LD Converter and Dedusting System for Steel Authority of India's Bokaro Plant

SAIL Bokaro faced the need to modernize their LD converter (BOF) operations to enhance metallurgical performance, increase productivity, and reduce production costs. At the same time, they were under pressure to meet stricter environmental standards, requiring effective off-gas recovery and substantial reductions in dust emissions within the melt shop and to the atmosphere. This transformation demanded the integration of advanced process automation, reliable off-gas treatment systems, and comprehensive infrastructure upgrades — all while ensuring uninterrupted steel production and long-term operational efficiency.

The new LD converter (BOF), with a tapping weight of 130 metric tons, is equipped with systems for suppressed combustion and gas recovery. The newly installed primary dedusting system recovers the converter off-gas, which can be added to the gas from the Bokaro blast furnaces, reducing the need for other fuels. The converter also features a bottom stirring system to improve the metallurgical process, a slag retaining system with SlagMon slag detection, a Lomas gas analysis system, and a new secondary dedusting system to reduce dust pollution inside the melt shop and in the atmosphere. Primetals Technologies supplied the process automation, including Level 1 process control, Level 2 process optimization with the Dynacon process model, and all relevant electrics and instrumentation. The new facilities, which entered service in early 2018, are designed to boost yield and productivity while cutting production costs.

During the project, the following equipment and systems were supplied to the customer: material handling system, slag yard, secondary gas cleaning, gas recovery and gas holder, water treatment plant, E-substations, process automation (Level 1 and Level 2), as well as all utility systems.