SYNTHETIC SLAG PLANT

[EIRI/EDPR/3705] J.C.: 1792XL

INTRODUCTION

Synthetic slag consists of prepared mixture of several individual oxides which is

used during secondary steelmaking to assist the steel treatment in the ladle from
the viewpoint of effective refinement. Synthetic slag practice is normally used to
obtain clean steels and also for the desulphurization of the liquid steel.

Secondary steelmaking is a critical quality control step between the primary

steelmaking and the continuous casting of the liquid steel. A key feature for
success with the secondary steelmaking processes is the slag control. Use of
synthetic slag which is specifically designed to have the required chemical
composition and physical properties helps in the slag control.

The desirable properties of the synthetic slag include (i) slag is to have high
sulphide capacity, (ii) it is to be basic in nature, (iii) it is to be fluid to obtain faster
reaction rates, and (iv) it is not to cause excessive refractory wear.

The secondary steelmaking slag is in liquid form in the ladle and floats on the
surface of liquid steel which is usually at temperature of 1,600 deg or higher. It
acts like a sponge to absorb the impurities consisting mainly of sulphur and non-
metallic inclusions. The design of the slag is a critical step impacting the efficiency
of the steel refining processes during the secondary steelmaking.

Slag regime in secondary steelmaking significantly influences the final quality of

the produced steel, particularly with respect to the achieved desulphurization of
steel. One of the possibilities for influencing the slag regime is the application of
synthetic slags to the ladle slag, formed from slag-making additions during the
liquid steel tapping. Synthetic slag practice during secondary steelmaking
maximizes the efficiency of the steel refining process by (i) improving steel quality,
(ii) improving productivity, (iii) reducing costs, and (iv) protecting the environment
(since it removes the need of addition of fluorspar also called fluorite).

www.eiriindia.org 1
 CONTENTS

INTRODUCTION
USES & APPLICATION
OVERVIEW OF INDIAN STEEL INDUSTRY
FAVOURABLE OUTLOOK FOR STEEL CONSUMPTION
MARKET POSITION OF INDIAN STEEL
PRODUCTION
FINISHED STEEL PRODUCTION - PRODUCER
FINISHED STEEL PRODUCTION - NON-ALLOYED STEEL - FLAT
& NON-FLAT PRODUCTS
FLAT STEEL PRODUCTION – NON-ALLOYED STEEL – NON-FLAT
EXPORTS & IMPORTS OF STEEL
PRESENT MANUFACTURING OF SYNTHETIC SLAG
SYNTHETIC SLAG PRACTICE IN STEEL INDUSTRY
DESULPHURIZATION OF STEEL
COMPOSITION OF PREMELTED SYNTHETIC SLAG
PREMELTED SYNTHETIC SLAG FOR LADLE DESULFURIZING MOLTEN STEEL
SYNTHETIC SLAG FOR STEEL MAKING AND ITS COMPOSITION
CHEMICAL COMPOSITION
DESIGN OF SYNTHETIC SLAG
CALCIUM ALUMINATE SYSTEM
PHASE DIAGRAM FOR CALCIUM ALUMINATE SYSTEM
CHEMICALS IN THE FORMATION OF SYNTHETIC SLAG
TRICALCIUM ALUMINATE
DODECALCIUMHEPT-THE ALUMINATE
MONOCALCIUM ALUMINATE
FORMULATION OF SYNTHETIC SLAG
MANUFACTURING PROCESS OF SYNTHETIC SLAG
PROCESS FLOW DIAGRAM
PRODUCTION OF SYNTHETIC SLAG
REFINING OF STEEL BY USING SYNTHETIC SLAG
FLUX USED FOR CONDITIONING OF STEEL SLAG
BLAST FURNACE IRON MAKING
REACTIONS IN THE UPPER ZONE
REACTIONS IN THE MIDDLE ZONE
REACTIONS IN THE LOWER ZONE
BLAST FURNACE SLAG AND ITS FUNCTION
FUNCTIONS OF SLAG:-
INTERNAL ZONES IN A BLAST FURNACE
PRINCIPLES OF PLANT LAYOUT

www.eiriindia.org 2
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
PROJECT IMPLEMENTATION SCHEDULES
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF RIBBON BLENDER
SUPPLIERS OF JAW CRUSHER
SUPPLIERS OF BELT FEEDER
SUPPLIERS OF PACKAGING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS
SUPPLIERS OF DG SETS
SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

www.eiriindia.org 3
 COST ESTIMATION

Plant Capacity 40 MT/Day

Land & Building (8000 sq.mt.) Rs. 2.47 Cr
Plant & Machinery Rs. 1.30 Cr
Working Capital for 2 Months Rs. 4.96 Cr
Total Capital Investment Rs. 8.43 Cr
Rate of Return 19%
Break Even Point 61%

www.eiriindia.org 4