DRI UPDATE

December, 2018
 EDITORIAL

Dear Readers,

I am sure you might have gone through our earlier E-Magazine of September, 2018
issue. I hope you might have found that interesting and informative.

We are bringing out this issue focusing on coal based DRI activities. It mainly
contains the details of Technical Workshop on Energy Efficiency Technologies
organized in association with Bureau of Energy Efficiency, Ministry of Power,
Karnataka Renewable Development Ltd, a Government of Karnataka Undertaking
and KSIMA on 28.11.2018 at Ballari, Karnataka.

The magazine contains two papers highlighting the innovative ideas which may
have major impact on the financial performance of coal based DRI producers. The
third paper is on the safety procedures and practices required to be followed
during the steel making through the induction furnace route.

I take this opportunity to wish our Readers a very Happy, Prosperous & Growth
Oriented 2019!

Deependra Kashiva
Executive Director
************
 Report on “Technical Workshop on Energy Efficiency Technologies”
Sponge Iron Manufacturers Association (SIMA) in association with BEE, Ministry of Power,
Karnataka Renewable Energy Development Limited (KREDL), a Karnataka Government Undertaking
organized a Technical Workshop on Energy Efficiency Technologies on 28.11.2018 at Ballari,
Karnataka.

The Inaugural Session was addressed by Mr. A B Basavaraju, MD, KREDL, Mr. A K Asthana, Sr.
Project Coordinator, GIZ Germany, Mr. Deependra Kashiva, Executive Director, SIMA and senior
office bearers from Karnataka Sponge Iron Manufacturers Association and South India Sponge Iron
Manufacturers Association.

In his key note address, Mr. Deependra Kashiva, ED, SIMA gave the background of conceiving this
workshop in the Ballari region. He highlighted the important role being played by Indian sponge
iron industry in the steel production. He also informed the participants about the importance
given to the sponge iron industry in the National Steel Policy 2017 which envisages the need to
produce 80 million tonnes of sponge iron from the current level of about 25 million tonnes to
achieve the targeted crude steel production of 255 million tonnes by 2030-31.

Senior representative of BEE along with sector expert presented a paper on “PAT Achievements
and Way Forward”. It was followed by Mr. Asthana’s presentation on “Coal Blending for
Enhancing Combustion Efficiency”. Other important papers presented by Representatives of EL
Measure, Elpro Energy Pvt Ltd, Thermax Ltd and Tata Sponge Iron Ltd.

Major “Takeaways” from this Workshop may be flagged as under:

1. During the discussions, it was found that few sponge iron (SI) producers have installed
WHRB power plant which is contrary to the sponge iron producers in Chhattisgarh and
Odisha where large number SI producers have installed the same. This was perhaps due to
the fact that they do not have subsequent steel making facilities and uncertainty about the
PPA. On the several requests, the representative of Thermax visited 4 SI units and made
suggestions to set up smaller WHRB power plant to meet their present power requirement
on a much smaller capex.

2. ED, SIMA requested the participants to volunteer to spare their rotary kiln for carrying out
the R&D for exploring the use of Syn Gas in the rotary kiln. Mr. T Srinivasa Rao, MD,
Balajiswamy Premium Steels Pvt Ltd offered his 50TPD kiln for this purpose.

3. Presentation from Tata Sponge Iron Ltd was very much liked and lot of the people showed
the interest in the action points outlined by their speaker which inter alia speak the use of
catalyst (Thermact) in the coal which substantially reduces the cost of production of
sponge iron.

Some of the photographs of the event are as under:

ED, SIMA delivering the keynote address

View of Participants

*************
 1

Energy Efficient Operations @Tata Sponge

Bijay Kumar Agrawal

Head-Electrical, CEA

28th November 2018

The phases so far… and ahead

1983-85 1998-2007
First plant commissioning & trials Growth and diversification into Power
• First plant of 90,000 tpa capacity • 2nd kiln – capacity to 240,000 tpa
• 2 Power Plants of 26 MW capacity
1986-91
• 3rd kiln -capacity to 390,000 tpa
Evolution and stabilizing operations
• Overcoming teething troubles
• Rehabilitation plans to stabilize 2008-17
operations (capacity increased to Towards Industry Leadership
120,000 tpa) • Improve equipment efficiencies (TPM)
• Benchmarking performances
1992-97 • 2nd Railway siding
Consolidation of operations and
market 2018-23
• Improve plant availability Growth Plan
• Recovery from all losses • Steelmaking
• First net profit and paid dividend • Captive raw material sourcing
• Own Railway siding #1
2
 3

Manufacturing Process with Energy mapping

5 1
1

3 1 2
2
3

Thermal Energy Use/Loss

Electrical Energy
4
WHR/Power Gen/Export 4

Approach toward Energy Management

WITH WHAT (Philosophies & Tools) WITH WHOM (Competence/Support)

•Rotary Kiln equipment
• Support from Promoter
•Power plant equipment.
• 3 level structure
• 220KV System equipment
• Competent & skilled Workforce
•Right Mix of Coal Procurement
• Professional Consultants
•TPM Methodology/ Statistical Tools

INPUTS OUTPUTS

• BEE/PAT Targets in ToE Energy • Compliance to PAT target

• Energy Policy Management
• Reduction in tCO2 emission per ton of
• Energy Audit recommendations
DRI
• Best Practices & Benchmarks

HOW (Procedures & Methods) WHAT RESULTS

Reduction in C/Fe Ratio Increase in Power Export
• Energy Awareness Campaign to Grid
• Energy Efficiency Improvement Activities
Efficiency

Effective

• Implementation of energy audit Reduction in Coal per

Reduction in SEC( Elec)
recommendations ton of DRI
• IT Based Systems (KPI tracking, ERP) Sp. Steam Consumption Reduction in SEC (Thermal)
• Automations to check energy wastage 4
 Approach to Energy Efficiency Improvement Activities 5

Mapping of Energy • External Energy Audits

Consumptions(Electrical & Thermal) • PAT Targets/Obligation
• ISO 50001 methodology
Identifying Thermal & Electrical
• Best Practices/Benchmark
Energy Losses
• Climate Change Policy
Formulation & Prioritization of • New Technologies
Action plans for both Thermal & • Training
Electrical ENCON projects

Form C F Team for Implementation of

the ENCON Projects
R&R
Data Collection
No Training
Target Yes
Analysis of Energy losses Upload in
achieved?
Develop Kaizen Ideas for Knowledge Portal
ENCON
Daily review through KPI Tracker, ERP/SAP,
Prioritization of options Check & Fortnightly review by COO(SB)
& kaizen Implementation Review Monthly review by MD
5

List of some of the implemented Encon Projects:

1. Implementation of Dynamic Operation model through use

of Artificial Neural Network(ANN) for accretion control ,
improving quality of product and improving Kiln
availability.
• Identified Basic parameters and their inter relationship
to control quality and accretion.
• Temperature control is of paramount important for
accretion control
• Parameters for prediction of temp at different zones
are FC in feed Coal, Kiln pressure and MLD
position(Regression analysis)
• Parameters identified to control quality are FC in
injection coal, Kiln RPM, air blown through PAB and SAB 6
 7

Benefit:
• Reduced fluctuation of Kiln inlet and outlet pressure.
• Auto operation of MLD of ID fan
• Gain in Operating Days of Kiln:14days.
• Surpassed the rated production capacity & produced
417000MT against the rated capacity of 390000MT of SI

2. Adding Value to Waste-Injection of char with prime

coal
• Mixing fresh char with injection coal (As imported
coal char contains around 40% FC)
• Char added up-to 4% (of total injection coal) in
yard in a mechanized way to reduce moisture
content in injection coal from 10.8% to 8.3%.
• Prevented frequent jamming of injection system
during rainy season.

8
 9

3. Briquetting of coal fines to reduce coal consumption

Parameter Before 15 • Trial was conducted
Unit After 7 days Remarks
days for 7 days.
Non-Magnetic % 14.6 14.8 No Change
• 1.6 Mt/hr coal
F.C. in Non-Magnetic % 40.3 37.8 Decreased
briquette replaced
As per design of
C/Fe Ratio 0.435 0.430 1.75Mt/hr Coal from
experiment
Back Flow Mt/day 1.00 1.00 No Change
feed end.
Fe(M) of lump Product % 81.6 83.9 Improved • FeM percentage in
Fe(M) of Fine Product % 82.0 81.8 No Change product increased by
Sulphur in Lump Product % 0.027 0.027 No Impact 0.5%.
Sulphur in Fine Product % 0.029 0.030 No Impact • All these data shows
[Link] ESP dust % 18.3 19.5 Increased briquette has
Shell Temperature Eye estimation No change No Change favorable impact to
Fines (-3mm)in Feed Coal % 33.0 32.5
Decreased due to fines in reduce coal.
Briquette
• Reduce 154 kg of
Steam Generation Mt/hr 35.0 36.0 No changes
coal/hr/Kiln.
ESP Silo discharge No of trips 4.52 4.68 increased
Kiln feed rate Mt/hr 27.0 27.0 Same
• Potential cost saving:
Production Mt/day 422 422 same
Rs 400/mt of DRI and
Use of SA Coal % 100 100 No Change Rs 273 lakh/year. 9

10

MIXING
PRESS DRYING

Briquette strength :
Achieved (T.I > 75%)

BRIQUETTES
10
 11

4. Use of Catalyst with coal to reduce Specific Coal consumption

• The catalyst-Thermact has been developed in IIT, Mumbai
• Directly charged alone with coal charged inside the kiln
• Improves char reactivity of coal and optimise coal
combustion.

5. Waste Heat recovery from Coal Based DRI Rotary Kilns

• Inhouse generation of 26MW of Power
• Inhouse consumption of 7MW is supplied through own
power.
• Surplus power is sold which contributes to 6 % of revenue of
the company.
11

12

6. Kiln Outer Shell Painting ….Improving Energy Efficiency

Painting of Heat resistance paint (Alumina based)- Tempshield on Kiln-3 shell

50 meters out of 80 meters.
Change of shell temperature :Uncoated shell -385°C and Coated shell - 370°C
12
 13

7. Supplementing the steam through auxiliary combustion of

waste DE dust at PCC.
8. VFD control of various pumps & fans which were running in
throttled conditions: Cold well Pump(90KW), Hot well
Pump(90KW), SAB (120KW) , PAB,
9. Replaced the impeller of ESP ID fan of Kiln-2 with energy
Efficient impeller. Energy consumption reduced by 2000units
/day.
[Link] control of operation of cooling tower fan with sponge
temperature.
[Link] of conventional light fittings with LED light
fittings at both inside plant and township.
12. Improved maintenance practices. 13

14

13. Installed 235KW Roof Top Solar Panel

14
 15

Over
Performance at the end of PAT-cycle-1 achieved the
SEC
reduction
target in PAT
cycle-1 &
Baseline SEC
SEC

awarded
Reduction in SEC
ESCerts
Target SEC

Y1 Y2 Y3
• Baseline SEC : 0.581 ToE /MT of SI
• Target SEC : 0.551ToE /MT of SI
• Baseline production : 344557MT
• PAT cycle :2012-2015
15

16

Technological Challenges:

1) Technological options for creating Oxygen Enrichment inside

the DRI rotary kiln to improve utilization of Thermal Energy.
2) Technological options for recovery of heat which is being lost
a)from exhaust gas (which is at 170-180°C )
b)Indirect cooling of product from 1050°C to 100°C

16
 17

Future plan

• Auto regulation of Roots blower to control the quality of

Sponge Iron.
• Auto control of SAB blowers to restrict accretion formation.
• Integration of dynamic model with multi gas analyzer to
improve the quality of SI.
• Use of MATLAB for better prediction of process parameters.
• Working further with supplier to improve life of the paint to
reduce the radiation loss
• Coal drying facilities to reduce specific coal consumptions

17

************
 Global Steel Innovation Forum

SURAJ PRODUCTS LIMITED

A 5 star rated company by SPCB, Odisha

[Link]
1

ABOUT US- A MICRO INTEGRATED STEEL PLANT

3 x 50 TPD 2 x 23 m3 Cold 6 MW 3 nos. Continuous

2002-2004

2007-2010

2010-2011

2017-2018

2017-2018

2019-2020

Sponge Micro Blast Briquetting Power Induction Caster-Hot

Iron (DRI) Furnace Unit Plant Furnace charging-
Kilns based on Rolling Mill
WHRB &
AFBC

2
INTEGRATION
POWER
PLANT
(WHRB)
SPONGE
IRON
INDUCTION
FURNACE

COLD BLAST
BRIQUITTE
HOT
FURNACE
CHARGING
- ROLLING
MILL

MICRO INTEGRATED STEEL PLANT

BF Flue
BF Flue Dust
Iron Ore Coal MET Mn Fines Fluxes i.e. Dust
Crusher Crusher Coke Briquette Dolomite, Quartz,
Lime stone, etc. LD Sludge

Sponge Iron (DRI) Kiln Cold

Blast Furnace Binders
Briquette
FLUE GAS PIG IRON Coke Fines
POWER POWER
POWER Mill Scale
Iron Ore
HOT HOT
Fines
CCM Rolling
STEAM

WHR Power Induction Metal Charging

Boiler Generation Furnace Mill

DOLO- INGOT
CHAR AFBC
Boiler ESP
SPONGE FINISHED
IRON Granulated
Products
Slag to
Cement Plants
Fly Ash for Brick
making

4
WE BELIEVE

BURDEN NURTURE
ENVIRONMENT ENVIRONMENT

INNOVATION

We found solutions without pollution

[Link]

6
SMART ADOPTION

NEW AND
EXISITNG
INNOVATIVE
TECHNOLOGY
TECHNOLOGY

[Link]
[Link]
7

FORCED DRAFT COOLING

Unnecessary water consumption by industries = Burden to the planet

COUNTER-ATTACKING THE ISSUE

We conceived, developed and installed Forced Draft (FD) Air Cooler

replacing Gas Conditioning Tower (GCT) to cool flue gases in sponge iron industry
saving millions of litres of water annually.

8
SINGLE WHRB USING THREE 50 TPD DRI KILN

SOLUTION

An in-house designed novel refractory damper and vessel

to use flue gases from multiple 50 TPD of Direct Reduced Iron kiln in
A Single Waste Heat Recovery Boiler (WHRB).

Moreover, we successfully test fired Blast Furnace gas in the same

WHR Boiler for enhancement of power generation.
9

WE BELIEVE

Waste is indeed not the

ultimate waste

10
PROBLEM

S IRON AND STEEL W

M
E
FERRO ALLOYS
A
L
S
CHROMITE
GENERATES
T
E
R
ETC.
T
S
E
11

Cold Briquetting
From
Industrial waste
THE CHALLENGE OF PROCESS FINES

Extract value and avoid disposal issues

13

THE CHALLENGE OF PROCESS FINES

• Baghouse dusts
• Wet or dry sludge
• Chips andfines
• Mill scale

14
SOLUTION

COLLECT
CREATE
CONVERT

COMMERCIALIZE

Waste created by existing To be utilized by the

Iron and Steel / Ferro Alloys “CREATERS”
Smelters
15

SOLUTION

Cold Sinter
&
COLD BRIQUETTE Briquettes
Pellets
FROM
INDUSTRIAL WASTE

Cold Briquettes are substitute of Sinter & Pellets

16
STIFF EXTRUSION - IDEAL FOR AGGLOMERATION

Agglomerates dust, sludge and various particle sizes and densities

Vacuum improves briquette strength and binder effect

Change size/shape of product in minutes

17

OUR TECHNOLOGY

INNOVATIVE TECHNOLOGY BY:

SURAJ PRODUCTS LIMITED

J. C. STEELE & SONS

18
STIFF EXTRUSION BY J C STEELE & SONS

Developed for brick and

structural clay products

Process forms bulk raw

materials into durable units

Strong enough for rough

handling in “green” state

19

STEELE STIFF EXTRUSION

STEELE - THE BEST OF STIFF EXTRUSION

•High pressure/vacuum for exceptional green strength

•Proven technology with simple, reliable equipment

•Continuous operation

20
COLD BRIQUETTING FROM INDUSTRIAL WASTE

RELAX
NO HEATING

NO RESIDUE
NO WASTE WATER

[Link]
[Link]
[Link]
[Link]

21

COLD BRIQUETTING FROM INDUSTRIAL WASTE IN IRON

AND STEEL INDUSTRY

• Blast Furnace Flue Dust

• L D Sludge
• Coke Fines
• Manganese Ore Fines
• Binders

100% Replacement of Iron Ore with Briquettes made of Steel Plant waste in
blast furnace OF SURAJ PRODUCTS LIMITED.

22
CHEMISTRY OF RAW MATERIALS FOR BRIQUETTING
IN IRON AND STEEL INDUSTRY

Chemical Analysis
Fe : 31-38%
Al2O3 : 12-13%
CaO : 7%
FLUE DUST MgO : 1%
SiO2 : 10-11%
PbO : 2-5%
Un-burnt Carbon : 14-30%

Chemical Analysis
Fe : 40-50%
CaO : 16-20%
MgO : 2-4% LD SLUDGE
SiO2 : 3-4%
Al2O3 : 1%

23

COLD BRIQUETTING FROM INDUSTRIAL WASTE IN FERRO

ALLOY INDUSTRY

• Ferro alloy fines and concentrates (Ni, Mn, Cr)

• Metallized fines
• Sludge, dust and fines
• Iron ores and concentrates
• Mill scale
• Coke breeze
• Any combination of the above

24
COLD BRIQUETTE

Producing
GREEN Pig Iron
using cold briquette
made from industrial waste

25

PROCESS OF COLD BRIQUETTE MAKING

RAW MATERIALS

SCREENING

BINDERS

MIXING AND MAKING

COLD BRIQUETTE

26
PROCESS OF COLD BRIQUETTE MAKING
Rejects & Spillages Return To Ground Hopper for Reuse

VIBRATING PRIMARY MIXER

SCREEN BINDERS
RAW
Material
FEEDER SECONDARY
MIXER

Ground
Hopper
MAKER

COLD BRIQUETTE

FLOWCHART OF COLD BRIQUETTE MAKING

27

GREEN BRIQUETTE JUST AFTER EXTRUSION

28
COLD BRIQUETTE

Our BRIQUETTES offer superior durability and reducibility

Shippable 300 km between production and smelter -

shipped by Suraj Products Limited

Rugged 20+ transfers

Weather-resistant Long exposure to weather with no negative effect

Chargeable Up to 50% charge rate / submerged EAF

29

AUGER EXTRUSION
Typical case study – development of an engineered pellet

Mechanical, metallurgical, and chemical evaluation of the pellet

Sample TOTAL Fe++ Satmagan C S SiO2 Al2O3 MnO
Fe Fe
Chemical analysis

Raw 39.88% 12.19% 8.90% 27.39 0.19% 6.03% 2.03% 0.20%

Material Mix %
Extruded 38.49% 10.15% 8.54% 24.42 0.24% 7.46% 2.31% 0.19%
Pellet %

Sample CaO MgO TiO2 P Na2O K2O ZnO LOI

Raw 2.38% 0.62% 0.18% 0.14% 0.11% 0.14% 0.12% 28.18%
Material Mix
Extruded 5.85% 0.75% 0.18% 0.11% 0.20% 0.15% 0.14% 26.59%
Pellet

ISO 3271 Tumble Test TI= 86.0 AI= 12.0

30
TOWARDS SUSTAINABILITY
Characterization of various agglomeration technologies
according to the criteria of the best available technologies (BAT)
BAT criterion Agglomerated iron-containing material
Sinter Pellet BREX*
1 The minimum level of impact on
the environment, kg / t:
- dust ≤1.200 ≤0.600 0.05
- nitrogen oxide ≤0.550 ≤0.535 0
- sulphur dioxide ≤4.000 ≤0.500 0
- carbon oxide ≤14.000 ~0 0
Total emissions, kg / t: ≤20.000 ≤2.000 ≤0.050
2 Resources consumption:
- solid fuel, kg/t 23.6-48.9 0 0
- gaseous fuel, m3/t 2.45-6.3 9.5-15.0 0
- Electricity, kWh / t 23.0-48.7 29.0-48.5 10.0-15.0
3 Investments, USD/t per day ~5000 ~5500 ~2000
4 Implementation period, years 3 2 1
* STRIFF EXTRUDED BRIQUETTES Above Table is represented by Dr. A. Bizhanov
31

AUGER EXTRUSION
Typical case study – development of an engineered pellet
ISO 13930 Dynamic Low Temperature Disintegration
+6.3 mm 6.3 x 3.15 mm 3.5 x 0.5 mm -0.5 mm Before Test After Test
(1/4") (6 M) (32 M) (-32 M) Weight, g Weight, g

97.00% 0.10% 0.20% 2.70% 500.5 456.2

“The results of the ISO 13930 testing were impressive, achieving

97% in the +1/4” size fraction.

…above‐average porosity (relative to a ‘normal’ iron oxide pellet)

due to the high amount of carbon loss during reduction

The samples should be thought of as a hybrid feedstock – part iron

ore, part carbon and part flux…”

--Jack Swanson
University of Minnesota Duluth
 USHER

Suraj Products Limited, India

ushers
GROWTH
and
INNOVATION
since 2011

Briquetting by JCSTEELE’s Stiff Extruder for metallurgical use pioneered by us is being followed by…

• Large Steel Plant, Japan (NDA) (Blast Furnace, since 2012)

• Assmang Cato Ridge, South Africa (Ferro Alloys, 2016)
• JSC Chelyabinsk Electrometallurgical Integrated Plant, Russia (Ferro Alloys, 2017)
• TNC Kazchrome, Kazakhstan (Ferro Alloys, 2017)
• Large Steel Plant, India (NDA) Blast Furnace, 2018
• many more…
[Link]
33

FINALLY

We have begun our journey towards “SUSTAINABLE” iron and steel production

[Link]

34

****************
 Induction Melting Furnaces Safety procedures
and practices
S. P. Chhabra, Steel Consultant

Medium Frequency Induction Furnaces have the potential to produce metals in

industrial settings safer than ever. However, proper precautions must be taken to
avoid injuries, damage or loss of product.

Safety precautions regarding melting technology are various and extensive. Here is a
basic guideline to suggest safety procedures and practices when using an induction
melting furnace.

A. General for all employees

1. Ensure All Employees are Properly Trained:

Training is a key step in preventing work place accidents. It

is the employer’s responsibility to make sure that only
qualified workers handle melting furnaces, and that
trainings are up-to-date and thorough. Induction furnace
manufacturers often produce their own safety guides and
user manuals for various melting furnace equipment. Make
sure that your workers have total access to all necessary
documents for reference.

2. Ensure All Workers Have Proper Gear

Even if your workers are properly trained and experienced with induction
melting, accidents still happen. Luckily, there are ways to minimize damage in
the case of an emergency or malfunction, such as a molten metal splash. One
of the biggest ways to reduce the likelihood of an injury is to require
employees to wear proper safety gear at all times and to strictly enforce
protective equipment regulations. Personal protective gear that can save lives
includes, but is not limited to:

 Safety hoods
 face shields
 Flame resistant aluminized coats, leggings, and gloves
 Lace less Safety Boots
  Secondary protective clothing, like natural-fiber coveralls and flame
retardant washable undergarments

3. Use Reminders to Prevent Common Safety Mistakes

Finally, though there are many potential safety

hazards involved with using induction melting
furnaces, some problems are more common and
more dangerous than others. As an extra
precaution, consider posting additional warning
signs and safety reminders in a clear, easy-to-see
location lest workers forget the basics. Be sure to
regularly remind workers of dangerously
common issues, such as bridging, cold charges,
and molten metal splash. Hanging reminders,
like the one below, might just save a life Use
brief, easy-to-read guides like this one for quick danger reminders:

Common Causes of Molten Metal Splash:

 Wet or moist charge material

 Dropping heavy metals into molten baths.
 Moisture or wetness on tools and additives
 Centrifugally cast or sealed scrap and scrap rolls

4. Emergency escape routes

There must always be two independent emergency escape routes from the
furnace platform to meet any emergency. These routes must be kept cleared
at all times and may not be blocked even for short time.

B. For Production employees

1. The refractory that is used to line the furnace must be suitable for the
material being melted.

Refer to the refractory manufacture’s specifications. Be sure that furnace

lining has been thoroughly dried and sintered in accordance with the
Manufacture’s recommendations.

2. Regularly inspect furnace lining to minimize the possibility of a dangerous

“run through “occurring.

3. Power must not be turned on in any one of the following conditions;

  There has been an earth leakage trip, indicating metal
penetration to the coil.
 The solid-state power supply start running at low
voltage and reduced power these conditions indicate
an eroded lining. (this condition also Indicated by low
power factor)
 There is excessive surface slag visible. This is evidence
of serious lining damage.
 The water temperature in the coil is higher than
normal (more than 60°C to 65°C)

Each of these conditions indicates that molten metal may be next to

the coil and require immediate evacuation of the area until all of the
metal in the furnace has solidified.

4. For manganese addition small box bucket to be used as there is possibility

of accident due to splashes.

5. Ensure all charge materials i.e. scrap / sponge iron / ferroalloys are dry.
Wet materials are serious safety hazard. Moisture instantly turns into
steam when coming in contact with molten metal, expanding to 1600
times its original volume and producing a violent explosion.

6. Workers doing their work near the heated area to be provided rest in
between to take care of heat stress.

7. Avoid overloading the furnace and its components.

8. Furnace platform to be always kept as clean as physically possible

C. For Maintenance employees

1. Keep all cabinet doors locked and make keys available only to those who require
access to the enclosure.

2. Always use independent methods to support a tilted furnace whenever working

on or near.

3. Never work or enter the high risk zone like running crucible/ “ON” condition of
solid state generator. Always work on electrical section of furnace with main
breaker off and keep fuses with yourself while working.
 4. Preventive maintenance schedule's (say bimonthly/monthly) to be strictly
followed. During this period specific attention should be given to the following:

 Ensure all interlock’s, limit switches, indicating lights, earth leakage

alarm and trip are functioning.
 Water flow in each circuit is sufficient.
 All terminal connections are tight.
 Hydraulic oil leakage, if any, is satisfactorily attended.
 Bulging MF capacitor, if any, is given due attention. A crack in a
capacitors weld may permit oil leakage, causing the unit to arc
internally and generate gas resulting in violent explosion.
 The furnace coil cradle assembly inspected, cleaned of dust, small
particles of scrap and other impurities using a vacuum cleaner.
 The furnace crucibles underground room area is thoroughly clean.
 Any problems faced subsequent to earlier preventive maintenance
are duly attended.
 Recurring nature of any problem to be thoroughly investigated
and attended to full satisfaction.

5. For attending MF capacitors or any other capacitors, wait for few minutes after
switching off the supply (breaker / switch). This allows capacitors to discharge.

6. At a given regular interval (say half yearly/yearly) transformer and motors IR

value, transformer oil dielectric strength, silica gel colour, operation of relays and
there setting and proper double earthling of all electrical equipment to be checked
and earth resistance is within limit ensured. Any abnormal sound or
malfunctioning should be investigated and duly attended.

Maintain proper record of all activities.

D. General

1. The furnace layout should consider safety of

personnel and equipment as of prime importance.

Between the furnace crucibles and electrical

equipments (Static frequency converter and MF
capacitors) solid wall is a prime need to avoid any
damage to costly equipment and for human safety
in case of metal leakage.

Prefer to have wall between two crucibles. If workers are working on standby
crucible and any accident happens in running furnace than middle wall will save
workers.
2. The furnace should have features like automatic charging systems, computer
control and compressing of the charged scrap by hydraulic pusher. These
systems enable people working with the furnace to stay further away and do
their job more efficiently as well as reduce the manpower requirement.

3. Provide a system to diligently examine all input

materials.

4. At a given regular interval (say once a month) to have

safety meeting wherein top management takes a
key part. Besides discussing, the team should go
around the furnace and critically observe
environment, hot spots, abnormalities’ and scope of
improvements in operation and maintenance.

5. Once in a year the organization should conduct safety

audit and have accreditation of OHSAAS: The relevant standard being; IS
18001:2007 Occupational hazard and safety requirement system.

Lastly, it is essential to ensure that statutory requirement such as pollution control,

ventilation system, installation of safety equipment i.e. for fire prevention and fire
fighting, first aid boxes at critical positions, glasses for eye protection and
availability of good quality drinking water etc. are taken care of.

Safety Must Be Key Corporate Value

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