Ancient times: Steel produced by heating Wrought iron with charcoal & approximately 3 tons coke burnt for producing one ton of steel.

1855 : With the invention of the Bessemer process, steel became an inexpensive mass-produced material

Then Open hearth furnaces in which excess carbon and other impurities were burnt out of pig iron to produce steel.

By the early 1990s, because of their slow operation, replaced by the basic oxygen furnace or electric arc furnace.

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Complete disappearance of basic open hearth processing

Continuous casting

Long product production to the electric arc furnace sector

Changed the way steel is made, the price, quality and range of

products generated

Changed the basic structure of the industry

Competitive forces and market globalization continue to drive the

development and adoption of new iron and steelmaking technologies

Refinements such as basic oxygen steelmaking (BOS), lowered the cost

of production while increasing the quality of the metal

Modern iron making and steelmaking is extremely intensive in material

and energy usage as well as in capital requirements

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o Customer demands

o Product properties

o Quality

o Price

o Delivery

o Environmental concerns

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Ore Bedding and Blending Facilities

Coke Dry Cooling Plant

Boiler, STG

Back pressure TG

Coke Oven Battery

Sintering Plant

Blast Furnace

Slab Caster, Various Mills

Raw Materials thru conveyors

Coke

Sized Ore

Coke plant 2750 tpd

RMHP

Sinter

SP‐3

Power & Utilities

CO Gas

Cold Blast

PCI

Water

Power

TB‐4

Water System

Power Plant

BF Gas

Power Unit‐TRT14 MW

Hot Metal

Slag

Grid

SMS&

PCM

SGP

2.5 MTPA Blast Furnace

ASP

Gas N/w

Gas N/w

Utilities (O2, N2 etc)

PCI Unit

9320 tpd

1400o C

2330 tpd

70 Lac cum/d

4.2 Lac NM3/d

5400 cum/d

13500 KWH

1070 tpd

50400 NM3/d 7150 tpd

Equipped with an array of supporting facilities to increase efficiency

Highly efficient, including Cowper stoves to pre-heat the blast air

Recovery systems to extract the heat from the hot gases exiting the furnace

Higher production rates

computer controlled weight hoppers weigh out the various raw materials

"Bell-less Top" system

Precise filling order which helps control gas flow and the chemical reactions inside the furnace

Coke, limestone flux, and iron ore "uptakes" allow the hot, dirty gas high in carbon monoxide content to exit the furnace throat

"Bleeder valves" protect the top of the furnace from sudden gas pressure surges

Coarse particles in the exhaust gas settle in the "dust catcher" and are disposed

The gas itself flows through a venturi scrubber and electrostatic precipitators and a gas cooler to reduce the temperature of the cleaned gas

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Higher plant capacity

Higher unit productivity

Higher plant availability and reliability

Improved hot metal quality and stability

Lower energy consumption

Reduced operational costs

Improved plant hygiene

Improved environmental performance

Improved plant safety

Longer campaign life

Industrial Automation has important role in any Industry because,- it saves time & Cost- replace Human operation which is physically hard- it can perform all the tasks very easily which are beyond of human capabilities

To achieve flexible control of burden distribution by application of parallel hoppers bell less top to maintain the lower thermal load inside the furnace wall

and stable furnace operation.

• Reduced coke rate: savings on Bell charged BF up to 10%

• Increased productivity; gain in output up to 7%

• Increased top pressure (2,5 bar)

• Longer BF campaign

• Better pig iron quality; standard deviation reduced due to more stable operations

• Possibility of charging coke to the BF center

• Optimal control of gas flow even at high PCI injection rates

• Increased availability due to reduced BF stops

• Reduced maintenance costs

• Best safety conditions during BF operation and during maintenance since because all maintenance is done outside of the blast furnace

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† Reliable, efficient and accurate injection of auxiliary reducing agents is vital for cost effective blast furnace operation.

† System provides the highest coal delivery accuracy to each tuyere injection lance.

† Excellent control of the distribution of coal to each injection lance.

† Flow control valves to achieve even higher coal distribution accuracy.

† Coal pre-heating technologies to increase injected coal efficiency and throughput for the furnace process.

*The PCI method is based on the simple concept of primary air (termed the "conveyinggas") carrying pulverized coal which injected through a lance to the tuyere, thenmixed with secondary hot air (termed the "blast") supplied through a blowpipe in thetuyere and then piped to a furnace to create a balloon-like cavity called a "raceway",which then propagates coal and coke combustion and melts the solid iron ore,releasing molten iron.

The most remarkable aspect of this method is that it allows for cheaper coal to beconsumed in the system, replace expensive coke, thereby remarkably cutting down oncosts

* Very compact design for maximum flexibility in the layout

* Continuous filtering and evacuation of dewatered slag sand

* Low fines content in the closed loop water circuit

* High reliability

* Measurement of slag flow rate

* Reduced emissions and air pollution control

* Low investment, operation and maintenance costs

* Low wear on drum body

*Handling of blast furnace slag is an important aspect of modern blast furnaceoperation. Today, blast furnace slag is a saleable product (granulated slag sold forproduction of cement) INBA slag granulation process, incorporates dynamic INBAdewatering drum. It is the most popular and effective means of processing blastfurnace slag in the world today.

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* Dust Monitoring System – Sox, Nox measurement at chimneys.

* Fume Extraction System from Cast House using Electrostatic Precipitators.

* Usage of DRI produces significantly less carbon emissions .

* Waste Water chemical treatment & recycling in the process.

* Handling of Coke Fines through conveyor.

*The past 5 decades have witnessed several dramatic technologicaldevelopments. Several new technologies have advanced to a fairlydeveloped stage and will likely be implemented on a production scalesometime in the future. Competitive forces and market globalizationwill continue to drive the development and adoption of newtechnologies

However, the extremely competitive marketplace has resulted in anenvironment where capital resources for research and developmentare limited and tolerance for failed technology concepts is very low.Therefore, the continued improvement of conventional processesand development and implementation of new technologies will dependheavily upon the determination, creativity, and resourcefulness.