AISTech 2019 — Proceedings of the Iron & Steel Technology Conference

6–9 May 2019, Pittsburgh, Pa., USA

DOI 10.1000.377.092

First Movable KR in India Has Successfully Started Up in JSW Steel at Vijayanagar

Masashi Nawafune 1, Kiyoharu Ito 1, Abhijit Sarkar 2, Navin Desai 2

1
Nippon Steel & Sumikin Engineering Co. Ltd
46-59 Nakabaru, Kitakyushu-city, Fukuoka, 804-8505, Japan
Phone: 81-93-588-7026
Email: nawafune.masashi.se7@eng.nssmc.com
2
JSW Steel Limited
Vidyanagar, Toranagallu Village, Bellary 583275, Karnataka, India
Phone: 91-8395-243283
Email: navin.desai@jsw.in

Keywords: Desulfurization process, KR, Injection process

INTRODUCTION
There has been a rapid increase in the demand for high-quality steel in India. Kanbara reactor desulfurization process
(hereafter KR), as part of the treatment process for hot metal, is integral to the stable and efficient production of high-quality
steel. Nippon Steel & Sumikin Engineering Co., Ltd. (hereafter NSENGI) has produced approximately 20 deliveries of KR,
both in Japan and overseas. Of the three KR units currently active in India, two are the movable KR which NSENGI
delivered and successfully started up at JSW Steel Limited Vijayanagar Works. High desulfurization ratio was performed
even though in the condition of high initial sulfur content rate. Introduction of KR and comparison between KR and injection
desulfurization process based on the actual operational data is described in this paper.

ABOUT KR AND MOVABLE KR

Kanbara reactor desulfurization process (KR)

KR is a mechanical mixer-type hot metal desulfurization unit in which a refractory coated impeller (rotor blade) is soaked
and stirred in hot metal to mechanically mix the hot metal and desulfurization agent. KR technology was developed by
NSENGI and this technology has been supplied to many customers both in Japan and overseas.

Equipment configuration
Figure 1 shows the overview of equipment configuration of KR. “Impeller lifting and stirring device” lowers and lifts the
impeller stirring carriage by wire rope and rotates the impeller at high speed (approx. 90 to 120rpm) inside the hot metal.
Hydraulic clamping devices are equipped on the impeller stirring carriage to anchor the equipment to the structure during
treatment to avoid vibration created by the reaction force of impeller which could cause a critical failure to the equipment
such as fatigue fracture.
Agents will be charged into the hot metal by the “Desulfurization agent handling device” during the KR treatment. Lime with
grain size from 0 to 3mm lime (hereafter Coarse Lime) is generally used as desulfurization agent, and CaF2 or aluminum
dross are used as a fluidizing agent. Agent will be lifted and stored in a silo above the KR unit by using a separate
pressurizing unit. These agents will be charged (dropped) into the hot metal during the initial impeller rotation stage.
“Impeller exchanging device” is used for impeller maintenance; to exchange the worn impeller with a new one. “Impeller
maintenance equipment” will be located near the KR which is used to mold and cast refractory to the impeller. “De-dusting
hood and skirt” is generally connected to the main de-dusting duct of the workshop and avoids dust generated during

© 2019 by the Association for Iron & Steel Technology. 881

operation. “Ladle transfer car” is used along with KR to carry the hot metal ladle below the KR. Slag skimmer and hot metal
ladle tilting device is used to remove the slag above the hot metal before and/or after the KR treatment.

Figure 1. KR Overview Figure 2. Operation flow

Operation philosophy
General operation flow of KR is shown on figure 2. After hot metal is poured into ladle and temperature measurement &
sampling will be conducted to evaluate the operational condition of KR treatment. Pre-slag-skimming is done to remove the
slag carried over from blast furnace; however this process is unnecessary when the slag volume is less. During KR treatment,
impeller will be lowered into the hot metal and will start rotating. Rotation will be increased up to approx. 80 rpm.
Desulfurization agent will be charged into the hot metal at this low rotation speed, to avoid the agents spilling out from the
hot metal surface. After agent charging, impeller rotation will be increased up to approx. 90 to 120 rpm depending on the
available free board. The rotation of impeller is generally between 90 to 120 rpm, which is determined and adjusted by the
wear level of the impeller refractory. General total stirring time including both low speed and maximum speed operation will
be approx. 10 to 12 minutes, and within this the general stirring time at maximum speed is 8 to 10 minutes. Stirring time does
not depend on the initial sulfur rate nor heat size. Total cycle time from start of impeller lowering to completion of impeller
lifting is between 16 to 20 minutes which is sufficient to match the tap-to-tap of BOF.

Desulfurization agent
Coarse Lime generally is used as main agent in KR. Coarse Lime is much cheaper and higher availability than lime in grain
size of less than 1mm (hereafter Fine Lime). Along with Coarse Lime, calcium fluoride (hereafter CaF2) or aluminum dross is
used. Chemical reaction of Coarse Lime with sulfur during KR treatment is as following:

S + CaO → CaS + O (1)

During stirring, above reaction will continuously occur by repeated suction of Coarse Lime into the hot metal vortex. After
stirring, CaS will be floating to the surface of hot metal. Generally consumption depends on the hot metal condition, however
in the condition of 0.06% of initial sulfur (temp. 1320 deg.), 10 to 12 kg/ton of Coarse Lime is required to decrease sulfur to
less than 0.003%. Consumption of CaF2 or aluminum dross is generally 10% to 15% of the Coarse Lime consumption.

Other desulfurization method and functional requirements of desulfurization units

Injection process (hereafter injection) is another method of desulfurization. “Refractory coated lance” is soaked deeply into
the hot metal to inject the agents. Agents will be injected along with pressurized nitrogen by using a “dispenser” and they can
be injected in mono injection or co injection form. Generally calcium carbide and/or magnesium are used as agents, however
Fine Lime are also been used in some cases [e.g., 1]. Chemical reaction of calcium carbide and/or magnesium with sulfur
during injection process is as following:

882 © 2019 by the Association for Iron & Steel Technology.

 S + Mg → MgS (2)

S + CaC 2 → CaS + 2C (3)

Above reaction will be done when calcium carbide or magnesium rises toward the hot metal surface. In case magnesium is
the main agent, after MgS reaches the surface, it can get in contact with oxygen which results in following reaction

2MgS + O 2 → 2MgO + 2S (4)

By the above reaction, sulfur re-dissolves into the hot metal which is called resulfurization. Main purpose of injecting
calcium carbide or Fine Lime along with magnesium is to bind sulfur with calcium to avoid resulfurization after MgS rises to
the hot metal surface.

Figure 3. Difference of KR and Injection

Major requirements of desulfurization units

Desulfurization ratio, production capacity, cost and safety are the major aspects for evaluation of desulfurization units.
Desulfurization ratio is one of the most important factors which directly affect the quality grade of final steel product. De
sulfurization ratio is usually mentioned in following figures. High and stable values are demanded in case of production of
high grade steel.

Initial [ S ] − Final [ S ]
Desulfurization ratio (%) = (5)
Initial [ S ]

Production capacity is also an important factor to evaluate the performance of desulfurization equipment. Short and stable
treatment time is required to increase the entire steel production. Also equipment availability shall also be maintained in a
high level for high production.
Cost in both aspects of CAPEX and OPEX is a major evaluation point for economic comparison. Especially OPEX is
considered more important than CAPEX since desulfurization unit is a long life equipment. Reagent, refractory, utility
consumable cost, etc. are considered in the OPEX.
Safety shall be fully taken care for either option for desulfurization equipment. Especially reagent material handling system
which uses hazardous materials is high risk for operating. Non dangerous agents are preferred to be used as desulfurization
treatment.

Advantage of Movable KR
Movable KR is another unique technology developed by NSENGI maximizing the equipment efficiency. Equipment
configuration is mentioned in the figure 4, “Impeller lifting and stirring device” which is mounted on “KR travelling car”
moves between multiple treatment positions. “Locking device” is attached to the “KR travelling car” which locks and
anchors the movable part to the fixed structure by hydraulic force during impeller rotation to avoid vibration created by the
reaction force of impeller. When impeller refractory is worn, “KR travelling car” will move to the impeller exchange position

© 2019 by the Association for Iron & Steel Technology. 883

to exchange the impeller with a new impeller. “Desulfurization agent handling system” is fixed on the structure which can be
common for each treatment position. As an option of desulfurization unit, movable KR allows for more flexibility to adapt to
space limitations in the workshop while maximizing the equipment efficiency.

Figure 4. Movable KR equipment overview

OPERATIONAL CONDITION AND PERFORMANCE RESULTS IN JSW STEEL, VIJAYANAGAR WORKS

SMS1 and SMS2 in Vijayanagar works

Vijayanagar works of JSW Steel Ltd. is one of the largest steel plants in India with capacity of more than 12 million ton per
annual. Currently there are 3 Steel-Melting-Shops, SMS1, SMS2 and SMS3. NSENGI has delivered a movable KR to both
SMS1 and SMS2 shops. SMS1 has a production of 3.8 million ton per annual and SMS2 has a production of 7.0 million ton
per annual.

JSW Vijayanagar works SMS1 3.8 Million ton

ARS* 3nos
Blast Furnace 2nos Injection 5nos Converter
LF 3nos SL-CC 4nos
COREX 2nos Movable KR 1no 140ton 3nos
RH 1no

JSW Vijayanagar works SMS2 7.0 Million ton

Injection 6nos ARS* 4nos

Converter BT-CC 1no
Blast Furnace 2nos Fixed KR 1no LF 4nos
195ton 4nos SL-CC 4nos
Movable KR 1no RH 2nos

*ARS : Argon Rinsing Station

Figure 5. Production flow

Overview of Movable KR in JSW Steel Vijayanagar works

Following are the basic overview of movable KR started up in SMS1 and SMS2 in Vijayanagar works. Different concepts
had been considered for SMS1 and SMS2 KR due to limitation of space and surrounding equipment.

884 © 2019 by the Association for Iron & Steel Technology.

 SMS-1 KR SMS-2 KR
Start-up date : May 2017 Start-up date : October 2016
Capacity : 140 ton/heat Capacity : 195 ton/heat
Number of KR treatment station : 3 stations Number of KR treatment station : 2 stations
Pre-Slag-skimming Post-Slag-skimming
machine machine
KR technological structure KR technological structure
Impeller exchanging device
Tilting ladle transfer car

KR treatment position

#1

#1

#2 Tilting ladle transfer car

KR treatment position #2

#3
KR travelling car KR travelling car
Ladle setting & Slag skimming
lifting position machine
Ladle setting
position (common for pre &
Ladle lifting post-slag-skimming)
position

Impeller exchanging device

Figure 6. Overview of SMS1 and SMS2 KR

Operational Condition and Performance Results

Performance of the equipment was tested in both SMS1 and SMS2. 1390 heats were tested in SMS1. Table 1 and table 2
shows the hot metal and operation condition and test results of the performance test in SMS1.

Table 1. Hot metal and operation condition (average)

Actual treatment weight 138 ton
Initial [S] (before treatment) 0.0736% (736ppm)
Temperature before treatment 1343°C
Stirring speed in high speed period 90 rpm
Stirring time at high speed 10 mins

Table 2. Average performance test results

Final [S] (after treatment) 0.0024% (24ppm)
Desulfurization ratio 96.8%
Temperature after treatment 1312°C
Temperature drop 31°C
Coarse Lime average consumption 11.6 kg/ton
CaF2 average consumption 1.4 kg/ton
Coarse Lime consumption per removed sulfur ratio 0.016 kg/ton･ppm

Average desulfurization ratio result of all tested heats were 96.8%. Desulfurization ratio of 60% of the total heats resulted
were over 98% as shown in figure 9. On the other hand, actual final sulfur rate was average 0.0024% (24ppm). Actual final
sulfur rate of 61% of total heats were under 0.001% (10ppm) as shown in figure 11.
Desulfurization agent consumption average values during tested heats were 11.6 kg/ton for Coarse Lime and 1.4 kg/ton for
CaF2. These consumption values are actual average results in condition of initial and final sulfur rate mentioned in table and
table. Figure 7 shows the relation between Coarse Lime consumption per desulfurization ratio and initial sulfur rate. Coarse
Lime consumption per desulfurization ratio is calculated in following equation. This value is the parameter to evaluate the
performance of consumption considering both weight of hot metal and absolute value of removed sulfur. As a result, it is
shown that Coarse Lime is reacting more efficiently at higher initial sulfur rate condition.

© 2019 by the Association for Iron & Steel Technology. 885

 Coarse lime consumption
w= (kg / ton ⋅ ppm ) (7)
Initial [ S ] − Final [ S ]

0.035

per removed sulfur ratio (kg/ton･ppm)

0.030
w : Coarse Lime consumption

0.025
Test Results
0.020

0.015

0.010

0.005

0.000
400 500 600 700 800 900 1000 1100
Initial [S] (ppm)

Figure 7. Relation between Coarse Lime consumption per removed sulfur ratio and Initial [S]
Treatment time for KR equipment is the actual stirring time of impeller. Initially impeller is rotated in low speed (approx.
80rpm) during charging de sulfurization agent from above the ladle for approx. 2 minutes. After low speed rotation, the
impeller will be rotated in high speed (approx. 90 to 120 rpm) for approx. 10 minutes. From the experience in SMS1 and
SMS2 KR, treatment time remains same regardless of heat size, initial sulfur rate, impeller life. However desulfurization ratio
became unstable by shortening the high rotation time under 10 minutes.
Production performance test was executed for continuous 7 operating days. Number of treatment heats per day was counted
and compensated considering actual waiting time for availability of hot metal or ladle. Maximum number of treatment heats
per day was 61 heats per day in SMS1 for 1 movable KR. While in SMS2 the results were 49 heats per day.
Difference of SMS1 and SMS2 number of treatment per day is due to the difference of layout. In layout of SMS1, the
bottleneck of cycle time is the occupation of KR. While in SMS2, the bottleneck of cycle time was the occupation of ladle
transfer car between KR workshop and BOF workshop. Nearly 60 heats will be possible to treat per day by fully occupying
one movable KR.
Availability of KR and ladle transfer cars was also checked during the productivity test. Availability was defined as
following.

(Number of actual operation ) − (Number of abnormal operation )

Availability (%) = × 100 (8)
Number of actual operation

Results for KR and all ladle transfer cars during test period were 100%. Generally, major operational troubles are caused by
vibration created during high speed rotation of impeller. Preventing vibration is one of the major factors to keep high
equipment availability. Vibration analysis for the KR including surrounded structure was conducted for both SMS1 and
SMS2 during engineering stage and locking device to fix the movable parts during treatment has been equipped on the KR
travelling car. Vibration speed was measured by placing vibration sensors on the KR lifting guide frame. As a result,
vibration speed was maintained on a low value which was 0.8m/sec in average.

886 © 2019 by the Association for Iron & Steel Technology.

 COMPARISON OF KR AND INJECTION DESULFURIZATION EQUIPMENTS

Desulfurization ratio comparison

Comparison test was executed for KR and mono injection equipment. Table 3 shows the detail of the test condition and
average results.

Table 3. Detail condition and results of comparison test

Mono injection KR
Number of test heats 428 heats 1390 heats
Average heat size 108 ton 138 ton
Coarse Lime; CaF2
Desulfurization agent CaC2 (CaC2≥42%)
(CaO≥90%,CaF2≥65%)
Average injection/stirring time 27 minutes 12 minutes
Injection/stirring speed 27 kg/min 90 rpm
Average Initial [S] 0.0492 % (492ppm) 0.0736 % (736ppm)
Average Final [S] 0.0068 % (68ppm) 0.0024 % (24ppm)
Desulfurization ratio 86.2% 96.8%
Average Initial temperature 1315 °C 1343 °C
Average Final temperature 1284 °C 1312 °C

Figure 8 and figure 9 shows the distribution of desulfurization ratio of mono injection and KR desulfurization equipment.
Desulfurization ratio of KR is stable at the level of above 98%. On the other hand, mono injection shows a higher deviation
in the figure. Figure 10 and figure 11 shows the distribution of final sulfur rate after treatment. This also shows that final
sulfur rate of KR is kept at low level mostly under 10ppm while mono injection final sulfur rate shows more deviation at
higher sulfur rate.

70 70

60 60
Frequency of heats (%)

50
Frequency of heats (%)

50

40 40

30 30

20 20

10 10

0 0
76 78 ≦80 82 84 86 88 90 92 94 96 98 100 102 76 78 ≦80 82 84 86 88 90 92 94 96 98 100 102
Desulfurization ratio (%) Desulfurization ratio (%)

Figure 8. Desulfurization ratio in Injection Figure 9. Desulfurization ratio in KR

70 70

60 60

50 50
Frequency of heats (%)

Frequency of heats (%)

40 40

30 30

20 20

10 10

0 0
-10 0 10 20 30 40 50 60 70 80 90 100 ≦ 110 120 -10 0 10 20 30 40 50 60 70 80 90 100 ≦ 110 120
Final sulfur (ppm) Final sulfur (ppm)

Figure 10. Final sulfur rate in Injection Figure 11. Final sulfur rate in KR

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Economical comparison
Most significant contribution of OPEX are desulfurization agent consumable cost, refractory cost, utility cost, indirect cost
due to iron loss and temperature drop of hot metal.

Desulfurization agent cost

As per the tested heats, average desulfurization agent consumable for KR was Coarse Lime 11.6 kg/ton and CaF2 1.4 kg/ton
while mono injection was CaC2 6.6 kg/ton. Considering these consumable and unit cost of each agent, KR agent consumable
cost is approx. 27% of the same of mono injection. Consumption is higher in KR however Coarse Lime has high availability
and lower cost compared to other desulfurization agents.

Refractory cost
Main factor of refractory cost is the cost of impeller/lance refractory cost. Average impeller refractory lifetime in KR is
160heats while lance refractory lifetime in mono injection is 45 heats. Considering lifetime of refractory and unit cost of
refractory, KR refractory cost is approx. 96% of the same of mono injection. Same ladle refractory is used in both KR and
mono injection.

Utility cost
Power, nitrogen, compressed air and fuel gas are the main utility used in KR. Power in KR has higher consumable compared
with mono injection since the mechanical stirring is done by electrical motor. Mainly nitrogen is used only for material
handling for storage silos while in mono injection is using nitrogen for injecting the agents into hot metal. Hence nitrogen
consumable becomes higher in mono injection. Compressed air is used for impeller cooling during treatment in KR while it is
not used in mono injection. Fuel gas is used for impeller refractory lining which is not used in mono injection. As a total KR
utility consumable cost is approx. 105% of the same of mono injection.

Other indirect costs

Iron loss during slag-skimming is one possible factor for impacting the OPEX. Nearly 60 samples were taken from the slag
after slag-skimming of KR and injection during the test period. Chemical analysis was conducted for each sample and to
evaluate the amount of Fe2O3 contained in the samples. Fe2O3 rate in slag was 8.5% in KR while in mono injection it was
10.7%. Amount of removed slag depends on the slag-skimming operational technique, however generated amount of slag is
higher in KR compared to mono injection related to the consumption of agents. Considering the contained total iron amount
in removed slag, the effect of iron loss is negligible compared to the entire OPEX. On the other hand, temperature loss was
average 31 degrees in both KR and mono injection during the test period. Cost difference is negligible for consideration of
iron loss and temperature loss.
Figure 12 shows the overall OPEX comparison of mono injection, KR and 3 types of co injection. OPEX of KR is
approximately 42% of the OPEX of mono injection. OPEX of co injection is higher than mono injection due to the high unit
cost of magnesium. Also unit price and availability of magnesium has an unstable aspect since major supply of magnesium is
relied to a limited area in the world. Since this data is based on cost per ton hot metal, the cost advantage per annual
production will be higher in high productivity (larger heat size, higher availability, larger number of heats per day). CAPEX
is generally higher in KR compared to injection due to large structure to stabilize the vibration however considering the life
cycle cost of the equipment, it is obvious that the OPEX advantage of KR will overwhelm injection process. Difference of
CAPEX for a single movable KR unit and 2 numbers of injection units are generally recovered in one year period considering
2.7 million ton per annual production.

888 © 2019 by the Association for Iron & Steel Technology.

 120.0

100.0

80.0

Cost ratio (%)

Utility
60.0 Refractory
Agent consumable
40.0

20.0

0.0
Mono Injection KR Co Injection Co Injection Co Injection
(42% CaC2) (85% CaO +Mg) (95% CaO +Mg) (42% CaC2 +Mg)

Figure 12. Comparison of OPEX of KR and Injection

Productivity comparison
Average stirring time for KR treatment was 12 minutes (2 minutes low speed stirring + 10 minutes high speed stirring) during
the test period. This time was almost stable regardless of initial hot metal condition such as temperature or initial sulfur rate.
Including approx. 12 minutes of stirring time, total 16 minutes was required for each KR treatment from impeller lowering to
lifting. Additional to 16 minutes, considering temperature measurement and sampling, movement of KR travelling car, the
total cycle which the movable KR is occupied for 1 treatment was approx. 23 minutes. Heat was treated every 23 minutes
which enabled stable production for more than 60 heats per day.
On the other hand, injection time for injection treatment was average 27 minutes with high deviation depending on initial
sulfur rate shown in figure 13. Standard deviation was 9.2 minutes for injection time while it was 1.1 minutes for KR stirring
time. Occasionally the total injection cycle time, including ladle handling and slag-skimming, will become more than the tap-
to-tap of the BOF which will hold the overall production. Unstable treatment time is not suitable for overall optimization of
the entire steel melt shop production.

90
90
80 Average : 27 minutes
Standard Deviation : 9.2 minutes 80
Average : 12 minutes
70
Standard Deviation : 1.1 minutes
70
Frequency of heats (%)

60
Frequency of heats (%)

60
50
50
40
40
30
30
20
20
10
10
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48≦
50 52 0
Injection time (min) 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48≦
50 52
KR stirring time (min)

Figure 13. Distribution of injection time Figure 14. Distribution of KR stirring time

Safety comparison
Reaction of CaC2 with water produces acetylene which is a highly flammable gas. CaC2 for injection shall be handled and
stored with caution to avoid contact from air. Moreover magnesium which is also used as an agent for injection is also a
hazardous flammable compound. Magnesium can catch fire in touch of air or water which requires caution for handling and
storage. On the other hand, lime which is used in KR is a safe compound compared to CaC2 or magnesium.

CONCLUSIONS
First movable KR in India has successfully started up at JSW Steel Limited Vijayanagar works. In this study, comparison
between KR and mono injection equipment in SMS1 workshop were made based on metallurgical performance, productivity

© 2019 by the Association for Iron & Steel Technology. 889

performance, cost and safety. The numbers mentioned in this study are specific operational and cost data of SMS1 workshop
and should not be considered solid in all circumstances. Following are the conclusion based on this study.
• Desulfurization ratio was 96.8% in KR while it was 86.2% in mono injection. Deviation was smaller in KR
compared to mono injection.
• OPEX advantage of KR overwhelms injection process. OPEX of KR is 42% of the mono injection according to the
comparison of desulfurization agent cost, utility cost, refractory cost and other indirect costs. KR has a major
advantage in cost since it uses Coarse Lime which has high availability and low unit rate.
• Operation time was mostly 12 minutes including low speed stirring in KR at all time. However mono injection time
for injection treatment was average 27 minutes with high deviation depending on initial sulfur rate.
• CaC2 and/or magnesium for injection process require safety measures for storage and handling. On the other hand,
lime required for KR process does not require any specific safety measures for handling nor storage.

ACKNOWLEDGMENTS
The authors would like to thank Takeshi Nakatani and Kento Nagata of NSENGI for their constructive comments.

REFERENCES
1. Frank Schrama and Bart van den Berg, “Comparison of Kanbara reactor magnesium mono-injection and lime–
magnesium co-injection for hot metal desulphurization”, MILLENNIUM STEEL INDIA 2014, 2014, pp 26-31.

890 © 2019 by the Association for Iron & Steel Technology.