The project involved developing a 10,000 t/d blast furnace for TATA Steel as part of a new integrated steelworks in India. The furnace design focused on combining the proven technological expertise from Primetals Technologies with the aim of delivering a high-performance furnace capable of meeting the growing demands of the market while ensuring efficiency, reliability, and sustainability. The project required a careful integration of advanced technology and local operational knowledge to optimize the furnace's productivity and minimize operational challenges.
Challenge
The project was to develop a 10,000 t/d furnace for TATA Steel as part of a new integrated steelworks in India. The furnace requirement was to integrate proven technologies from Primetals Technologies with TATA’s experience of operating conditions in India.
Tata Steel KPO Blast Furnace No.1
Solution
A contract was awarded to Primetals Technologies to design and supply the new 14 m hearth diameter blast furnace and additional facilities as part of the overall site arrangement at Kalinganagar, as part of the first phase of the project. This project, in addition to the blast furnace, included steelmaking facilities, a coke plant, and a sinter plant. Primetals Technologies provided supervision for the construction and commissioning of the furnace, working closely with the customer and contractors at the greenfield site in Orissa.
Scope of Delivery
- Blast furnace equipment: engineering and supply for TATA’s largest blast furnace
- Blast furnace proper and related plant areas: basic engineering of structures, vessels, pipework, etc
- Construction and commissioning supervision
- Performance guarantees for key production and operating parameters
New Blast Furnace
- State-of-the-art cooling water system
- Copper and cast iron staves
- Closed circuit cooling
Slag Granulation System
- Heavy-duty screw dewatering to cope with slag surges
- Quality granulated slag, generating a high-value product for the cement industry
Clean Gas System
- Dust catcher
- Tangential cyclone single entry, to maximize dry dust recycle
- Triple cone scrubber, coupled to an energy recovery turbine, for efficient and cost-beneficial clean gas generation
Stockhouse
- Separate coke and ferrous stockhouses, each with a gathering conveyor feeding intermediate batch holding hoppers
- Single main charge belt conveyor, feeding a parallel hopper top
Tata Steel KPO Blast Furnace No.1
Results
Furnace Design Parameters
- Average production: 9,150 t/d
- Peak production: 10,065 t/d
- Furnace hearth diameter: 13.9 m
- Furnace working volume: 3,633 m³
- Furnace inner volume: 4,384 m³
- Top gas operating pressure: 2.50 bar g
- Blast pressure at furnace: 4.10 bar g
- Normal productivity on inner volume: 2.52 tHM/d/m³
- Normal productivity per hearth area: 60.30 tHM/d/m²
- Number of tuyeres: 38
- Number of tapholes: 4
Stove Design Parameters
- Number of stoves: 3
- Type of stoves: External
- Hot blast volume: 478,000 Nm³/h
- Hot blast temperature: 1,200 °C
- Heating area per stove: 85,000 m²
- Stove refractories: Silica/Alumina
- Stove burner: Ceramic
Tata Steel KPO Blast Furnace No.1
Benefits
- State-of-the-art cooling water system.
- Quality granulated slag generating high value product for the cement industry.
- Tangential cyclone single entry, to maximize dry dust recycle.
- Triple cone scrubber, coupled to an energy recovery turbine.
Conclusion
- Primetals Technologies largest external combustion chamber stoves incorporating enhanced cross-over.
- Complete suite of Primetals Technologies casthouse equipment, guns, drills and cover manipulator.
- Level 1 PLC system for the complete furnace, including operating condition monitoring.
- Performance guarantees for key production and operating parameters.
