A TRAINING REPORT ON

optimization of scale in tunnel furnace at csp-mill

Essar Steel Ltd.

Hazira, Surat
In
CSP-MILL Department
(15nd May 12 14nd July 12)

Submitted by

Guided by

Name:
Vikash kumar yadav
Ref. Code: VT/GE/064/12-13

Mr. T.R.K. Sharma

Mr. Satish kumar pandey

Discipline: Chemical Engineering

College: IIT(BHU), Varanasi.
Date: 10/07/2014

ACKNOWLEDGEMENT
It has been an immense pleasure and truly enriching experience doing our vocational training
at ESSAR STEEL LIMITED, Hazira. We take this opportunity to thank all those people who have
made this experience a memorable one. First, we would like to thank our guide
MR. T.R.K. SHARMA , HEAD, CSP-MILL and MR. SATISH KUMAR PANDEY ,ZONAL HEAD , CSP
who has been the guiding force behind the completion of this project and correcting various documents
of ours with attention and care. They have taken pain to go through the project and make necessary
correction as and when needed.
We are heartily thankful to MR. TRKS and MR. SATISH PANDEY for their co-operation, valuable
support and proper guidance whenever we approached them in any dilemma. We are sincerely thankful
to all staff members of CSP-MILL Dept. for their valuable help and guidance in the completion of our
training. We are also indebted to MR. , SR. MANAGER HR Dept. for giving us an opportunity to
work with ESSAR STEEL LIMITED. Finally, we are grateful for the joint support from the Essar
Group as a whole for the opportunity and assistance they provided us to do our training here. And last
but not least we would also like to thank the entire technical services team for their support during the entire
duration.

Vikash kumar yadav

July, 2014

ABSTRACT
This report prepared at Essar Steel Limited, Hazira contains a brief description of the Essar Steel
Limited with CSP-MILL overview and flow diagram. This report contains a detailed description of
COMPARISON OF IRON LOSSES FOR DIFFERENT PROCESS CONDITIONS(ALLOYING
MATERIAL,TEMPERATURE,OXYGEN PERCENTAGE,RESIDENCE TIME) in all furnaces of
CSP as a focus area.
The details of the project done as a part of practical training along with the details of the calculations
done, the methodology and procedure adapted as a part of the project work is also presented in this
report.

PREFACE
Any amount of theoretical knowledge is incomplete without exposure to industrial practice. Practical
knowledge means visualization and application of knowledge which we read in books. Theoretical
studies cannot be perfect without practical training. Hence, in-plant training is of great importance for
an engineering student. Teaching gives theoretical aspect of technology, but practical training gives
knowledge of industrial activities.
Our aim for this industrial training was to get a detail idea of different types of Reactors used in
different units, with different services and analyze their performance at Essar Steel, Hazira and apply
our already acquired knowledge to perform various calculations relating to them. As a part of our
project we have prepared a Microsoft Office Excel file that can perform various calculations regarding
the HBI Plant. Besides the technical aspects, we also tried to observe important aspects of industrial
behavior, discipline and safety precautions.
This project report presents a detailed summary of my enriching industrial experience at the Essar
Steel, Hazira.

CONTENTS

 The Essar Group: A Profile

The Essar Group is a multinational conglomerate and a leading player in the sectors of Steel, Oil & Gas, Power,
Telecom & BPO, Shipping, Ports, and Projects. With operations in more than 25 countries across five continents,
the Group employs 75,000 people, with revenues of USD 17 billion.
Essar began as a construction company in 1969 and diversified into manufacturing, services and retail. Over the
last decade, it has grown through strategic global acquisitions and partnerships, or through Greenfield and
Brownfield development projects, capturing new markets and discovering new raw material sources.
Today, the Group continues to expand its global footprint, focusing on markets in Asia, Africa, Europe, the
Americas and Australia. Essar invests significantly in the latest technology to drive forward and backward
integration in its businesses, and on leveraging synergies between these businesses. It also focuses on in-house
research and innovation to be a low-cost manufacturer with high quality products and innovative customer
offerings.
Alongside its ambitious business pursuits, Essar has been committed to its social responsibility. The Group runs
community outreach initiatives in all its plant locations, with a focus on education, healthcare, environmental and
agricultural development, and self employment. Essar is committed to sustainable business practices. Our HSE
(Health, Safety and Environment) management system is on par with global standards. We are also taking
climate change initiatives to reduce our carbon footprint. This includes several CDM (Clean Development
Mechanism) projects that can earn the company CER (Certified Emission Reduction) credits. A growing number
of our businesseswith new businesses joining the list every yearare certified to international environment
standards, like ISO 9001 /14001, and health and safety standards, like OHSAS 18001.
The Essar Group is widely regarded as a responsible and conscientious global employer. It has experience in
managing businesses in different geographies with a culturally diverse workforce. This is why its people
practices are sensitive to cross-cultural nuances. The Group's people strategy is focused on promoting a learning
culture that continually enhances the professional skills of its employees.
The combined assets of Essar Power and Essar Oil constitute Essar Energy plc, a company that was listed on the
London Stock Exchange in 2010 following a highly successful Initial Public Offer (IPO), the second largest
overseas IPO ever floated by a company of Indian origin.

All the groups investments have been consolidate under Essar Global Ltd. With its six sectors
holding companies:

ESSAR steel holdings ltd.

ESSAR power holdings ltd.
ESSAR energy holdings ltd.
ESSAR communication holdings ltd.
ESSAR shipping & logistics ltd. And
ESSAR construction FZE

It headed by Chairman Shashi Ruia & Vice Chairman Ravi Ruia.

 MISSION
To create enduring value for customers and stakeholders in core manufacturing and service businesses, through
world-class operating standards, state-of-the-art technology and the positive attitude of our people.
Business Interests of Essar Group
Steel:
Essar Steel Holdings Limited is a global producer of steel with presence in India, Canada, USA, Middle East
and Asia. It is a fully integrated flat carbon steel manufacturer from iron ore to ready-to-market products. Essar
Steel is India's largest exporter of flat products.
Energy:
Essar Oil Ltd. (EOL) is leading integrated Oil and Gas Company spanning the entire value chain: Exploration &
Production, Refinery, &Marketing. Essar was one of the first private companies to bid for exploration blocks in
1993. It was also among the first to enter the refining sector when it was opened to private participation. Its
refinery at VADINAR, Gujarat has a capacity of 20 MMTPA.
Power:
Essar Power has two gas-based plants, of 500-MW and 515-MW capacities in Bhander and Hazira respectively,
a 500-MW co-generation plant in Vadinar (all in Gujarat, India) and an 85-MW plant in Algoma (Ontario,
Canada).
Work is currently under way to expand the current generation capacity of 1,600 MW to 6,100 MW by 2012, with
a goal to achieve 11,470 MW by 2014. Essar Power has recently moved seven power projects in to the
construction phase, taking the total installed capacity under construction to 9,870 MW.
Communications:
Today, Essar is venturing into emerging markets in Africa and South Asia. In Kenya, we have created a new
cellular services brand called yu, becoming the fourth telecom operator in the country. This is a GSM-based
mobile services network in Kenya, with over one million subscribers. We have over 140 million telecom
subscribers in India and Kenya. We also have a majority stake in the telecom assets of the Dhabi Group in
Uganda and the Republic of Congo.
Shipping:
The sea transportation business has a diversified fleet of 27 vessels including VLCCs, mini-bulk carriers,
Supramaxes, tugs and cape-sizes to provide crude oil and product transportation services. We have more than
220 ship years serving leading Indian and global oil majors and commodity traders and a combined tonnage of
over 1.4 million.
Construction:
Essar Projects Limited (EPL) is a global engineering, procurement and construction (EPC) company with more
than 2,500 construction management staff, 1,200 engineering and technical personnel, and almost 45,000 on-site
workers. Headquartered in Dubai, EPL has business footprints in India, Africa, Middle East, South East Asia,
and Australasia, and is expanding rapidly in other countries. Today, EPL offers strong capabilities in
engineering, sourcing, construction, fabrications and project management to both the Essar Group and the
outside world. The company has served external clients such as ONGC, GAIL India and BORL.
Major Achievements of Essar Group:
Set up India's first new generation independent power plant with a 515 MW combined cycle capacity at
Hazira.
Built the world's largest gas-based sponge iron plant
Pioneered the laying of offshore oil and gas pipelines in India .
Built India's first and longest island breakwater.

Project work
scale
During the reheating operation, hot steel surfaces react with the in-furnace oxidizing
atmosphere resulting in the formation of an iron oxides layer ,that is known as scale.
scale layer consist of three phases ,these are1) Wustite - FeO
2) Magnetite - Fe3O4
3) Hematite - Fe2O3
Wustite ,Magnetite ,Hematite consist around 95% ,4% ,1% of scale respectively. Wustite is the
inner most layer of scale after that Magnetite and then outer most layer of Hematite. there are
few advantages and disadvantage of scale classified as ADVANTAGE OF SCALE
(1) scale eliminates surface defects such as impurities of mould powder embedded in the
surface from the continuous caster, oxides and surface cracks, and hence results in smooth
and clean steel surface.
(2) the heat given-off to the steel during the oxidation process (exothermic reactions),
which accounts for about 2 to 3% of total heat input.
(3) the scale layer reduces the heat flux from the slab to the environment (due to its lower
thermal conductivity) when the slabs are transported to the rolling mill.
DISADVANTAGE OF SCALE
(1) steel loss representing a mass loss between 1 to 3 % of the slab depending of furnace
operating conditions and slab thickness.
(2) scale pile-ups inside the furnace and slab transport path which requires a furnace shutdown period for cleaning.
(3) hindered heat transfer from the furnace environment into the steel. necessitating longer
heating cycles.
REACTION INVOLVED
3Fe + 2O2
2Fe + O2
6FeO + O2
4Fe3O4 + O2

Fe3O4
2FeO
2Fe3O4
6Fe2O3

THE OXIDATION OF

METALS

First, oxygen molecules diffuse

through oxide layer then react
with iron ,so reaction can be
either chemical controlled or
diffusion controlled. But in most
of the cases it is diffusion
controlling because it's a slow
process.
MECHANISM

FeO

Fe2O3
OOO

Fe3O4

3+
OO
O
Fe

Fe2+

OOo
oO

Fe2+

Iron

Fe3+

e-

oxygen

ee-

O2-

Ionization of Iron-Wustite
Fe

Fe2+ + 2e-

Wustite-Magnetite Interface
Fe2+ + 2e- + Fe3O4

4FeO

Magnetite-Hematite interface
Fen+ + ne- 4Fe2O3

Hematite-gas interface
O2 + 4 e-

2O2-

3Fe3O4

n = 2,3

 Hematite formation
2Fe3+ +3O2-

Fe2O3

PARAMETER AFFECTING SCALE

a)
b)
c)
d)

Alloying materials
Temperature
Oxygen
Residence time

EFFECT OF TEMPERATURE
The oxidation process is controlled namely by cation transport through wustite and
magnetite .after assuming diffusion controlling mechanism we can define a parabolic rate
constant that is highly depending on process temperature . As temperature rises value of
parabolic rate constant also increases exponentially .so that rate of formation of scale increases
rapidly.
0.25

0.2

0.15

R-cons. FeO
R-cons. Fe3O4

0.1

R-cons Fe2O3

0.05

0
0

500

expressions for parabolic rate constant

1000

1500

Value of parabolic rate constant for different reactions are as shown in table-

The dependence of the parabolic rate constant of FeO on temperature is given below in Figure.
The distinct break in the curve between about 560 to 600 oC is obviously due to the fact that
wustite is unstable below 570 oC .

A combined effect of temperature and time will later explained with growth of scale layer
thickness.
TEMPERATURE REQUIRED
Temperature required to roll a slab of certain dimensions is based on material property like bending
stress ,thermal stress etc.
For rolling purpose it is necessary to heat a slab up to 1150 oC .
FRACTION OF OXIDES AT DIFFERENT TEMPERATURE
At lower temperature magnetite is more stable than wustite so at lower temperature major portion
is magnetite .After 560 oC temperature wustite is highly stable so magnetite converts into wustite .
hematite formation occurs only at high temperature .it is almost negligible .

120
100
80
FeO

60

Fe3O4
40

Fe2O3

20
0
0

500

1000

1500

-20

EFFECT OF OXYGEN
In the hot strip mill, slabs are heated above 1150 0C for the subsequent rolling process, so the
low-temperature slabs are pushed into the reheating furnace from the charging side and heated
gradually via the pre-heating zone, heating zone and soaking zone and extracted at the
discharging door . Oxygen is an essential element for the combustion reaction in the reheating
furnace, though the oxygen in the furnace also participates in some of the reactions, including the
formation of nitrogen oxides (NOx), or oxide layer on the surface of the slab .
The best situation is to ensure the complete combustion of the fuel under the premise of
minimizing the residual oxygen or, in other words, to maintain a low level of oxygen
concentration in the exhaust gas. On the other hand, in the high-temperature furnace area, such as
the heating zone and soaking zone, to supply deficient oxygen can effectively slow down the
oxidation rate of steel slabs, so it is necessary to ensure that all the residual fuel is burnt in the
down-stream zone.

Every few minutes, the discharge door is opened briefly to extract the heated slabs. Since there is
a difference in the ambient temperature inside and outside the furnace, there exists a vertical
pressure drop. The vertical pressure drop causes negative pressure at the bottom of the furnace
while the door is opening and the outside air is inhaled into the furnace. Therefore, the furnace
temperature in the soaking zone is significantly decreased and the oxygen concentration of the
exhaust gas appears to peak after the door is opened
Parabolic rate constant increases with increase in oxygen percentage, especially at higher
temperatures.

In Above table it is clear that parabolic rate constant at all temperature increases with oxygen
percentage .A certain amount of excess oxygen is required for complete combustion of fuel and
to overcome from leakage of air from furnace .Excess air should lie between 20 to 70% of
stoichiometericaly required air .
TYPE OF FURNACE ENVIRONMENT
1. Reducing atmosphere
CO and H2 are acting as reducing agents during heating .
Reactions :FeO + CO

Fe + CO2

FeO + H2

Fe + H2O

2. oxidising atmosphere
CO2 and H2O are acting as reducing agents during heating .
Reaction :-

Fe + CO2

FeO + CO

Fe + H2O

FeO + H2

EFFECT OF ALLOYING MATERIAL

1. Effect of Carbon
The effect of carbon on the oxidation of steel has been studied by many researchers. In
the majority of these studies. carbon has shown to decrease the scaling rate of steel. This
decrease is believed to be a result of carbon oxidation to CO, which would have the tendency
to retard the oxidizing action.
Pores filled with CO develop at the scale/metal interface, and hence hinder the diffusion
process of ions from the metal to the oxidizing atmosphere .
2. Effect of Manganese
Manganese does not contribute to any major effect on the oxidation of steel.

3. Effect of Chromium and aluminum

Chromium and aluminum, when present at residual levels in the steel, have negligible effects
on its oxidation properties. At higher levels, chromium forms a protective layer of Cr2O3, which
provides oxidation resistance. Similarly, aluminum forms a hard protective layer, Al2O3 which
reduces the oxidation rate.
4. Effect of Silicon
Silicon reacts with oxygen diffusing into the steel below the oxide/metal interface to forms
silica, SiO2. Silica forms a separate phase, Fayalite 2FeO.Si02, which has a melting point of 1171
o
C. When this phase melts, the oxidation rate increases due to the acceleration of the diffusion
process through the molten phase
5. Effect of Nickel
Nickel diffusion in steel is low and hence it is concentrated at the steel/oxide interface
which lowers the oxidation rate. The resulting nickel alloy has the tendency to increase scale
adhesion to the substrate. The problem becomes more severe when nickel is present at high
concentrations.

6. Effect of copper
Copper, like nickel, is concentrated at the metal/oxide interface but does not cause scale
stickiness as in the case of nickel.