TATA STEEL, India

Upgrade of Blast Furnace “G”2005

Blast Furnace Constructions, Rebuilds & Relines

Introduction

During the 12 years’ life of its first cam-paign, BF “G” produced 14 million tons of hot metal. The upgrading work was undertaken to enhance the capacity of the furnace to 1.8 MTPA and a projected minimum life of 15 years, using state-of-the-art technology.

Tata Steel chose Paul Wurth as technologi-cal supplier in association with L&T for the upgrade of BF “G”.

Project Realisation

To achieve a cost effective upgrade, a critical study of existing and proposed new facilities, and striking a judicious balance between old and new facilities, was carried out. In addition to capacity enhancement, the upgraded “G” furnace has been equipped with a sophisti-cated monitoring and control system and an up-to-date automation system to enable the furnace to produce high quality hot metal at the lowest cost.

To minimize the shutdown period, a project monitoring system comparable to the world’s best practices was put in place to execute the project in optimum time. A substantial quantity of work was completed during the pre-shutdown period while the furnace was in operation. Areas of concerns were: Safety hazards of BF gas, space constraint, working at heights.

Project Description

Supermicropore hearth carbon blocks

Gas cleaning plant Blow-in

Project Data

Project overall duration (from order placement to blow-in) : 24 months

Pre-shutdown activities : 15 months

BF shutdown activities : 125 days

Blow-in date : 6 April 2005

Major Technical Reline Objectives

` increase of working volume from 1 581 m3 to 2 308 m3

` improve BF cooling by introduction of copper staves and 5 closed loop cooling circuits

` provision of a new 2nd casthouse

` extension of cooled surface area

` hearth geometry/materials quality upgrade

Services

` Basic engineering and detail engineering for selected items

` Supervision of detail engineering developed in India (for critical items)

` Supervision and testing of critical items manufactured in India

` Supervision of erection, commissioning and performance tests

Supplies

` Raw material preparation

y Upgrade of existing stockhouse equipment

y Remote flow control for ore and sinter

` Furnace top equipment

y Expansion of hopper volume

y New bleeder valves

y Increased length of rotating chute

` Furnace body

y Introduction of stave coolers (copper & cast iron)

y Profilemeter for improvement in burden distribution *

y Introduction of supermicropore carbon in hearth

` Coal injection

y Enhancement of coal injection capacity up to 200 kg/tHM

y Installation of one new additional coal mill (15 tph)

` Stoves

y Hydraulic actuation of stove valves

` Cooling system

y Demin water system for stave coolers

y Five separate closed cooling circuits

` Casthouse equipment *

y New powerful hydraulic drill machines & mud gun

y Splash cover manipulator

y Provision of a new 2nd casthouse

` Gas Cleaning Plant

y Introduction of ceramic tiles in cyclone

y Improvement in venturi scrubber

y Addition of external demister

Paul Wurth Reline Scope

Phases of shell erection

Bustle pipe gunniting

Major Technical Reline Objectives

` increase of working volume from 1 581 m3 to 2 308 m3

` improve BF cooling by introduction of copper staves and 5 closed loop cooling circuits

` provision of a new 2nd casthouse

` extension of cooled surface area

` hearth geometry/materials quality upgrade

Blast Furnace Data

Daily Production : 5 150 tHM

Hearth Diameter : 11.05 m

BF working volume : 2 308 m3

BF inner volume : 2 648 m3

Top pressure : 1.5 bar g

Tuyeres : 30

Number of tapholes : 2

Tuyere injection : PCI

International presence:Brazil, Chile, Czech Republic, Germany, India, Italy, Japan, Korea, Mexico, P.R. China, Russia, South Africa, Taiwan, Ukraine, U.S.A., Vietnam

© Copyright 2005-2015 Paul Wurth S.A. – all rights reserved

Non Contractual Data: Paul Wurth believes that the data contained in this folder are correct and accurate, but cannot guarantee same or better performances for any specific site without a detailed quote. Patents and Patents pending. — Paul Wurth equipment and processes are protected in many countries by patents.

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TIFIED SAFETY SYSTEM

VINCOTTE

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BUREAU VERITASCertification

Technical Highlights

Paul Wurth S.A.32, rue d’AlsaceL-1122 LuxembourgPhone: (+352) 4970-1Fax: (+352) 4970-2209paulwurth@paulwurth.comwww.paulwurth.com

* TMT – Tapping Measuring Technology, a joint company of Dango & Dienenthal and Paul Wurth.

Bell Less Top®

Copper staves

Casthouse *Furnace shell lifting by crane

Blast furnace “G” Hot stoves & blast furnace