and the emulsion could be obtained and three such burners have been installed resulting in additional generation of 20 t/hr of steam at a pressure of 40 bar.
• An improved heating facility for ladle on Steel Transfer Car (STC ) in SMS-II,. BSL has been designed, fabricated, installed and commissioned. It has resulted in complete elimination of cold heat; heating of circulating ladles up to 900-1000 C; and improvement of ladle life of 24.8 to 25.8 heats.

1998-99: 

• The strip rinsing system in Pickling Line (PL) #2 at BSL, was improved with the introduction of flat jet Poly Venyl- Di Flourine (PVDF) nozzles and modified poly-propylene rinsing headers. This resulted in reduction in chloride ions in emulsion of Tandem Cold Mill (TCM) - II from average 200 ppm to 60 ppm. Brighter strips with increase in average surface reflectance from 40% to 70% was achieved by introducing air wiping system in TCM-II and wet skin pass system in Skin pass Mill-II. The overall impact of these activities lead to reduction of diversion of CR products due to surface defects like black patch, soot and rusting etc. to 0.1%.
• The mathematical models were developed using a new technique namely, Artificial neural network (ANN) for predicting the campaign life of BOF using real life data from DSP. Prediction results with ANN technique were much better than those obtained from other techniques like Group Method of Data Handling (GMDII) and regression. The prediction errors were within 6%.
• A control system has been designed, developed and implemented at DSP for automatic positioning of coiler jaws. The control system consists of PLC, Non-contact Infrared Sensors and mechanical gear reducer assembly. This control system adopts dynamic breaking and armature current control for slow rotation of coiler motor. This system has eliminated the earlier practice of manual jaw alignment.
• The technology of slag splashing was introduced in Converter-C of SMS-1, BSL in Aug'97 after extensive cold model and hot model studies. The technology has been extended to converter-B, D and E. There has been considerable improvement in converter lining life after introduction of slag splashing facilities.
• RDCIS along with IIT, Kharagpur has developed a laboratory scale remote viewing optical sensor based instrumentation for detection of onset of slag in the molten steel stream on two principles viz emission spectrum technique and image processing technique.
• In order to avoid the problem of deslagging the hot metal after desulphurisation at RSP laboratory experiments were carried out with emulsified slag sample collected from DSP & RSP using various additives. It was found that lime addition (optimum-20%) proved helpful in fludising the slag in hot metal with a metal separation of around 80% of total weight of slag metal emulsion.

Development of new products:

 1997-98: 

• Experimental production of spade M-1 plates at RSP
• Development of modified 409M abrasive and corrosion resistance stainless steel at RDCIS.

• Development of SAE 1020 steel at BSL.
• Development of low nickel austenitic stainless steel through ASP-SSP route at SSP.
• Development of fire resistant steel at RDCIS.

 Energy Conservation:

 Consumption of energy in four integrated steel plants (all forms to G. Cal.) including electricity consumption (KWH) per tonne of crude steel have been as follows: 

R&D Expenditure (Rs. in crores)

THE TATA IRON AND STEEL COMPANY LIMITED

 Objectives of R&D activities: 

• To make Tata Steel a Profitable & World class producer of Quality Steels.
• To identify and develop new products and processes so that the Company stays ahead of its competitors.

 Significant Achievement during 1998-99: 

• Two grades of interstitial free(IF) steels (Nb & Ti-stabilised) have been commercialized; the customers have found the r-values ( 1.9) quite attractive.
• Si-free (Semi-processed ) Electrical Steels have been developed and marketed. The watt-loss values of = 5W/kg. (at 0.5 mm, 1.5 T, 50 Hz) have been fully accepted by the customer.
• Corrosion Resistant (CRS) rebars (CRS-42) through the CC route (without LF) have now been commercially introduced. CRI values are attractive.
• An appropriate coal blend has been worked out for battery No. 8 (during its prestabilisation period) in order to produce acceptable coke under safe coking operation.
• An off-line simulator for the ladle cycle at LD#2 has been developed which predicts the bulk temperature of liquid steel at any stage in the cycle as well as the thermal profile of the refractory linings.
• Grinding-aid for the grinding of cement clinker at Sonadih has been recommended that would result in productivity increase by 2.5 tph and power reduction of about 4%.
• A new reagent based on CaO-Al-CaF2 has been developed for desulphurisation at OLP; plant trials have established that for non-desulphurised heats, the reduction in sulphur upto 40% can be achieved.
• An optimised procedure has been identified for producing good quality S.G. Iron Pellets of IS-400/12 grade.

Energy Conservation:

 Total Energy Consumption in G. Cal/tonne of Crude Steel during last 3 years has been as follows:

Major Achievements in Reduction of Energy Consumption: 

• Higher Coke Oven gas yield by 6N cum/t is achieved during April-Sept.'98.
• The middling coal consumption for steam & power generation is reduced significantly by 41358 t in boilers due to higher usage of by-product gases.
• Lowest specific Petro-fuel consumption of 5.38 Kg/tss is achieved.
• The system of oxygen enrichment of cold blast in A - F Blast Furnace was commissioned in April '98 for better furnace productivity.
• Rich Coke Oven Gas firing system was introduced in M/c. # 1 of Sinter Plant # 1 for better energy efficiency.
• Lowest-ever Plant Specific Energy Consumption of 8.321 Gcal/tcs during April-Sept'98 achieved.

 R&D Expenditure (Rs. in Crores)

 RASHTRIYA ISPAT NIGAM LTD

 Objectives/thrust on R&D

 The research and development efforts of the company are directed towards process improvement in the form of carrying out small but decisive changes, continuous search for variation in raw materials, recycling of wastes, additions in the technologies available in the company and optimisation of process parameters to derive the benefits of enchanced efficiency, reduction of cost, improved productivity and improved product quality.

Highlights of the R & D Activities: 

• Production and stabilization of 12 mm rebar in Wire Road Mill (WRM)
• Stabilization of two line rolling of higher diameter rounds and rebars in Bar Mill.
• Production of high carbon and forging quality steel through ladle furnace for special applications.
• During the period April-September'98 Spring steel billets were developed.

R&D Expenditure (Rs. in crores)

 Energy Conservation.

Savings during last 3 years:

KUDREMUKH IRON ORE COMPANY LIMITED

Objectives of R&D Activities: 

1. Objective of R&D activities at KIOCL are directed towards quality improvement through process development / modifications to suit multiproduct needs and to modify Process Flow Chart. Various value added by-products are also being developed like ceramicTiles, super concentrate etc., with a view to optimise/extend existing production activities.

 Details of Activities :

R&D activities undertaken at KIOCL include implementation of new technology/processes like Column Flotation and High Rate Thickner for reduction of silica in final product to enable value addition and ensure better quality pellets. Also after identification of problems like high material and energy consumption, studies are undertaken to minimise high value material consumption and also energy consumption. This is a continuous process and is tackled on merit of the cases.

 M/s J.K. Tech of Australia have been engaged for studies on optimization of energy consumption for Ball Mill Regrinding circuit as grinding consumes major portion of energy for the process requirement.

 M/s Met-Chem of Canada have been engaged for mathematical modeling and detailing statistical process control methods for pelletisation.

R&D Expenditure(Rs. in crores)

MANGANESE ORE (INDIA) LIMITED

1. Development of alternative Mining and Support methods.
2. Exploratory Core drilling, Trenching, Pitting etc. for locating new reserves and upgrading the confidence levels of the existing reserves.
3. Beneficiation of medium and low grade ore, as well as medium grade Dioxide ore to battery grade.
4. Development of processes for manufacture of Manganese base compounds.
5. Improvement of surface environment around mining areas.

 R&D Expenditure (Rs. in crores)

SPONGE IRON INDIA LTD.

Objective/Thrust on R&D:

1. To develop further the existing direct reduction process and operation in order to lower the specific consumption norms of raw materials as well as to improve overall economics of operations.
2. To find out and assess the techno economic feasibility of raw materials received from agencies if any, to whom technical know-how is imparted for sponge iron manufacture.
3. Better utilization of waste products and energy generated during the process to boost the economics of the reduction process.

Highlights of R&D activities:  

• New Technology/Process:
• Development of a suitable and convenient system in order to inject iron ore fines into the rotary kiln for coverting them into sponge iron fines is almost near to completion.

• By injecting waste iron ore fines of less than 3mm size from the discharge end of rotary kiln for reduction improved the productivity of the plant.
• Reduction in consumption of material and improvement in yield and quality: By increasing the production with the help of reduction of iron ore fines by injecting them from discharge end of rotary kiln reduced the overall specific consumption of iron ore per metric tonne of production.

• The development of suitable liner in the feed tube helps to change the profile of flow of material at the preheating zone leading to better utilization of energy supplied from reductant i.e coal.

Development of new products: 

• Experiments are under progress for reducing Manganese ores using solid reductants i.e. non-coking coal and lignite.

Quality improvement programme: 

• Better utilization of energy by incorporating specially lined feed tube helps for maintaining quality further consistantly.

Energy Conservation: 

R&D Expenditure(Rs. in crores)

NATIONAL MINERAL DEVELOPMENT CORPORATION

 Objectives of R&D Activities:

 To achieve optimum utilization of mine wastes and production of value added products.

Highlights of R&D Activities: 

• Development of process for production of synthetic Rutile & High Grade Ferric Oxide from Ilmenite concentrate obtained from Bhimunipatnam beach stands.
• Development of Ferrite powder mix from High Grade Ferric Oxide/UPFO.
• Process Development for treatment of UPFO effluents.
• Development of mineral Beneficiation process for production of High Grade Ferric Oxide from Blue Dust.
• Setting up of Pilot Plant for Brick/Hollow Bricks for Kimberlite waste and its evaluation.
• With the implementation of Prem-Roll magnetic separation technique based on R&D studies in the diamond processing plant at Diamond Mining Projects, Panna, there is a substantial increase in production and productivity.

R&D Expenditure (Rs. in crores)

SUNFLAG IRON & STEEL COMPANY LTD

• Post Combustion Injection Technology in EAF for enhancing Oxygen usage & Energy saving.
• Intelligent Arc Furnace Controller for opting EAF operation, electrode, productivity, power and refractory consumption.
• Gainful utilization of Iron Ore fines.
• Power input optimisation to reduce further power consumption.

IMPROVEMENT IN ENERGY CONSUMPTION:

 Consumption of Energy (all forms of G'Cal) including Electricity consumption (kwh) per tonne of Crude Steel for wholoe plant;

R&D Expenditure (Rs. in crores):

MALVIKA STEEL LTD

 Highllights of R&D activities: 

1. Modification in BF refractory lining.
2. Modification in Cast House runner design and layout.
3. Increasing the length of PCM-II.
4. Modification in ladle repair shop.
5. Modification in pig yard.
6. Modification of the PCM runner ("Y" - shape from "T" shape)
7. Nut Coke charging in BF on a regular basis.
8. Stock Rod modification.
9. Gas scal pressure measurement.
10. Continuous monitoring of burden permeability, velocity at tuyeres and the raft temperature has been incorporated in the PCC system.
11. Development of Level-2 automation.

FERRO ALLOYS CORPORATION LTD

 Objectives:

 Product/process development, improvement in existing furnace operations in the production of Ferro alloys, Pollution Control and Energy Conservation.

New Technology process 

• Usage of hot charge mix (chrome concentrate+Lime) directly in the production of low carbon Ferro chrome.
• Balancing of fixed carbon inputs in the form of Coke & Coal in the production of HC FeCr, HC FeMn and SiMn to get low Phosphorus runs content in the alloy around 0.025 to 0.030% and better electrode management.
• SiCr Slag as flux in the production of HC Ferro Chrome.
• Waste product in the production of Sea Water Magnesia is used as binder along with molasses in agglomeration of chrome ore fines.

• Introduced nozzle tappings in the production of HC FeCr and SiMn for better productivity.
• Sensible heat from the hot metal is used during casting to inrease the productivity by dressing 3-10 mm metal chipps in the pans.

• Usage of beneficiated ore agglomerates in the production of HC FeCr, improved the productivity and also reduced the specific power consumption.
• Change in the orientation of charging chutes in the submerged arc smelting furnaces helped in avoiding heat losses and considerable advantage in specific power consumption of the alloy.

R&D Expenditure(Rs. in crores)

MUKAND LIMITED

 Objectives: 

• Yield improvement and quality upgradation for customer satisfaction.
• Increase in exports and substitution in imports.

Process Development: 

1. Computer based Mathematical Modelling for quality improvement in susceptible grades.
2. Improvement in Welding characteristics of Cr-Mo steels for foundry.
3. Standardisation of metalllurgical parameters for M⁴ Cr Mo steel castings.
4. Development of High Emmissivity Coating for foundry furnaces.

R&D Expenditure(Rs. in crores)

MAHINDRA UGINE STEEL COMPANY LIMITED

Development of New Technologies & Products: 

• New Polygonal ingot of 6 T developed which reduced the tendency of ingots developing longitudinal corner cracks.
• Hydraulically operated slide gate system installed in the Arc Furnace which prevents carry over of slag ; thus improving cleanliness.
• Hydraulic circuit of 2 Centro-Maskin machines modified to reduce one motor of 7.5 KW each.
• Water seal being incorporated in Rolling Mill Walking Beam Furnace to save heat losses.

R&D Expenditure(Rs. in crores)