58th Refractory Operating Committee Meeting 25-26 October,Bhilai Steel Plant, Chhattisgarh

PERFROMANCE DATA (Refractory & Operat Plant:BSP For discussion

Refractory Sp.Consumption & Sp. Cost

Department/Shop Unit 2013-14 2014-15 2014-15 2015-16 Best

Specific consumption kg/tcs (till Sep'13) (till Sep'15)

consumption includes working & safety
RED ( Total plant excluding C/R) kg/tcs 17.17 17.46 17.77 18.36 lining and all repairs

SMS ( without operation) kg/tcs

SMS operation kg/tcs 0.32 0.31 0.33 1.56

BF operation+BF running repairs kg/tcs 2.99 3.00 2.97 3.23

Total consumption (RED+ SMS(O)+ B kg/tcs 20.53 20.77 21.19 23.17

Specific Cost Rs/tcs

RED Total Rs/tcs 639.03 690.52 716.42 702.89

Operation(SMS+BF) Rs/tcs 122.97 132.56 134 207.05

RED+Operation Total Rs/tcs 762.00 823.08 850.42 909.94

Steel Melting Shop (I+II) RED only(S Rs/tcs

Comments
BOF Converter unit 2012-13 2014-15 2014-15 Best
Annual
Number of Converter & Production(SMNo/MT 3/110-130 3/110-130 3/110-130 3/110-130

Converter life (SMS-II) heats 7690 7946.33 7841 8953.5 12325

Lining weight (Working / Safety) tonne 265/50 265/50 265/50 265/50 Specify working and safety separately
SMS-II
only refractory relining time in hrs
Relining time (SMS-II) Hr 60 60

Original lining thickness in (SMS-I / mm 690 690

Top cone mm 600 600

Chare pad & Tap Belly mm 690 690

Trunnion mm 690 690

Lower cone/Knuckle area mm 690 690

Left over lining thickness in c/pad, mm 230 230

& Trunnion at the end of campaign 150 150
Refractory lining consumption kg/tcs 0.25 0.54 working + Safety lining
Converter
including all spraying and gunning
Gunning repair consumption kg/tcs 0.55 0.24 materials
state taphole type
Taphole sleeve life heat 143.92 134.18
brick-slag setting brick-slag setting brick-slag setting
Maintenance charge pad tonne

Taphole resleeve time min 60 60

Converter refractory cost (incl.Tap Rs/tcs 40.51 33.47 23.71 31.63 Work and safety lining, gunning/repair
hole) SMS-II Rs/tcs cost. State whether including taphole
cost
State the limiting factor of refractories or
Limiting factor on life Btm Buildup Btm Buildup other factors like mechanical or planning

BOF Operational Data

Capacity (SMS-I / SMS-II) Tonne 110/130 110/130

Heat weight (SMS-I / SMS-II) Tonne 118.37 120.52

Avg. blow /day (SMS-I / SMS-II) No 62.31 58.0

Avg. blow /day/converter No 20-21 19-21

Average Tap-to-tap time Minute 61 60

TMI (Total Metallic Input) Kg/tcs 1144 1143

Reblow % 8 10

Turn down bath carbon % 0.07-0.15 0.07-0.15

Tapping temp.>1700 C % heat 10 8

Tap temp.heat between 1660-1700C % heat

Max Max
0.6-0.8,0.02-0.055, 0.65-1.1,0.0.02-
Hot metal analysis( Si,S,P) % 0.12-0.15 0.055, 0.12-0.15

Slag analysis( MgO,FeO,Basicity) % 8-10, 16-21, 3-3.3 8-10, 16-21, 3-3.3

Blowing details

Blow end to tap start time Minute 15 15

Slag splashing details % 100 100

Brick-slag setting practice Y/N Y Y

Comments
Steel Ladle unit 2012-13 2014-15 2014-15 Best

Ladle capacity Tonne 130 130

Process route followed ARS/LF/RH ARS/LF/RH ARS/LF/RH

 In slag zone, Metal zone, Bottom impact
Type of bricks used in different zone etc.
any repair in slag line, striker or ladle top
Steel ladle life (SMS-II) heats 63.85 57.57 58.72 52.48 rings
any repair in slag line, striker or ladle top
VAD/RH Ladle life heats 53.41 53.81 55.1 50.42 rings

Specific consumtion in ladle (SMS-II) kg/tcs 6.76 7.38 7.23 9.01

* Consumption of Intermediate repairs
Working lining (SMS-II) Tonne 34.25 34.25 included
* Consumption of Intermediate repairs
Safety lining (SMS-II) Tonne 17.65 17.65 included

Intermediate repairs in a campaign * Tonne 2.6 2.46

Total ladle Consumption (SMS-II) Tonne 18602 19569.72 9080 11085

changes in volume or tapping weight
Ladle heat size Tonne 120.9 120.2

Total ladle specific cost (SMS-II) Rs/tcs 406 471.79 453.93 523.72
(SMS-II)
Total cost/campaign (excl. safety lininRs. In lakh 27.00 28.65
any repairs and the details
Wellblock life (SMS-II) heats 20-25 20-25

Housing block life (SMS-II) heats 20-25 20-25

exchangeable or fixed
Avg. Purging plug life (SMS-I / SMS-II heat 18-20 18-21

Free opening rate % >90 >90

any reconditions/repairs
Slide gate plate life (SMS-I / SMS-II) heat NG= 2 NG= 2

hot changing of inner nozzle/p plug Y/N N N

reasons for intermediate repairs
Intermediate repairs in a campaign No.

Operational

Total number of ladle No 31 31

Ladle in circulation No. 14 13

Ladle under relining,repair,heating No 4,4,4 4,4,4

Tap start to Cast finish
Metal holding time in ladle Minutes 200 200
Cast finish to ladle preparation bay
Ladle return time 30 30

LF/ARS treatment time Minutes 40/10 40/10

Casting time Minutes 40-60 40-60

No. of heats/day/ladle No. 4-5 4-5

Slide gate plate life heats NG=2 NG=2

Slag in ladle kg/tcs 4.2 4.2

Retainer plate life Campaign Every Repair Every Repair

Comments
RH Degasser unit 2013-14 2014-15 2014-15 Best
Direct Bonded Direct Bonded Mag-
Refractory used in upper/lower vessel Type Mag- Chrome Chrome
Direct Bonded Direct Bonded Mag-
Snorkel Mag- Chrome Chrome
both inner and outer snorkel
Snorkel life heat 119.79 137.93 132.94 131
specify life of also hearth
Lower vessel life heat 119.79 137.93 132.94 131

Upper vessel life heat 2500 2500

only snorkel refractory cost, excluding
Snorkel refractory cost Rs/tcs labour
materials cost, stating whtether including
152.86 128.104204507466 143.79 130.78
Lower vessel refractory cost Rs/tcs or excluding safety lining
materials cost, stating whtether including
Upper vessel refractory cost Rs/tcs or excluding safety lining
any repairs, gunning materials and labour
Gunning/repair consumption kg/tcs 1.98 1.99 cost

Freequency of gunning No every heat every heat

clearly stating all repairs, gunning
materials and whether including labour
Gunning/repairing cost Rs/tcs 88.3 88.9
cost

Comments
BF Hot metal ladle unit 2012-13 2013-14 Best

Type of refractory used for lining Alumina Alumina

Ladle life ( 80 T ) heat 767.06 882.31 866.74 901.68

both work lining and safety lining
Refractory cost ( 80 T ) Rs/tcs 5.43 9.29 6.85 10.55 refractory cost, excluding labour
including all repair materials
Refractory consumption ( 80 T) kg/tcs 0.32 0.65 0.32 0.67

Total cost ( 80 T ) Rs/tcs

No of intermediate repairs/campaign No 3-4 1-2

Operational

Track time Hrs. 3.5 3.5

No. of heats/day/ladle No 3.5 3.5

Ladle tare weight at start & down Tonne 60/54 60/54

Torpedo ladle details
Comments
unit 2012-13 2013-14 Best

Type of refractory used for lining

Ladle life heat

both work lining and safety lining
Refractory cost Rs/tcs refractory cost, excluding labour
including all repair materials
Refractory consumption kg/tcs

Total cost Rs/tcs

No of intermediate repairs/campaign No

Operational

Track time Hrs.

No. of heats/day/ladle No

Ladle tare weight at start & down Tonne

Comments
Tundish unit 2012-13 2013-14 Best

Capacity Tonne 15-40

1,2,3= Slab, 4= 15-40
1,2,3= Slab, 4=
3strand, 5= 4 3strand, 5= 4 strand, specify the tundish for which
Tundish for which caster strand, 6= slab 6= slab caster( Slab,Bloom,Billet, Any other)
MgO board, Vibro MgO board, Vibro
Refractories in working lining Type mass,Spray Mass mass,Spray Mass

For safety lining Type Castable(LCC) Castable(LCC)

Precast (Alumina Precast (Alumina
Impact pad/TID refractories lining based) based)

Work lining life (20 T / 30 T) Seq.Size

Safety lining life campaign 1,2,3=2.06

>800 heats
, 4= >800 heats
2.52, 5= 1.32, 6= 1,2,3= 1.71, 4= 2.3,
Excludes TTM set T/S/Mass
Work lining consumption (T/S/Mass on kg/tcs 1.028 5= 1.203, 6= 0.826
1,2,3=109 , 4= 239, 1,2,3=91 , 4= 219,
Work lining cost (T/S/Mass only) Rs/tcs 5= 110, 6= 129 5= 100, 6= 104

Safety lining cost(total excl. T/S/Mass Rs/tcs 3.4 3.4

Tundish shell temperature o

C 250-300 250-300

Min 60 min, & 40 min 60 min, & 40 min

Casting duration
BF Cast House Refractories 2012-13 2013-14 Best

Trough
Type of refractory material used
Trough lining refractories Type DRM, Castable DRM, Castable
DRM=65-100, DRM=65-100,
Initial installation
Tonnage of refractory used Tonne Castable=100-105 Castable=100-105
DRM=50000, DRM=50000,
HM throughput including repairs: Castable=120000 Castable=120000
SiO2=65.59, SiO2=65.59,
Main Trough Tonne
Al2O3=18.84, Al2O3=18.84,
CaO=32.81, CaO=32.81,
Metal Runner Tonne MgO=9.66, MgO=9.66,
FeO=0.58, FeO=0.58,
HM slag analysis % MnO=0.17, S=0.86 MnO=0.17, S=0.86

Relining & repair time Hrs. 14-96, 10-90 14-96, 10-90

BF Mudgun
Resin & Tar
Type of material Bonded Resin & Tar Bonded

Tap-hole length Meter 2-2.5 2-2.5

Blast pressure kg/cm2 1.41-1.96 1.41-1.96

Top pressure kg/cm2 0.55-0.92 0.55-0.92

Casting rate Ton/minute

Casting time Hrs 15-18 15-18

No of cast/day No 8-13 8-13

BF operation

HM Production /day/furnace tonnes 1800-3700 1800-3700

No of tap hole No 1-2 1-2

HM Temp. o
C 1400 1400

Hot blast temp. o

C 860-950 860-950
 60th Refractory Operating Committee Meeting 09-10 December,TISCO, Jamshedpur

PERFROMANCE DATA (Refractory & Operation) Plant:BSP For discussion

Refractory Sp.Consumption & Sp. Cost

Department/Shop Unit 2012-13 2013-14 2014-15 2015-16 Best

Specific consumption kg/tcs (Apr-Oct)

consumption includes working & safety
RED ( Total plant excluding C/R) kg/tcs 17.91 17.17 17.46 18.31 lining and all repairs

SMS operation kg/tcs 0.36 0.32 0.31 1.48

BF operation+BF running repairs kg/tcs 3.23 2.99 3.00 3.29

CO running + repairs kg/tcs 0.28 0.05 0.25 0.02

Total consumption (RED+ SMS(O)+
BF(O) + CO) kg/tcs 21.78 20.53 21.02 23.10

Specific Cost Rs/tcs

RED Total Rs/tcs 617.84 639.03 690.52 712.91

Operation(SMS+BF+CO) Rs/tcs 145.35 122.97 132.56 207.59

RED+Operation Total Rs/tcs 763.19 762.00 823.08 920.50

Steel Melting Shop (I+II) RED only(Sh Rs/tcs

Comments
BOF Converter unit 2012-13 2013-14 2014-15 2015-16 Best
Annual
Number of Converter & Production(SM No/MT 3/110-130 3/110-130 3/110-130 3/110-130

Converter life (SMS-II) heats 7690 7946.33 7841 8953.5 12325

Lining weight (Working / Safety) tonne 265/50 265/50 265/50 265/50 Specify working and safety separately
SMS-II
only refractory relining time in hrs
Relining time (SMS-II) Hr 60 60 60 60

Original lining thickness in (SMS-I / S mm 690 690 690 690

Top cone mm 600 600 600 600

Chare pad & Tap Belly mm 690 690 690 690

Trunnion mm 690 690 690 690

Lower cone/Knuckle area mm 690 690 690 690

Left over lining thickness in c/pad, mm 230 230 230 230

& Trunnion at the end of campaign 150 150 150 150

Refractory lining consumption kg/tcs 0.53 0.25 0.39 0.47 working + Safety lining
Converter

Number of Converter Repairs No. 4 2 3 2

including all spraying and gunning
Gunning repair consumption kg/tcs 0.54 0.42 0.51 0.64 materials
state taphole type
Taphole sleeve life heat 154.85 143.92 143.8 147.93
brick-slag setting brick-slag setting brick-slag setting brick-slag setting brick-slag setting
Maintenance charge pad tonne

Taphole resleeve time min 60 60 60 60

Converter refractory cost (incl.Tap Rs/tcs 40.51 33.47 23.71 31.63 Work and safety lining, gunning/repair
hole) SMS-II cost. State whether including taphole
Gunning repair Cost (Sp. Cost) Rs/tcs 17.34 13.70 16.72 21.93 cost

State the limiting factor of refractories or

Limiting factor on life Btm Buildup Btm Buildup Btm Buildup Btm Buildup other factors like mechanical or planning

BOF Operational Data

Capacity (SMS-I / SMS-II) Tonne 110/130 110/130 110/131

Heat weight (SMS-I / SMS-II) Tonne 120.91 119.98 119.01

Avg. blow /day (SMS-I / SMS-II) No 62.31 58.01 65.33

Avg. blow /day/converter No 20-21 19-21 19-22

Average Tap-to-tap time Minute 61 60 60

TMI (Total Metallic Input) Kg/tcs 1144 1143 1143

Reblow % 8 10 10

Turn down bath carbon % 0.07-0.15 0.07-0.15 0.07-0.16

Tapping temp.>1700 C % heat 10 8 9

Tap temp.heat between 1660-1700C % heat

Max Max Max
0.6-0.8,0.02-0.055, 0.65-1.1,0.0.02- 0.65-1.1,0.0.02-
Hot metal analysis( Si,S,P) % 0.12-0.15 0.055, 0.12-0.15 0.055, 0.12-0.16

Slag analysis( MgO,FeO,Basicity) % 8-10, 16-21, 3-3.3 8-10, 16-21, 3-3.3 5-8, 16-21, 3-3.4

Blowing details

Blow end to tap start time Minute 15 15 15

Slag splashing details % 100 100 90

Brick-slag setting practice Y/N Y Y Y

Comments
Steel Ladle unit 2012-13 2013-14 2014-15 2015-16 Best

Ladle capacity Tonne 130 130 130 130

Process route followed ARS/LF/RH ARS/LF/RH ARS/LF/RH ARS/LF/RH ARS/LF/RH

 In slag zone, Metal zone, Bottom impact
Type of bricks used in different zone MCB MCB MCB MCB etc.
any repair in slag line, striker or ladle top
Steel ladle life (SMS-II) heats 62.33 63.85 57.57 52.56 rings
any repair in slag line, striker or ladle top
VAD/LF/RH Ladle life heats 51.68 53.41 53.81 50.29 rings

Heats through LF?RH Heats 15177 15428 16401 9729

Specific consumtion in ladle (SMS-II) kg/tcs 6.90 6.76 7.38 8.63

* Consumption of Intermediate repairs
Working lining (SMS-II) Tonne 34.25 34.25 34.25 34.25 included
* Consumption of Intermediate repairs
Safety lining (SMS-II) Tonne 17.65 17.65 17.65 17.65 included

Intermediate repairs in a campaign * Tonne 2.52 2.60 2.46 2.34

Total ladle Consumption (SMS-II) Tonne 18063 18602 19056 12625

changes in volume or tapping weight
Ladle heat size Tonne 118.37 120.91 119.98 119.01

Total ladle specific cost (SMS-II) Rs/tcs 381.45 406.13 470.13 514.85
Total cost/campaign (excl. safety Rs. In
(SMS-II)
lining) lakh 24.61 26.89 28.65 31.76
any repairs and the details
Wellblock life (SMS-II) heats 20-25 20-25 20-25 20-25

Housing block life (SMS-II) heats 20-25 20-25 20-25 20-25

exchangeable or fixed
Avg. Purging plug life (SMS-I / SMS-II) heat 18-20 18-20 18-21 18-20

Free opening rate % >90 >90 >90 >90

any reconditions/repairs
Slide gate plate life (SMS-I / SMS-II) heat NG= 2 NG= 2 NG= 2 NG= 2
Practice has been started
hot changing of inner nozzle/p plug Y/N N N N Y
reasons for intermediate repairs
Intermediate repairs in a campaign No.

Operational

Total number of ladle No 31 31 31 31

Ladle in circulation No. 11-14 11-14 11-14 11-14

Ladle under relining,repair,heating No 4,4,4 4,4,5 4,4,4 4,4,4

Tap start to Cast finish
Metal holding time in ladle Minutes 200 200 200 200
Cast finish to ladle preparation bay
Ladle return time 30 30 30 30

LF/ARS treatment time Minutes 40/10 40/11 40/10 40/10

Casting time Minutes 40-60 40-61 40-60 40-60

No. of heats/day/ladle No. 4-5 4-6 4-5 4-5

Slide gate plate life heats NG=2 NG=3 NG=2 NG=3

Slag in ladle kg/tcs 4.2 4.2 4.2 4.2

Retainer plate life Campaign Every Repair Every Repair Every Repair Every Repair

Comments
RH Degasser unit 2012-13 2013-14 2014-15 2015-16 Best
Direct Bonded Direct Bonded Direct Bonded Mag- Direct Bonded Mag-
Refractory used in upper/lower vessel Type Mag- Chrome Mag- Chrome Chrome Chrome
Direct Bonded Direct Bonded Direct Bonded Mag- Direct Bonded Mag-
Snorkel Mag- Chrome Mag- Chrome Chrome Chrome

RH Heats Heat 13397 14004 14743 8604

both inner and outer snorkel
Snorkel life heat 130.44 119.79 137.93 127.42
specify life of also hearth
Lower vessel life heat 130.44 119.79 137.93 127.42

Upper vessel life heat 2500 2500 2500 2500

only snorkel refractory cost, excluding
98.23 152.86 128.10 132.42
RH Refractory cost (Total Cost) Rs/tcs labour
materials cost, stating whtether including
95.48 150.39 126.04 128.55
Snorkel+Lower vessel refractory cost Rs/tcs or excluding safety lining
materials cost, stating whtether including
2.75 2.47 2.06 3.87
Upper vessel refractory cost Rs/tcs or excluding safety lining
any repairs, gunning materials and labour
Snorkel Gunning consumption kg/tcs 1.83 1.98 1.89 1.90 cost

Freequency of gunning No every heat every heat every heat every heat
clearly stating all repairs, gunning
materials and whether including labour
Snorkel Gunning cost Rs/tcs 34.73 53.44 63.98 55.62
cost

Comments
BF Hot metal ladle unit 2012-13 2013-14 2014-15 2015-16 Best

Type of refractory used for lining 70% Alumina 70% Alumina 70% Alumina 70% Alumina

Ladle life ( 80 T ) heat 779.14 767.06 882.31 905.73

both work lining and safety lining
Refractory cost ( 80 T ) per Set Rs Lacs 1.097 1.094 1.010 1.013 refractory cost, excluding labour
including all repair materials
Refractory consumption ( 80 T) kg/tcs 0.32 0.30 0.34 0.37

Specific cost ( 80 T ) Rs/tcs 3.16 2.62 2.43 2.59

No of intermediate repairs/campaign No 3-4 3-4 1-2 1-2

Operational

Track time Hrs. 3.5 3.5

No. of heats/day/ladle No 3.5 3.5

Ladle tare weight at start & down Tonne 60/54 60/54

Torpedo ladle details
Comments
unit 2012-13 2013-14 2014-15 2015-16 Best

Type of refractory used for lining

Ladle life heat

both work lining and safety lining
Refractory cost Rs/tcs refractory cost, excluding labour
including all repair materials
Refractory consumption kg/tcs

Total cost Rs/tcs

No of intermediate repairs/campaign No

Operational

Track time Hrs.

No. of heats/day/ladle No

Ladle tare weight at start & down Tonne

Comments
Tundish unit 2012-13 2013-14 2014-15 2015-16 Best

Capacity Tonne 15-40 15-40 15-40 15-40

1,2,3= Slab, 1,2,3= Slab, 1,2,3= Slab, 1,2,3= Slab,
4= 3strand Bloom, 4= 3strand Bloom, 4= 3strand Bloom, 4= 3strand Bloom, specify the tundish for which
Tundish for which caster
5= 4 strand 5= 4 strand 5= 4 strand bloom, 5= 4 strand bloom, caster( Slab,Bloom,Billet, Any other)
bloom, 6= slab bloom, 6= slab 6= slab 6= slab
MgO board, Vibro MgO board, Vibro MgO board, Vibro MgO board, Vibro
Refractories in working lining Type mass,Spray Mass mass,Spray Mass mass,Spray Mass mass,Spray Mass

For safety lining Type Castable(LCC) Castable(LCC) Castable(LCC) Castable(LCC)

Precast (Alumina Precast (Alumina Precast (Alumina Precast (Alumina
Impact pad/TID refractories lining based) based) based) based)

Work lining life (20 T / 30 T) Seq.Size

Safety lining life campaign >800 heats >800 heats >800 heats >800 heats
M/c 1,2, 3 = 87,467;
M/c 4 = 1,06,380;
M/c 5 = 1,37,911;
Total Tundish Management Rs/Set M/c 6 = 2,43,513
M/c 1,2, 3 = 5.86; M/c 1,2, 3 = 5.86;
M/c 4 = 3.95; M/c 4 = 3.95;
M/c 5 = 9.57; M/c 5 = 9.57;
Tundish Average Life Heats M/c 6 = 18.44 M/c 6 = 18.45
M/c 1,2, 3 = 11; M/c 1,2, 3 = 11;
M/c 4 = 6; M/c 4 = 6;
M/c 5 = 18; M/c 5 = 14;
Tundish Best Life Heats M/c 6 = 35 M/c 6 = 36
Tundish shell temperature o
C 250-300 250-300 250-300 250-300

Min 60 min, & 40 min 60 min, & 40 min 60 min, & 40 min 60 min, & 40 min
Casting duration

BF Cast House Refractories 2012-13 2013-14 2014-15 2015-16 Best

Trough
Type of refractory material used
Trough lining refractories Type DRM, Castable DRM, Castable
DRM=65-100, DRM=65-100,
Initial installation
Tonnage of refractory used Tonne Castable=100-105 Castable=100-105
DRM=50000, DRM=50000,
HM throughput including repairs: Castable=120000 Castable=120000
SiO2=65.59, SiO2=65.59,
Main Trough Tonne
Al2O3=18.84, Al2O3=18.84,
CaO=32.81, CaO=32.81,
Metal Runner Tonne MgO=9.66, MgO=9.66,
FeO=0.58, FeO=0.58,
HM slag analysis % MnO=0.17, S=0.86 MnO=0.17, S=0.86

Relining & repair time Hrs. 14-96, 10-90 14-96, 10-90

BF Mudgun
Resin & Tar
Type of material Bonded Resin & Tar Bonded

Tap-hole length Meter 2-2.5 2-2.5

Blast pressure kg/cm2 1.41-1.96 1.41-1.96

Top pressure kg/cm2 0.55-0.92 0.55-0.92

Casting rate Ton/minute

Casting time Hrs 15-18 15-18

No of cast/day No 8-13 8-13

BF operation

HM Production /day/furnace tonnes 1800-3700 1800-3700

No of tap hole No 1-2 1-2

HM Temp. o
C 1400 1400

Hot blast temp. o

C 860-950 860-950
 56th Refractory Operating Committee Meeting 28-29th December,

PERFROMANCE DATA (Refractory & Operation)

Refractory Sp.Consumption & Sp. Cost
Department/Shop Unit 2010-11 2011-12 Best
Specific consumption kg/tcs (till Nov'11)

RED ( Total plant excluding C/R) kg/tcs 9.66 10.07 9.66

SMS ( without operation) kg/tcs 6.88 6.88
SMS operation kg/tcs 2.31 2.24 2.24
BF operation kg/tcs 3.65 3.73 3.65
Total consumption (RED+ Opns.) kg/tcs 15.62 16.04 15.62
(SMS operation + BF operation)
Specific Cost Rs/tcs
RED Total Rs/tcs 252.93 247.29 247.29
Operation(SMS+BF) Rs/tcs 213.30 208.53 208.53
RED+Operation Total Rs/tcs 466.23 455.82 455.82
Steel Melting Shop Rs/tcs
BOF Converter unit 2010-11 2011-12 Best
Number of Converter & Production(SMS-I / II) No/MT 2/ 1.80 2/ 1.80
Converter life (SMS-I / SMS-II) heats 1815 / 3525 2350 / 6543
Lining weight (Working / Safety) SMS-I tonne 162 + 45 162 + 45
SMS-II 455 + 91 455 + 91

Relining time (SMS-I / SMS-II) day 1.5 / 3 1.5 / 3 1.5 / 3

Original lining thickness in (SMS-I / SMS-II) mm 800 / 850 800 / 850
Top cone mm
Chare pad & Tap Belly mm
Trunnion mm
Lower cone/Knuckle area mm
Left over lining thickness in c/pad, mm
& Trunnion at the end of campaign
Refractory lining consumption SMS-I kg/tcs 1.43 2.44 1.43
SMS-II kg/tcs 0.88 0.40 0.40
Gunning repair consumption kg/tcs 0.00008/0.21 0.10/0.23
Taphole sleeve life heat Mag.Carb
Maintenance charge pad & tap belly tonne
Taphole resleeve time min
Converter refractory cost (incl.Tap hole) SMS- Rs/tcs 1.43 2.44
I SMS-II Rs/tcs 0.88 0.40

Limiting factor on life

BOF Operational Data

Capacity (SMS-I / SMS-II) Tonne 55 /150 55 /150
Heat weight (SMS-I / SMS-II) Tonne 66.55 / 150.52
Avg. blow /day (SMS-I / SMS-II) No 14 / 32 9.34 / 21.35
Avg. blow /day/converter No 7 / 16 7 / 16
Average Tap-to-tap time Minute 45 / 72 45 / 72
TMI (Total Metallic Input) Kg/tcs
Reblow % 25 - 5 25 - 5
Turn down bath carbon %
Tapping temp.>1700 C % heat
Tap temp.heat between 1660-1700C %heat % heat

Hot metal analysis( Si,S,P) %

Slag analysis( MgO,FeO,Basicity) %
Blowing details
Blow end to tap start time Minute
Slag splashing details %
Brick-slag setting practice Y/N
Steel Ladle unit 2010-11 2011-12 Best
Ladle capacity Tonne 66 & 150 66 & 150
Process route followed ARS/LF/RH
Type of bricks used in different zone FMC FMC
Steel ladle life (SMS-I / SMS-II) heats 64.27 / 98.92 68.44 / 99.42 84 / 140
VAD/RH Ladle life heats
Specific consumtion in ladle (SMS-I / SMS-II) kg/tcs 9.63 / 5.05 8.86 / 5.64
Working lining (SMS-I / SMS-II) Tonne 3089 / 2892 1593 / 2380
Safety lining (SMS-I / SMS-II) Tonne 807 / 6084 407 / 4415
Intermediate repairs in a campaign * Tonne
Total ladle Tonne 3896 / 8976 2000 / 6795
Ladle heat size Tonne 66 / 150 66 / 150
Total ladle specific cost (SMS-I + SMS-II) Rs/tcs 118.55
Total cost/campaign (excl. safety lining) Rs. In lakh 8.79 / 15.41 7.9 / 17.85
Wellblock life heats 49.08
Housing block life heats 48.89
Avg. Purging plug life heat 10.03
Free opening rate %
Slide gate plate life heat 2.28
hot changing of inner nozzle/p plug Y/N
Intermediate repairs in a campaign No. 2 2

Operational
Total number of ladle No 18 18
Ladle in circulation No. 7 7
Ladle under relining,repair,heating No 9 9
Metal holding time in ladle Minutes
Ladle return time
LF/ARS treatment time Minutes
Casting time Minutes
No. of heats/day/ladle No. 3 3
Slide gate plate life heats 2.28
Slag in ladle kg/tcs
Retainer plate life Campaign
Slag analysis(ARS/LF/RH in & out) %

RH Degasser unit 2010-11 2011-12 Best

Refractory used in upper/lower vessel Type
Snorkel
Snorkel life heat
Lower vessel life heat
Upper vessel life heat
Snorkel refractory cost Rs/tcs

Lower vessel refractory cost Rs/tcs

Upper vessel refractory cost Rs/tcs

Gunning/repair consumption kg/tcs
Freequency of gunning No

Gunning/repairing cost Rs/tcs

BF Hot metal ladle unit 2010-11 2011-12 Best

Type of refractory used for lining F/C 38%
Ladle life ( 80 T / 140 T) heat 589 / 1453 690 / 1563 1662

Refractory cost ( 80 T + 140 T) Rs/tcs 3.14 2.65 720 / 1662

Refractory consumption ( 80 T / 140 T) kg/tcs 0.64 0.57
Total cost ( 80 T / 140 T) Rs/tcs 3.14 2.65
No of intermediate repairs/campaign No

Operational
Track time Hrs.
No. of heats/day/ladle No
Ladle tare weight at start & down Tonne

Torpedo ladle details

unit 2010-11 2011-12 Best
Type of refractory used for lining
Ladle life heat

Refractory cost Rs/tcs

Refractory consumption kg/tcs
Total cost Rs/tcs
No of intermediate repairs/campaign No
Operational
Track time Hrs.
No. of heats/day/ladle No
Ladle tare weight at start & down Tonne

Tundish unit 2010-11 2011-12 Best

Capacity Tonne

Tundish for which caster

Refractories in working lining Type Basic Basic
For safety lining Type Monolithic Monolithic
Impact pad/TID refractories lining H/A-70 Br. H/A-70 Br.
Work lining life (20 T / 30 T) heats 5.93 / 6.94 6.02 / 7.39
Safety lining life campaign
Work lining consumption (T/S/M only) kg/tcs 0.56 / 1.09 0.63 1.07
Work lining cost (T/S/M only) Rs/tcs 10.81 / 22.09 10.57 / 23.36
Safety lining cost(total excl. T/S/M) Rs/tcs 6.22 / 12.82 4.27 / 10.38
Tundish furniture cost Rs/tcs

Black refractory cost Rs/tcs

Tundish shell temperature o
C
Casting duration Min

BF Cast House Refractories 2010-11 2011-12

Trough
Trough lining refractories Type

Tonnage of refractory used Tonne

HM throughput including repairs:
Main Trough Tonne
Metal Runner Tonne
HM slag analysis %
Relining & repair time Hrs.

BF Mudgun
Type of material
Tap-hole length Meter
Blast pressure kg/cm2
Top pressure kg/cm2
Casting rate Ton/minute
Casting time Hrs
No of cast/day No
BF operation
HM Production /day/furnace tonnes 1750 1750
No of tap hole No
HM Temp. o
C
Hot blast temp. o
C
eeting 28-29th December,

For discussion

consumption includes working & safety lining and all

repairs

Comments
Annual
2350 / 6543
Specify working and safety separately

only refractory relining time( SMS-I - 24.00 Hrs. & SMS-II

- 66.00 Hrs.)

working + Safety lining

including all spraying and gunning materials

state taphole type
brick-slag setting

Work and safety lining, gunning/repair cost. State whether

including taphole cost
State the limiting factor of refractories or other factors like
mechanical or planning
Define reblow norm

Comments

In slag zone, Metal zone, Bottom impact etc.

any repair in slag line, striker or ladle top rings
any repair in slag line, striker or ladle top rings

* Consumption of Intermediate repairs included

* Consumption of Intermediate repairs included

changes in volume or tapping weight

(SMS-I / SMS-II)
any repairs and the details

exchangeable or fixed

any reconditions/repairs

reasons for intermediate repairs

Tap start to Cast finish

Cast finish to ladle preparation bay
Comments

both inner and outer snorkel

specify life of also hearth

only snorkel refractory cost, excluding labour

materials cost, stating whtether including or excluding
safety lining
materials cost, stating whtether including or excluding
safety lining
any repairs, gunning materials and labour cost

clearly stating all repairs, gunning materials and whether

including labour cost

Comments

both work lining and safety lining refractory cost,

excluding labour
including all repair materials

Comments

both work lining and safety lining refractory cost,

excluding labour
including all repair materials
Comments

specify the tundish for which caster( Slab,Bloom,Billet,

Any other)

include all dam, turbostop, weir and chimney etc

include ladle Shroud, SEN/SES, stopper and mononozzle

Type of refractory material used

Initial installation and during repairs in the whole
campaign throughput