DEPARTMENT OF MECHANICAL ENGINEERING

SIDDARTHA EDUCATIONAL ACADEMY

GROUP OF INSTITUTIONS-INTEGRATED CAMPUS
Affiliated to Jawaharlal Nehru Technological University, Ananthapuramu.
Approved by A.I.C.T.E, New Delhi.
Near C.Gollapalli, Tirupati -517505

CERTIFICATE
This is to certify that the project work entitled PERFORMANCE OF EVAPORATIVE
COOLING SYSTEM RECIRCULATING PUMP IN RE-HEATING FURNACE being submitted to
JNTUA, Ananthapuramu in partial fulfillment requirements for the degree of Bachelor of
Technology, Mechanical engineering is a record of original work done by
G.SOMA SEKHAR 139L1A0315
K.JAYACHANDRA 139L1A0326
K.AJAY KUMAR 139L1A0329
N.UPENDRA REDDY 139L1A0337
P.VIJAY KUMAR 139L1A0342
S.JYOTHI PRAKASH 139L1A0353

During the period of study at SIDDARTHA EDUCATIONAL ACADEMY GROUP OF

INSTITUTIONS, under my supervision and guidance. It is their original work and had not been
submitted to any other university for the award of any degree or diploma.

GUIDE: ___________________ HOD: ___________________

Mr. S.BHASKAR, M. Tech, (Ph. D) Mr. D.MALLIKARJUNA REDDY, M. Tech.
Assistant Professor Assistant Professor

Submitted for the viva voce examination held on: ______________

INTERNAL EXAMINER EXTERNAL EXAMINER

RASHTRIYA ISPAT NIGAM LIMITED,

VISAKHAPATANAM STEEL PLANT.
 CERTIFICATE
This is to certify that Students of Mechanical Engineering has completed the project work
titledPERFORMANCE OF EVAPORATIVE COOLING SYSTEM RECIRCULATING PUMP IN
RE-HEATING FURNACE which is a Bonafide record of the work carried out with group and
systematically under my guidance,

Names: Roll No:

G.SOMA SEKHAR 139L1A0315

K.JAYACHANDRA 139L1A0326
K.AJAY KUMAR 139L1A0329
N.UPENDRA REDDY 139L1A0337
P.VIJAY KUMAR 139L1A0342
S.JYOTHI PRAKASH 139L1A0353

This project work has been carried out in partial fulfillment of the requirements for his
training period as an project Mechanical Engineering and has been implemented successfully as per
the guidance laid down by the SIDDARTHA EDUCATIONAL ACADEMY GROUP OF
INSTITUTIONS, TIRUPATI.

(Mr. N. VENUGOPALA RAO)

Asst. General Manager (Mech.), MMSM.
 ABSTRACT

In the steel making process, rolling mills play a vital role in transforming the steel to
finished products. Rolling mills at VSP consists of LMMM, WRM & MMSM. The blooms from
SMS are charged into reheating furnaces of MMSM for heating then up to 1200 deg and subsequent
rolling. Reheating furnace at MMSM of 130 T/hr capacities is running with these by-product
energies as fuel and yielding limited output up to 150 T/hr of steel for rolling.
This project report deals with the study of Evaporative cooling system (ECS) and its
recirculating pump performance in walking beam-reheating furnaces at rolling mills in steel plant. A
keen study of the system was made in Medium Merchant and Structural Mill (MMSM) at
Visakhapatnam Steel Plant (VSP), the first integrated and most modernized steel plant in the
country.
Evaporative Cooling System (ECS) forms an important component in cooling the skids (The
supports used for carrying blooms at temperature 1200 0C) in walking beam-reheating furnaces. This
project describes the basic principle and working of the system in detail with specifications. The
troubles that may be encountered in various components of ECS like turbines, governors, pumps
etc., along with their possible solutions have been dealt with.
We calculated the efficiency of the recirculating pumps (centrifugal pump) in both the
furnaces for better operation and maintenance of the furnace ECS system.
 ACKNOWLEDGEMENT
The work submitted here is performed as project work under the valuable guidance of Mr.
S.BHASKAR Assistant professor, Department of Mechanical Engineering. We thank him for
guidance and participation in developing the project work on PERFORMANCE OF
EVAPORATIVE COOLING SYSTEM RECIRCULATING PUMP IN RE-HEATING
FURNACE.
We wish to express our deep sense of gratitude to Mr. N. VENUGOPALA RAO, Asst.
General Manager of Mechanical Department at Medium Merchant And Structural Mill at
VISAKHAPATNAM STEEL PLANT for providing facilities to carry out the project along with
efficient guidance to complete our work fulfledgely.
We would like to express our heart full thanks to Sri D.MALLIKARJUNA REDDY, Head
of Department of Mechanical Engineering for standing like a backbone for us throughout
completion of project and suggesting us professionally with patience.
It gives us great pleasure to express our heartfelt gratitude to our beloved principal Dr. K.
RAJASEKHAR who encouraged us in taking a project in our interested area to carry our project.
Finally we extend our gratefulness to all the other directly or indirectly involved in the
successful completion of this project work.

1) G.SOMA SEKHAR
2) K.JAYACHANDRA
3) K.AJAY KUMAR
4) N.UPENDRA REDDY
5) P.VIJAY KUMAR
6) S.JYOTHI PRAKESH
 CONTENTS PAGE.NO

CHAPTER 1- INTRODUCTION AND SURVEY OF STEEL LITERATURE 1-5

1.1 STEEL 1

1.2 HISTORY OF STEEL 1-3

1.3 WORLD STEEL STATICS 3-4

1.4 INDIAN STEEL INDUSTRY 4-5

CHAPTER 2- VISAKHAPATNAM STEEL PLANT (VSP) 6-9

2.1 INTRODUCTION 6-7

2.2 HISTORY 7-8

2.3 EXPANSION 8-9

CHAPTER 3- MAJOR UNITS OF STEEL PLANT 10-26

3.1 BEFORE EXPANSION 10-21

3.2 AFTER EXPANSION 22-26

CHAPTER 4- AREA OF STUDY 27-38

4.1 TYPES OF FURNACES 27-28

4.2 WALKING BEAM FURNACE OF MMSM 29-35

4.3 COMBUSTION CHARACTERISTICS 35-37

4.4 CHARACTERISTICS OF AN EFFICIENT FURNACE 38

CHAPTER 5- COOLING SYSTEMS IN FURNACE 39-40

5.1 DIFFERENT TYPES OF COOLING SYSTEMS 39-40

CHAPTER 6- ABOUT ECS SYSTEM 41-52

6.1 INTRODUCTION 41-42

6.2 WORKING OF THE SYSTEM 43-44

6.3 SPECIFICATIONS OF THE SYSTEM 44-52

CHAPTER 7- DATA COLLECTION 53-58

CHAPTER 8- CALCULATIONS OF PUMP EFFICIENCY 59-61

CHAPTER 9- CONCLUSIONS 62

CHAPTER 10- BIBLIOGRAPHY 63

 LIST OF FIGURES

Number Description Page No.

CHAPTER 1 Figure.1 Steel Making 01

Figure.2 World Steel Statics 03
Figure.3 Major Indian steel industries 05
CHAPTER 2 Figure.4 Roll of Raw Material to Finished Product 06
Figure.5 Expansion Details 09
CHAPTER 3 Figure.6 Raw Material Handling Plant 10
Figure.7 Coke Ovens & Coal Chemical Plant 11
Figure.8 Sinter Plant 12
Figure.9 Calcining and Refractory Material Plant 13
Figure.10 Blast Furnace 14
Figure.11 Steel Melting Shop 15
Figure.12 Continuous Casting Department 16
Figure.13 Light And Medium Merchant Mill 17
Figure.14 Wire Rod Mill 18
Figure.15 Medium Merchant and Structural Mill 19
Figure.16 Roll Shop and Repair Shop 20
Figure.17 Thermal Power Plant and Blower House 21
Figure.18 Sinter Plant-3 22
Figure.19 Blast Furnace-3 23
Figure.20 Steel Melt Shop-2 24
Figure.21 Wire Rod Mill-2 25
CHAPTER 4 Figure.22 Furnace Classification 27
Figure.23 Walking Beam Furnaces 28
Figure.24 Skids & Posts 29
Figure.25 Mode of Heat Transfer in the Furnace 34
CHAPTER 6 Figure.26 ECS Block Diagram 42
Figure.27 Circuit Diagram of ECS Drum 45
Figure.28 MMSM Furnace ECS Control 46
 Figure.29 ECS Drum 47
Figure.30 DMDA Station for MMSM 48
Figure.31 ECS Station Pump With Motor 50
Figure.32 ECS Station Pump With Steam Turbine 51
CHAPTER 7 Figure.33 Centrifugal Pump 54
Figure.34 Pump Performance Curve 55
Figure.35 Pump Operation Point 57

LIST OF TABLES

Number Description Page No.

CHAPTER 4 Table 1Furnace Dimensions 30

Table 2Burners Arrangement in the Furnace 33
 CHAPTER - 1
INTRODUCTION AND STEEL SURVEY OF LITERATURE
1.1 STEEL:

Fig-1
Steels are alloys of Iron and Carbon, widely used in construction and other applications
because of its high tensile strength and low cost. The Carbon in typical Steel alloy may contribute
up to 2.1% of its weight. Varying the amount of alloying elements, their formation in the steel
either as solute elements controls the qualities of steel such as Hardness, Ductility and Tensile
Strength
1.2 HISTORY OF STEEL:

The history of steel-making in India can be traced back to 400 BC when the Greek
emperors used to recruit Indian archers for their army who used arrows tipped with steel. Many
more evidences are there of Indians perfect knowledge of steel-making long before the advent of
Christ. Archaeological finds in Mesopotamia and Egypt testify to the fact that use of iron and steel
was known to mankind for more than six thousand years and that some of the best products were
made in India. Among the widely-known relics is the Iron Pillar near QutabMinar in Delhi. The
pillar, built between 350 and 380 AD, did not rust so far an engineering marvel that baffles the
scientists even today. Yet another engineering feat is the famous Sun Temple at Konark in Orissa,
built around 1200 AD, where steel structurals were used for the first time in the world.

These were the halcyon days when India flourished in all directions and when its prosperity
was a matter of envy for the foreigners. But as ill luck would have it, Indias prosperity gave way
to poverty after the advent of the foreign rule. Indias indigenous industry languished because of a
deliberate policy of the colonial rulers to make the country only a supplier of raw materials.

Steel Role plays a vital role in the development of any modern economy. The per capita
consumption of steel is generally accepted as a yardstick to measure the level of socio-economic
development and living standards of the people. As such, no developing country can afford to
ignore the steel industry

At the time of independence India had a small iron and steel industry with production of
about a million tons (Mt). IN due course the government was mainly focused on developing basic
steel industry, where crude steel constituted a major part of total steel production, many public
sector units were established and thus public sector had a dominant share in steel production till
early 1990s, mostly private players were in downstream production, which was mainly producing
finished steel using crude steel products.

Basically, the steel industry was developing under a control regime , which established
more public sector steel companies in various segments till early in 1990s, when economic
liberalization reform were introduced, the steel industry continued to be under controlled regime,
which largely constituted regulations such as large plant capacities were reserved only for public
sector under capacity control measures; price regulation; foreign investment was restricted, and
there were restriction on imports as well as exports, undoubtedly there has been significant
government bias toward public sector undertaking. But not all government action has been
beneficial for the public sector companies.
1.3 WORLD STEEL STATICS:

Steel is a cornerstone and key driver for the worlds economy. The steel industry directly employs
more than two million people worldwide, plus two million contractors and four million people in
supporting industries. Including industries such as construction, transport and energy, the steel
industry is a source of employment for more than 50 million people. It is at the core of the green
economy, in which economic growth and environmental responsibility work hand in hand. It is the
main material used in delivering renewable energy: solar, tidal and wind. Steel is 100% recyclable
and can be used in new products and applications amounting to significant energy and raw
material savings. The amount of energy required to produce a tonne of steel has been reduced by
50% in the past 30 years.
Fig-2

Steel is everywhere in our lives. No other material has the same unique combination of
strength, formability and versatility. Steel surfaces are hygienic and easy to clean. Surgical and
safety equipment and commercial kitchens are all made with steel. Almost 200 billion cans of food
are produced each year. Steel cans ensure that food remains safe and nutritious while saving
energy as refrigeration is not needed. Steel is an innovative and progressive industry committed to
the safety and health of its people. The industry is committed to the goal of an injury-free
workplace. Safety metrics show that the lost-time injury frequency rate is decreasing. Globally, the
steel industry spends more than 12 billion per year on process improvements, new product
development and future breakthrough technology
1.4 INDIAN STEEL INDUSTRY:
 INDIAN STEEL INDUSTRY STRUCTURE
The Indian steel industry is divided into primary and secondary sectors. The primary sector
comprises a few large integrated steel providers producing billets, slabs and hot rolled coils,
among others. The secondary sector comprises small units focused on the production of value
added products such as cold rolled coils, galvanized coils, angles, columns, beams and other re-
rollers, and sponge iron units. Both sectors cater to different market segments.
On the basis of ownership, the Indian steel industry is broadly divided into private and
public sector enterprises. The private sector dominates production accounting for almost 78
percent of the finished steel outputwhile the public sector has higher capacity utilizations.
MAJOR INDIAN STEEL INDUSTREIS
COMPANY PRODUCTS
Steel Authority of India Semis, Structurals, Rods,
Ltd. (SAIL) Bars, Rebars, Plates, Pig
Iron and Special Steel

Rashtriya Ispat Nigam Structurals, Plain rounds,

Ltd. (RINL) Bars, Plain Wire Rods in
Coils, Forged rounds and
Special Steel
Tata Steel Ltd. Flats, Longs, Structurals,
Agricultural Implements and
Bearings

Essar Steel India Ltd. Plates, Pipes, Factory welded

beams, Trapezoidal blanks,
Chequered plates, Hot and
Cold rolled Steel Sheets

Bhushan Steel Cold rolled Steel Sheets,

Strips and Coils

JSW Steel Ltd. Hot rolled Steel Sheets,

Strips and Coils
 Jindal Steel and Power Iron and Steel
Ltd.

Ispat Industries Ltd. Hot rolled Steel Sheets,

Strips and Coils

WelspunMaxsteel Ltd. Tubes and Pipes

Fig- 3

CHAPTER - 2
VISAKHAPATANAM STEEL PLANT (VSP)
2.1 INTRODUCTION:
 Visakhapatnam Steel Plant, popularly known as Vizag Steel is the most advanced steel
producer and largest single site plant in India, with the help of German and soviet technology. Its
products have been rated the best in the world market. Almost 80% of its income comes from the
exports of steel products to Japan, Germany, United States, Singapore, Dubai, Australia, South
American countries and many more. The company has grown from a loss making industry to 3
billion dollar Turnover Company registering a growth of 203.6% in just 4 years.

Fig-4
LOCATION:
The plant is located in Visakhapatnam city, which is on the coast of Bay of Bengal.
Visakhapatnam city is an important commercial center of Andhra Pradesh. It has the deepest port
and is one of the principal outlets for countrys exporting Iron ore. The city has many large
industries such as Hindustan Petroleum refinery, Bharat Heavy Plates Electricals ltd., Coromandal
Fertilizers, Hindustan Shipyard etc. The city is situated on the main broad gauge railway line
between Kolkata and Chennai and is well connected with other major cities and state capitals by
rail, road and air. The Visakhapatnam steel plant is located south west of Visakhapatnam Harbor
and is about 26 Km from Visakhapatnam city.
2.2 HISTORY:

On 17 April 1970, the then Prime Minister of India, the late Indira Gandhi, announced the
government's decision in the Parliament to establish a steel plant at Visakhapatnam. Planning
started by appointing site selection committee in June 1970 and subsequently the committee's
report was approved. On 20 January 1971, Gandhi laid the foundation stone of the plant.
Consultants were appointed in February 1971, and feasibility reports were submitted in 1972. The
first block of land was taken over on 7 April 1974. M/s M.N. Dastur& Co was appointed as the
consultants for preparing the detailed project report in April 1975 and in October 1977 they
submitted a proposal for 3.4 Mtpa of liquid steel. With the offer for assistance from the
government of the erstwhile USSR, a revised project evolved. A detailed project report for a plant
with a capacity of 3.4 Mtpa was prepared by M/s M.N. Dastur& Co in November 1980. In
February 1981, a contract was signed with the USSR for the preparation of working drawings of
coke ovens, blast furnace and sinter plant. The blast furnace foundation was laid, with first mass
concreting, in January 1982. The construction of the local township was also started at the same
time.

In the 1970s, KurupamZamindars donated 6,000 acres of land for Vizag Steel Plant. A new
companyRashtriyaIspat Nigam Limited (RINL) was formed on 18 February 1982. Visakhapatnam
Steel Plant was separated from SAIL and RINL was made the corporate entity of Visakhapatnam
Steel Plant in April 1982.

Vizag Steel Plant is the only Indian shore-based steel plant and is situated on 33,000 acres
(13,000 ha), and is poised to expand to produce up to 20 MT in a single campus. Turnover in
2011-2012 was Rs 14,457crores. On 20 May 2009, Prime Minister Manmohan Singh launched the
expansion project of Visakhapatnam Steel Plant from a capacity of 3.6 MT to 6.3 MT at a cost of
Rs. 8,692 crores. But the investment was revised to 14,489 crores with the following
classification:

a) Expenditure for the financial year 2009-10 Rs 1840 crores.

b) Rs 5883 crores since inception of the project.
c) Total commitment, including enabling works, steel procurement, consultancy, spares, etc.
is Rs 11591 crores as of 25 March 2010.
 The expansion project is expected to become functional by 2012. It has been rated the best
place to work in India" for consecutive five years.
2.3 EXPANSION:

RINL has completed the current phase of expansion for doubling the capacity from 3 Mtpa
to 6.3 Mtpa. Stabilization of the units is in progress for ramping up the production progressively.

Stage - 1:

All major units of Stage-1 were commissioned progressively from December 2011 to
March 2014. Major units which have been commissioned and put into operation include the Raw
Material Handling Plant, Sinter Plant-3, Blast Furnace-3, Steel Melt Shop-2, Wire Rod Mill-2,
Oxygen Plant, Turbo Blower-4 and several auxiliary systems, viz. water, power & utility systems.

Stage - 2:

Special Bar Mill has been commissioned on 3rd April 2015. Structural Mill has been
commissioned on 30th April 2015. Stabilization of the units is in progress for ramping up the
production progressively.
 With the commissioning of both Mills under stage-2, the 6.3 Mtpa Expansion of RINL is
completed.

Fig-5
 CHAPTER - 3
MAJOR UNITS OF STEEL PLANT
3.1 BEFORE EXPANSION:
RAW MATERIAL HANDLING PLANT (RMHP)

Fig-6
The Raw Material Handling Plant (RMHP) receives the basic raw materials required for
the steel making process from various sources through railway wagons and by road. These are
stacked by stackers and reclaimed by re- claimers and distributed to various departments of VSP
through conveyor system. The Iron Ore Fines, Iron Ore Lump, Sized Iron Ore, Limestone (BF &
SMS grades), Dolomite (BF & SMS grades), Sand, Quartzite and Manganese lumps are stacked at
Ore& Flux Yard. The Imported Coking Coal (ICC), Medium Coking Coal (MCC), Boiler Coal
(BC) is stacked in Coal Yard. Coke is sent directly to Blast Furnace after tippling from ore and
flux wagon tipplers.
 COKE OVENS & COAL CHEMICAL PLANT (CO&CCP)

Fig-7
Blast furnace require huge quantities of strong, hard and porous solid fuel in the form of
hard metallurgical coke for supplying necessary heat for carrying out the reduction and refining
reactions. Coke is manufactured by heating crushed cooking coal (<3mm) in absence of air at a
temperature of 1000C for 16-18 hours. At VSP the other 3 coke ovens batteries, 7m tall & having
67 ovens each, each oven has a volume of 41.6 m 3 and can hold up to 31.6 tons of dry coal charge.
Red hot coke is pushed out of the oven and sent to coke dry cooling plants where nitrogen gas is
used a cooling medium. The heat recovery from nitrogen is done by generating steam and
expanding in two backpressure turbines to produce 7.5MW power each respectively. Another
feature is the dry cooling of coke carried out by the inert gas nitrogen thus, reducing pollution
considerably
 SINTER PLANT (SP)

Fig-8
Sinter is a hard and porous ferrous material obtained by agglomeration of iron ore fines,
coke breeze limestone fines, metallurgical wastes like flue dust, mill waste, LD slag etc. Sinter is a
better feed material to blast furnace in comparison to iron ore lumps and its usage in blast furnaces
help in increasing productivity, decreasing the coke rate and improving the quality of hot metal
produced. Sintering in two sinter machines of 312 m 2 by heating the prepared feed on a continuous
metallic belt made of pallets at 1200-1300C. Hot sinter discharged from sintering machine is
crushed to 5mm to 50mm size and cooled before dispatching to blast furnace. Sinter plant of VSP
has the capacity to produce 5.256 MT of sinter per annum, which will cater for 80 % of Iron
bearing feed to Blast furnace. Two Sintering machines of Dwight Lloyd type having 312 M2 total
grate area are provided for this purpose. Sinter machine is designed to operate at the rate of 1.2
T/hr/M2 for 330 days in a year.
 CALCINING AND REFRACTORY MATERIAL PLANT (CRMP)

Fig-9
CRMP, i.e. Calcining& Refractory Materials Plant is an integrated unit of Visakhapatnam
Steel Plant. This plant plays a significant role in the manufacturing of liquid steel. The main
customer of CRMP is Steel Melting Shop (SMS).
Calcining plant produces lime and calcined dolomite, which are used for refining of hot
metal to steel in the converter. This plant has 5 rotary kilns of 325 tons/day capacity. Lime is
produced by Calcining limestone and calcined dolomite is produced by Calcining dolomite.
Limestone is procured from Oman & Thailand and Dolomite (SMS grade) from Madharam mines
of VSP. The size of both the raw materials is (25 - 60) mm. Both the raw materials are received
and stacked at RMHP.RMHP reclaims these materials and conveys to LSDS (Limestone &
Dolomite Screening Plant) via a stream of conveyors. LSDS has two screens of 25mm size (VS6
& VS7) to screen out the minus fraction from raw materials. The -25mm size is sent to RMHP for
use in Sinter Plant. The +25mmsize limestone is stored in bunker 5 and +25mm dolomite is stored
in bunker 6. These materials are then conveyed to the stone bins of all the kilns by operating the
weigh feeders below the two bunkers. Limestone and dolomite are charged to separate kilns
 BLAST FURNACE (BF)

Fig-10
VSP has two Blast Furnaces named as Godavari & Krishna with an effective volume
of 3200 m3, each of which are the largest in the country equipped with Paul worth Bell less top
equipment with conveyor charging. Blast Furnace is charged with coke, iron ore and sinter from
the top and produces about 5000 tons of molten iron per day. Its novel circular cast house with
four tap holes ensures continuous tapping of hot metal. The annual production capacity of these
Blast Furnaces is 3.4 million tons of liquid iron. Provision exists for granulation of 100% liquid
slag at blast furnace cast house and utilization of blast furnace gas top pressure (1.5-2.0
atmospheric pressure) to generate 12 MW of power in each furnace by employing gas expansion
turbines.
 STEEL MELTING SHOP (SMS)

Fig-11
Steel is an alloy of iron with carbon up to 1.8%. Hot metal produced in the blast furnaces
contain impurities such as carbon (3.5-4.25%), silicon (0.4-0.5%), manganese (03.-0.4%),
sulphur(0.04%max) and phosphorus (0.14% max) is not suitable as a common engineering
material to Improve the quality that impurities are to be eliminated or decreased by oxidation
process.
VSP employs three top blown oxygen converters called LD- convertors each having
133m3 volume capable of producing three million tons of liquid steel annually. 99.5% of pure
oxygen at 15-16 KSCG pressure is blown in the convertor through an oxygen lance having
convergent divergent copper nozzles at the blowing end. Oxygen oxidizes the impurities present
in the hot metal that are fixed as slag with basic fluxes such as lime. During the process heat is
generated by exothermic reactions of oxidation of metalloids like Si, Mn, p & c and temperatures
rising 1700C enabling refining and slag formation. Different grades of steel of superior quality
can be made by this process by controlling the oxygen blow or addition of various Ferro alloys or
special additives such as FeSi, FeMn, Si-Mn, coke breeze, Al in required quantities while liquid
steel is being tapped from the convertor into a steel ladle. Convertor gas produced as a byproduct
is used as secondary fuel
 CONTINUOUS CASTING DEPARTMENT (CCD)

Fig-12
Continuous casting may be defined as teaming of liquid steel in a mould with a false
bottom through which partially solidified bar is continuously withdrawn at the same rate at which
liquid steel is teamed in the mould. Facilities at a continuous casting machine include a lift and
turntable for ladles, copper mould, oscillating system tundish, primary and secondary cooling
arrangement to cool the steel bloom. Gas cutting machines is used for cutting the blooms in
required lengths of 6m long. At VSP we have six-4strand continuous casting machines capable of
producing 2.82 million tons per year blooms of size 250X250mm and 250X320mm. The entire
quantity of molten steel produced (100%) is continuously cast in radial bloom casters, which help
in energy conservation as well as production of superior quality products.

ROLLING MILLS
Blooms produced in SMS-CCD do not find much applications as such and are required to
be shaped into products such as billets, round, squares, angles (equal and unequal), channels, I-PE
beams, HE beams, wire rod and reinforcements by rolling them in, there sophisticated high
capacity, high speed, fully automated rolling mills, namely Light and Medium Merchant Mills
(LMMM), Wire Rod Mills (WRM) and Medium Merchant and Structural Mill (MMSM).
 LIGHT AND MEDIUM MERCHANT MILL (LMMM)

Fig-13
The cast blooms from continuous casting department are heated and rolled in the two high
speed and fully automated rolling mills namely Light & Medium Merchant Mill (LMMM) and
Medium Merchant & Structural Mill (MMSM). The billets produced in LMMM are further rolled
in Bar Mill / Wire Rod Mill (WRM). The finished products include wire rods & long products like
Reinforcement bars, rounds, squares, flats, angles, channels, billets etc. LMMM comprises of two
units in the billets/break down mill 250 320 mm size blooms are rolled into billets of 125 mm size
after heating them in two nos. of walking beam furnaces of 200T/hr capacity each. This unit
comprises of 7 stands (2 horizontal 859 1200mm) and 5 alternations vertical and horizontal stands
(730 1000 mm and 630 1000 mm) billets are supplied from this mill to bar mill of LMMM, wire
rod mills (WRM).
 WIRE ROD MILL (WRM)

Fig-14
The Wire Rod Mill of VSP is high speed 4 strand No-Twist continuous mill designed to
produce 8,50,000 T of wire rod coils. The mill is designed to produce plain wire rods from 5.5 mm
to 12.7 mm diameter and Rebar in 8mm, 10mm and 12mm diameter in coil form. However sizes
up to 14mm are being rolled presently. Rolled billets of 125 mm x 125 mm square cross section,
length ranging from 9.8 m to 10.4 m and weighing approx 1250 kgs are used as input material.
The mill is designed to roll steel stock of 0.9% max Carbon content.
 MEDIUM MERCHANT AND STRUCTURAL MILL

Fig-15
The Medium Merchant and Structural Mill (MMSM) is one of the modern rolling mills of
Visakhapatnam Steel Plant. This is a single strand continuous mill having production capacity of 8,
50,000 T/year. The important feature of this mill is that Universal beams (parallel flange) have
been rolled first time in India using Universal stands. Parallel flange beams have advantage over
conventional beams as, for the same weight; the section is stronger and stiffer due to greater
moment of inertia and higher radius of gyration
 ROLL SHOP AND REPAIR SHOP (RS & RS)

Fig-16
Roll Shop and repair shop plays a major role in fulfilling the technological needs of all the
mills and caters in respect of Roll Pass Design, Roll redressing, roll assembles, guides, and few
maintenance spares. During Rolling, Roll passes tend to wear out and gradually lose their initial
shape resulting in the size or surface finish of the product being rolled deviated from the allowable
tolerances. This is remedied by Redressing that is by turning the rolls to restoring the width and
depth of pass to its original dimensions. The main activities are roll pass design, redressing of
rolls, new rolls turning, assembly of rolls with bearings, preparation of guides, and their service
and manufacturing or repair of mill maintenance spares. The roll pass design section designs
development of new sections, modification of existing pass designs for improving the productivity
and quality, preparation of rolling schedules, groove detail and distribution and template drawings,
part programming for grooving of rolls on CNC lathes.
 THERMAL POWER PLANT AND BLOWER HOUSE (TPP&BH)

Fig-17
VSP has a separate thermal power plant to meet substantial part of its power requirement.
The power plant also includes blower house for blowing hot air to the blast furnaces. The power
plant utilizes surplus coke oven and blast furnace gasses for heating boilers. To meet the balance
requirement of the boilers thermal coal is procured. Thus the power plant helps in reducing cost of
production of VSP.
3.2 AFTER EXPANSION:

SINTER PLANT- 3
For meeting the requirement of new Blast Furnace -3 to produce 2.5Mtpa hot metal, 1 No.
Sinter machine of 400sq.m is envisaged. The Raw materials required to produce Product sinter are
Base mix consisting of 100% iron bearing material including revert material including revert
materials, flux, coke, floating return fines and calcined lime which is fed into Blast Furnace - 3.
Considering 80% sinter ratio in the burden of new Blast Furnace, the requirement of Sinter charge
will be 3.25mtpa for production of 2.5mtpa Hot metal.
 Fig-18
Hence new sinter will receive 'Base mix' which will be prepared in bedding and blending
yard by mixing all iron bearing materials and about 80% of flux and fuel. Balance flux and fuel, as
well as calcined lime, will be added in proportioning section of sinter plant. The facilities
envisaged are -Proportionating system, Mixing and Nodulizing system, sinter Machine section and
Sinter cooler section. Sinter stabilizing section and Waste gas system. New technology -Circular
Cooler, Multi- slit burner and benefits derived are being more energy efficient and utilization of
heat recovered from Sinter cooler to pre - heat the combustion due to which energy consumption is
reduced has been incorporated in the new Sinter plant -3. Product Sinter produced in sinter plant
will be supplied to the Blast Furnace through conveyor system
BLAST FURNACE-3
To achieve the desired hot metal production of 6.5Mtpa, additional 1 no. BF is installed
with a capacity of 3800Cu.m producing 2.5mtpa. The Raw materials required for manufacturing
process are Sinter, Sized ore, Quartzite, Coke and Injection coal. Raw materials and coke from
stock yard are transported to the stock house bunkers through junction houses. The main charging
conveyor feeds the burden into the Blast Furnace. Hot stoves deliver the host blast into the Blast
furnace via bustle main and tuyers. Pulverized coal from coal grinding plant to coal distributor
which distributes the coal into individual tuyers.
 Fig-19
Inside Blast furnace, the iron ore is reduced to form iron and slag, which collects at the
hearth. From there, Hot metal and slag is periodically tapped through tap holes. Hot metal is
channelled via tilting runners into torpedo ladle cars, which carries it away. Slag is granulated in
the slag granulation plant, dewatered and subsequently carried away by a conveyor to slag storage
yard. The blast Furnace top gases enter into the dust catcher for primary cleaning and then to
annular scrubber for final cleaning. The facilities envisaged are - Stock house and Charging
system, Cooling elements and system, Cast House, Gas cleaning Plant
Hot Blast stoves, Pulverized coal Injection system, Slag Granulation and StockHouse.New
technology - Pulverized Coal Injection, Profilometer, Copper staves in high heat zones, Hearth
bottom cooling with water and benefits derived are reduced coke consumption, improved
productivity, improved process control & better campaign life. The hot metal produced (7150 tons/
day) at a temperature of 1500 degrees temp is transported to Steel melt Shop by Torpedo car.
STEEL MELT SHOP-2
Steelmaking capacity of the plant is correspondingly increased by utilizing higher
availability of Hot metal. The Raw materials required for manufacturing process are - Hot Metal,
Scrap, Flux, Ferro alloys. New Steel melts shop comprising of two (2) converters each of 150cu.m
capacity. 2Nos. Ladle Furnaces were envisaged to make the operation of the 2
 Converters independent of the requirements of continuous casting machines thereby acting
as buffer between the converter and the caster.

Fig-20
The steel temperature and steel chemistry will be humanized in LF by inert gases and 1 no.
RH degaussing system is envisaged for production of special grade with low gas contents. Three
(3) 6 strand billet mill. Three casters are available for 200 days in a year and two casters are
available for 165 days in a year. Cast Billets will be fed to new bar mill and wire rod mill.
Part of rolled billets will also be for sale. The other major facilities installed are - Hot
Metal Desulphurization Plant, Scrap Handling system, BOF Gas cleaning Plant, Secondary
Emission control, Ferro alloy Handling Facilities, Ladle &tundish predation facilities. New
technology -Converter Shop - Combined Blowing, Secondary Fume Extraction system, Contour &
bath level measurement and benefits derived are reduced consumption of ferroalloys, better yield
andquality, Cleaner environment and measurement of refractory lining. Continuous casting
Machines - Auto mould level control & 100% Billet casting and benefits derived are reduced in
break outs and energy saving. LF & RH -Electromagnetic stirrer and benefits derived are cleaner
steel. Provision is made and tendering activities for award of Consultancy is in process for
installation of 3rd converter and 4th caster.
 WIRE ROD MILL-2
The mill will produce 6 ltpy of plain rounds in coil form. The wire rod size will be in range
of 5.5 to 20 mm (dia). Provision is kept for the mill for producing 7.7 ltpy on the market demand.
The rolling mill will use the cast billets of size 150 x 150 mm having length of about 12 m and
rolled billets of size 125 x 125 x 9.7 to 10.2 M. The mill will roll Low carbon (85,000 tons/ yr.),
Medium carbon (93,000 tons/yr), High carbon (93,000 tons/yr.), spring steel (25,000 tons/yr), cold
heading (1,34,000 tons/yr), welding rod (85,000 tons/yr), Bearing steel (25,000 tons/yr), Free
cutting steel (35,000 tons/yr) and case hardening (25,000 tons/yr.).

Fig-21
The billet will be charged into 200 ton /hr. capacity reheating furnace one by one. The
0
billets after heated up to 1200 C will be discharged. The billets will be rolled down in the
breakdown mill and passes through pre-finishing mill. The finished product will come out of
reducing and sizing mill in coil form.
SPECIAL BAR MILL
The special bar mill will produce about 750,000 tons per year of plain rounds in straight
length and in coil form. The bar size shall be in the range of 16 mm to 40 mm. Provision will be
kept in the mill for producing 900,000 tons per year of special bar when the market demand
increases. The mill will roll medium and high carbon steel, case hardening steel, cold heading
quality steel, electrode steel, spring steel, bearing steel and free cutting steel.
The mill shall use continuous cast billets of 150 mm square size and 12 m length.
Considering the yield of 96% for losses due to scale, shear cropping, cobbles etc. the requirement
of billets for producing 750,000 tons of bar shall be about 781,000 tons.
 STRUCTURAL MILL
The structural mill will produce about 700,000 tons per year of light structurals in straight
length. The Structural Mill shall be able to produce wide range of products inclusive of plain
round, rebars, semis, besides structurals and product-mix of the mill shall have to be decided
depending upon the market demand and supply patterns at the time of implementation. Provision
will be kept in the mill for producing 850,000 tons per year of structurals when the market
demand increases. The mill will roll constructional steel conforming to standards of structural
products.
The mill shall be operated in 3 shifts per day and 300 days in a year. Operation of about
5000 hours shall be considered for producing 850,000 tons per year at an average production rate
of 170 tons per hour. The mill shall use continuous cast billets of 200 mm square size and 6 m
length. Considering yield of 92.0% for losses due to scale, shear cropping, cobbles etc the
requirement of billets for producing 700,000 tons of bar shall be about 761,000 tons
 CHAPTER - 4
AREA OF STUDY
4.1 TYPES OF FURNACES:
A furnace is an equipment to melt metals for casting or heat materials for change of shape
(rolling, forging etc) or change of properties (heat treatment).
TYPES AND CLASSIFICATION OF DIFFERENT FURNACES:
Based on the method of generating heat, furnaces are broadly classified into two types
namely combustion type (using fuels) and electric type. In case of combustion type furnace,
depending upon the kind of combustion, it can be broadly classified as oil fired, coal fired or gas
fired.
a) Based on the mode of charging of material furnaces can be classified as (i) Intermittent or
Batch type furnace or Periodical furnace and (ii) Continuous furnace.
b) Based on mode of waste heat recovery as recuperative and regenerative furnaces.
c) Another type of furnace classification is made based on mode of heat transfer, mode of
charging and mode of heat recovery as shown in the Figure below.

Fig-
22
TYPES OF CONTINUOUS REHEATING FURNACE:
Continuous reheating furnaces are primarily categorized by the method by which stock is
transported through the furnace. There are two basic methods:
a) Stock is butted together to form a stream of material that is pushed through the furnace.
Such furnaces are called pusher type furnaces.
 b) Stock is placed on a moving hearth or supporting structure which transports the steel
through the furnace. Such types include walking beam, walking hearth, rotary hearth and
continuous recirculation bogie furnaces.

The major consideration with respect to furnace energy use is that the inlet and outlet apertures
should be minimal in size and designed to avoid air infiltration.
WALKING BEAM FURNACES
The walking beam furnace overcomes many of the problems of pusher furnaces and
permits heating of the bottom face of the stock. This allows shorter stock heating times and
furnace lengths and thus better control of heating rates, uniform stock discharge temperatures and
operational flexibility. In common with top and bottom fired pusher furnaces, however, much of
the furnace is below the level of the mill; this may be a constraint in some applications. Its figure
is as shown.

Fig-23
4.2 WALKING BEAM FURNACE OF MMSM:
Walking Beam Furnace heat the steel blooms, casted in CCD, to the rolling
temperature of 1200C. Two pushers push the bloom into the furnace from the bloom charging
side. Blooms travel on skid pipes through heating zones and then solid hearth in soaking zones.
The furnace has five zones out of which three are called heating zones and two are soaking zones.
There are in total 59 burners. The combustion air is preheated to 450-500C in air recuperator and
gase is preheated to 350-400C in gas recupurator. Flue gases are used for preheating the
combustion air before being exhausted to the atmosphere through chimney. Finally, the flue gases
are exhausted out through the stack. Furnace pressure in soaking zone is maintained positive.
Control and measuring instruments required to control furnace pressure and temperature as well as
efficient fuel utilization are provided. Evaporative Cooling System (ECS) is used for skid pipe
cooling during which waste heat steam is produced.

Fig-24
MMSM is equipped with two, top and bottom fired walking beam type reheating furnaces
each having a capacity of 130T/hr. Walking Beam Furnaces will be utilized to reheat the blooms of
250mm thick x 250mm width x 6000mm long in two rows to 1200C. The stock will travel
through the furnace by means of walking and stationery beams, properly lined, which will be
cooled by means of an ECS producing steam.
FURNACE DIMENSIONS
Table:-1
Centerline distance between charging and 25,500mm
discharging
roller tables
Overall width of the furnace 14,510mm
Inside length of the furnace(from charging to the 21,700mm
discharging door)
Maximum effective length 20,700mm
Inside width(wall to wall) 13,500mm
Maximum effective width 13,000mm
Maximum effective area 240m2
Upper level of the rollers and skid tubes 1060mm
Pit lower level 8,400mm
 Top level of the stack 80,000mm
Bloom size 250*250mm
Furnace hearth output 0.5T/m2.hr

ZONAL HEATING SYSTEM

In the furnace, the temperature is maintained variable along the furnace length, so it is said
to operate in zonal mode. Thermal stresses that appear in metal being heated shouldnt exceed a
certain tolerable level. If the body being heated is massive thermally, sharp rise in temperature
may result in excessive temperature gradient. For that reason massive metal bodies are heated
slowly and gradually until the metal becomes plastic enough. This is done by properly heating the
metal in various zones:
1) PREHEATING ZONE, the cold metal is gradually heated up, while going inside the
furnace after pushing the bloom with the pusher.
2) HEATING ZONE, metal is heated until its surface has the specified final temperature,
3) SOAKING ZONE, the temperature of the surface remains constant, but temperature is
equalized across the metal.

The metal is charged into a zone having the lowest temperature and when moving in the
direction opposite to that of the waste gas it is gradually heated up. In the preheating zone, first in
the path of the metal, the metal is gradually heated before entering a high temperature zone. The
metal should be always heated from 40C to 550C in order to avoid excessive thermal stresses.
The total drop of temperature of waste gases is appreciable. The high temperature zone is divided
into two zones to increase the total temperature level and productivity. Here the surface of the
blooms is heated quickly to the final temperature. The temperature of metal heating is usually up
to 1200C. The soaking zone is the second in the path of the metal and serves to equalize the
temperature over the cross-section of the metal blooms. The temperature in the soaking zone is
maintained at a level of 30-50C above the desired temperature of metal heating. The temperature
of metal surface in that zone remains essentially unchanged and only temperature equalization
over the cross-section of blooms takes place.
With bottom heating metal blooms are moved on (water cooled) skid pipes laid along the
surface bottom. As the cooling effective of the skid pipes is considerable, more heat must be
supplied into the bottom portion of the heating zone. Skid pipes are usually provided in the
preheating, heating and soaking zones. To protect skid pipes from abrasion by sliding blooms,
they are provided with metal pads welded at their tops.
 HEAT GENERATION
TYPE OF FUEL: MIXED GAS
Mixed gas is used as a fuel for heat generation in the furnace. Mixed gas is the combination
of blast furnace gas, coke oven gas and LD converter gas in the ratio of 1.15:0.89:1.Calorific value
of mixed gas is 2369Kcal/Nm3.
GAS BURNERS
Fuel burning devices, burners convert the chemical energy of fuel into thermal energy. The
main purpose of the gas burners is to provide the specified economically favorable conditions of
furnace operations. To serve this purpose, a burner should ensure the following:
1) The supply and mixing of gaseous fuel and air in the required amounts.
2) Complete combustion of the fuel within the working space of the furnace.
3) The formation of a flame that can ensure the required level of heat transfer in the furnace
space.

There are two types of burners installed in the RHFFlame burners and Long flame
burners. The Flat/Short flame burners are of Forced Air and Gas nozzle mixed type. Combustion
air is supplied at high speed to an eccentrically piping resulting in a spin action. This whirling
pulse, together with the special design of the tile, results into fuel developed in to a flame all
around the tile and perpendicular to the axis. A turn down ratio [TDR refers to the ratio of
maximum burner output to the minimum burner output. The TDR strikes the balance between the
capability of the fuel burner neither to allow the lift off of the flame (due to high output) nor create
back firing/ flashback (due to low output)] of 10:1 is general maintained for these burners. In this
method of roof firing almost all burners are arranged in the furnace roof. They serve to heat the
internal surface of the roof up to 1400C so as to ensure the maximum possible radiation from the
roof surface on to the meat being heated.
The Long Flame Burners are small in size and are used for bottom heating in the hearth of
the furnace. When fired on rich gas the TDR is 8:1. A total of 16 burners are aligned in the zone to
provide a temperature up to 1200C-1250C in the hearth. The main feature of these burners is
outside mixing; the gas and air are supplied via separate channels in the burners and mixed only at
the burner outlet in the furnace space.

BURNERS ARRANGEMENT IN THE FURNACE

Table: - 2
 Name of the zone Number of burners

Top heating 12(Roof burners)

Top heating 12(Roof burners)

Bottom heating 8(Front burners)

Top soaking 18(Roof burners)

Bottom soaking 9(Front burners)

ENERGY GENERATION IN REHEATING FURNACE

There are two stages in heat transfer:
1) The heat is transferred from the heat carrier (flame) to the surface of material. This heat
transfer is mainly through thermal radiation and convection.
2) Subsequently the heat transferred from the surface into the depth of the material by
conduction.

In the convective mode of heat transfer, heat is transferred due to the bulk movement of gas
over the gas and is caused by the physical movement of molecules by virtue of density difference
between them. The air requirements for combustion is met by combustion air blower which has
been envisaged for each furnace with an additional combustion air blower as stand by for both the
furnaces in order to allow continuous supply.
Convective heat transfer is suppressed by radiative heat transfer who takes place between
the combustion products and the stock, as well as between the furnace refractory and the stock.
The amount of heat reaching the stock surface from the total radiated heat transfer mainly depends
on the relative geometry of the wall and the stock surfaces.
 Fig-25 Mode of heat transfer in the furnace
DISTIRBUTION OF HEAT IN A FURNACE:
Most of the heat is released in the combustion zone at the left and travels from there to the right.
The heat thus liberated should be absorbed by
1) The charge, which is most desirable. But the heat also goes elsewhere; some of it is passed
into the furnace and into the hearth.
2) Another portion of the heat is lost to the surroundings by radiation and convection from the
outer surface of the walls or by convection into the ground.
3) Heat also passes through cracks or other openings and furnace gasses pass out around the
floor.
4) Heat radiates away from the door when opened.
5) A major quantity of heart goes out of the furnace chamber with the hot flue gases, as
potential as well as sensible heat due to incomplete combustion.

The furnaces are equipped with air recuperators for preheating the air required for
combustion. Products of combustion from the furnaces during their passage through underground
flue will pass through recuperates leading to a chimney.

4.3 COMBUSTION CHARACTERISTICS:

COMBUSTION THEORY
 Combustion is a process of interaction between fuel and oxygen accompanied by liberation
of heat and sometimes emissions of light. In the overwhelming majority of cases, the oxidizer is
atmospheric oxygen. Any combustion implies oxygen and fuel brought in contact so that the
combustion takes place in two stages
1) Mixing of both these constituents, and
2) Evolution of heat from the combustion reaction.

GASEOUS FUELS
In general fuels such as gas, oil, coal are used in industries. Steel plants use secondary fuels
such as Coke Oven gas, LD Gas, and BF Gas in a particular proportion so that the following
advantages are derived
1) The gas as a fuel can be produced at one point, say coke oven plants or BF and easily
distributed to utility points through pipelines.
2) Remote and instant control of combustion is possible from mixing stations.
3) Smoke and disposal difficulty are eliminated thus is the hygiene is also maintained.
4) Low grade slid fuels can be successfully used by gasification in steel production which
otherwise need superior quality fuels.
5) Complete combustion without pollution is possible due to uniform mixing of air and
gaseous fuel.
6) The use of gaseous fuel as by products proves economical and is an important ingredient in
energy conservations is steel plants.

In case of VSP, the BF, Coke Oven and LD Converter liberate huge amount of flue gases
used for all types of furnaces in the plant. The correct proportion is mixed in the gas mixing station
based on the production rate of these gases and the CV of the mixed gas desired. Normally, the
proportion is 1.15:0.89:1 as CO, BF and the LD gas respectively which gives a CV of 2369Kcal/hr.
COMBUSTION PROCESS
Heterogeneous combustion and Homogeneous combustion are the two types of combustion
distinguished. The Heterogeneous combustion involves Heat and Mass transfer between bodies in
different states of aggregation, for instance, combustion between a natural gas and a solid fuel. In
Homogeneous combustion the process of Heat and Mass transfer occurs between bodies in the
same state of aggregation, for instance, where mixed gas and air are used as combustion inputs.
The degree of mixing of fuel gas and air is controlled by burner design. In the present case the
burners are both short flame and long flame. The requirements for combustion are fuel oxygen and
the three Ts namely time for combustion, temperature of ignition, and turbulence for fuel air
mixture.
REQUIREMENT OF THEORITICAL AIR AND EXCESS FOR COMBUSTION
 For the combustion the common oxidizer is air. Air is roughly a mixture of 21% oxygen
and 79% nitrogen on volume basis. That means one k mole of oxygen is accompanied by 3.76k
mole of nitrogen. The minimum amount of air required for the complete combustion of a fuel is
called the theoretical air or stoichiometric air. But in practice it is difficult to achieve complete
combustion with theoretical quantity of air and therefore fuels are supplied with excess air to burn
it completely. Hence the air supplied in excess of the air requirement is called the excess air and is
expressed as a percentage of theoretical air.
EXCESS AIR = (Actual Air- Theoretical Air)/Theoretical Air*100

LOSSES DUE TO EXCESS AIR

A combustion process with high excess air increases the amount of fuel gas going the
stack. When we reduce this excess air, we reduce the volume of flue gas and the hot gases spend
more time in contact with the heat transfer surfaces. This reduces the exit flue gas temperature. If
we supply too little air, combustion is incomplete and results in the formation of carbon monoxide
which can be visible by smoke and particle emission. Supply of too much air results in higher
stack losses and other problems such as high due point temperature depending on the fuel being
used. The aim to supply just enough air to burn all the fuel and then maintain this high combustion
efficiency by controlling the air/fuel ratio.
TEMPERATURE
1. IGNITION TEMPERATURE:

Before the fuel can burn in the presence of sufficient air, the temperature of air/fuel mixture
must be high enough to start the combustion. This is called the ignition temperature.
2. FLAME TEMPERATURE:

This is the highest temperature produced in combustion. Flame temperatures of most fuels
are in the range of 1850-2100C.
3. THEORETICAL FLAME TEMPERATURE:

It is the temperature attained by the product of combustion gas when it is burnt with
theoretical quantity of air and no heat loss of air is allowed to the surrounding. The actual flame
temperature is however less due to the fact that fuels are burnt with excess air and heat is lost to
the surroundings.
The flame temperature of fuel depends upon:
a. Calorific value of the gas.
 b. Volume and specific heat of total gaseous products.
c. Losses by radiation.
d. Latent heat in steam in the combustion products.
4.4 CHARACTERISTICS OF AN EFFICIENT FURNACE:

Furnace should be designed so that in a given time, as much of material as possible can be
heated to a uniform temperature as possible with the least possible fuel and labour. To achieve this
end, the following parameters can be considered:
a. Determination of the quantity of heat to be imparted to the material or charge.
b. Liberation of sufficient heat within the furnace to heat the stock and overcome all heat
losses.
c. Transfer of available part of that heat from the furnace gases to the surface of the heating
stock.
d. Equalization of the temperature within the stock.
e. Reduction of heat losses from the furnace to the minimum possible extent

CHAPTER - 5
COOLING SYSTEMS IN FURNACE

COOLING SYSTEMS:

There are 3 basic types of cooling systems that you can choose from to meet the cooling
needs of your load. Each one has its strengths and weaknesses. This article was written to identify
the different types of cooling systems and identify their strengths and weaknesses so that you can
make an informed choice based on your needs.
5.1DIFFERENT TYPES OF COOLING SYSTEM:
a) In direct cooling system
b) Direct cooling system
c) Evaporate cooling system
a) In direct cooling system:

The in direct cooling system is used to cooling the indirect systems include intermediate
liquid for transportation of cooled fluid between refrigeration equipment and process. Indirect:
With indirect cooling, the water is re-used repeatedly by being recycled in a closed loop system.
The cooling media does not come into direct contact with the product, so no dust or emissions are
created. This eliminates the need for pollution control equipment and makes tight emission limits
easier to meet. In addition, indirect bulk solids cooling minimize product abrasion and
degradation. For example doors, lintels, lasers, cameras etc.

b) Direct cooling system:

Direct cooling systems, heat transfer directly volatile refrigerant.Direct cooling of bulk
solids results in high emissions. Using air to cool bulk solids is a once-through proposition. Air
is taken in, chilled, passed across the product, and must then be disposed of through a stack. The
large quantity of air required for direct cooling results in a large quantity of dust and emissions.
Permits for stacks are becoming more difficult to acquire, and with ever-tighter pollution controls,
emissions must be cleaned and scrubbed before being dumped into the atmosphere. For example
conveyors, rollers etc.

c) Evaporative cooling system:

In evaporative cooling, hot water at boiling temperature is fed from a steam drum to the
cooling components. Because of the heat energy to be absorbed by the cooling components, a part
of the water is evaporated at almo9st constant temperature.
The steam/water mixture returning to the steam drum is separated into saturated steam and
water. The steam is drawn from the drum and the water is available for recirculation. Consequently
in evaporative cooling, at normally constant pressure in the seam drum, every point of the circuit
has a constant temperature independent of the respective heat load. For example skids, posts etc.
Advantages:
The advantages of using water cooling over air cooling include water's higher specific heat
capacity, density, and thermal conductivity. This allows water to transmit heat over greater
distances with much less volumetric flow and reduced temperature difference.
 CHAPTER - 6
ABOUT ECS SYSTEM
6.1 INTRODUCTION:
In evaporative cooling, also called steam or vapour cooling, the temperature of cooling
water is allowed to reach a temperature of 100oC.
This method of cooling utilizes the high latent heat of water to obtain cooling with
minimum of water the cooling circuit is such that the coolant is always liquid but the steam formed
is flashed of in a separate vessel. The makeup water so form is sent back for cooling.
PRINCIPLE:
The principle underlying evaporative cooling is the fact that water must have heat applied
to it to change from a liquid to a vapour. When evaporation occurs, this heat is taken from the
water that remains in the liquid state, resulting in a cooler liquid.
CONCEPT BEHIND ECS:
1) In evaporative cooling, hot water at boiling temperature is fed from a steam drum to the
cooling components. Because of the heat energy to be absorbed by the cooling
components, a part of the water is evaporated at almost constant temperature.
2) The steam/water mixture returning to the steam drum is separated into saturated steam and
water. The steam is drawn from the drum and the water is available for recirculation.
Consequently in evaporative cooling, at normally constant pressure in the seam drum,
 every point of the circuit has a constant temperature independent of the respective heat
load.
3) On the other hand, in hot water cooling the heat energy to be absorbed by a cooling
component is used to increase the temperature of the water flowing through it, In such
circuits it must in any case be ensured that at every point of the cooling system the water
has a lower temperature than the boiling temperature corresponding to the pressure. If this
condition is not achieved, there will be local generation of steam, which can lead to
damages.
4) Furthermore, hot water cooling requires guaranteed removal of the heat energy from the
water circuit by means of a heat exchanger, In case of emergency the heat energy cannot be
vented to atmosphere not even for short periods of time-as it would be possible with
evaporative cooling.

Compared with other cooling systems the evaporative cooling has a further substantial advantage;
to absorb and transfer much higher heat amounts.
Fig-26
6.2 WORKING OF THE SYSTEM:

The Major Components of ECS are the steam drum where hot water around 95 to 100 C
exists in the drum along with the steam. The working pressure of drum is around 13 to 15 bars thus
acting as boiler.
This hot water is circulated to the furnace skids for cooling purpose through recirculating
centrifugal pumps. There are three such pumps in which one is electric motor driven and
the other two are steam turbine driven. In case the power gets shut down unavoidable
circumstances the steam turbine coupled with the pump starts automatically to circulate
water to the skids.
Hot water after passing through the furnace skids(which is around 1200 C),the latent heat
of vaporization by which it partially converts into steam and returns back to steam drum,
where the steam and water gets separated . The amount of water converted into steam is
compensated by the feed water supplied by DMDA (De-Mineralized, De-Aeration) plant
through multistage centrifugal pumps. The steam produced in the system can be utilized by
supplying it to the steam network or to drive the steam turbine.
There are two pressure relief valves and an exhaust valve for relieving the excess steam
pressure, when the pressure in the steam drum exceeds permissible value (which is around
17 bar).There is a dosing drum connected with pipe network for maintaining a constant ph
around 7.5 by adding chemicals periods sampling of drum water is done for regularly
monitoring the specified standards of boiler water.

FORCED CIRCULATION OR NATURAL CIRCULATION:

In forced circulation the circuit is maintained by recirculation pumps. Forced circulation
can be used for all types of hot cooling. Natural circulation, however, is only possible in
evaporative cooling, whereby the steam drum must always be installed above the cooling
components.
In the down comers (between steam drum and cooling components) there is always water
of a substantially higher specific weight than that of the steam/ water mixture in the risers
(between cooling components and steam drum).
In this way sufficient lifting force is generated for maintaining the necessary water
circulation.

6.3 SPECIFICATIONS OF THE SYSTEM:

Recirculated water for fixed skids& posts:
Flow rate - 200 m3/hr
 Temperature - 2010C
Pressure - 24.5 bar
Heating surface - 2x31.5 m2 (skids), 4x9.2 m2 (posts)
Recirculated water for moving skids & posts:
Flow rate - 228 m3/hr
Temperature - 2010C
Pressure - 24.5bar
Heating surface - 2x43.5m2 (skids), 2x19m2 (posts)

CIRCUIT DIAGRAM OF ECS DRUM/BOILER:

 Fig-27

Fig-28
STEAM DRUM SPECIFICATIONS:
Working pressure - 15 to 17 bar
Working temperature - 201 to 207C
Volume - 12 m3
Dimensions - 1600 mm
Length 6000 mm
Blow off flow rate - 1.3 m3/hr
Saturated steam blow off rate (capacity) - 13.2 T/ hr
Effective pick up pressure - 17 bar
Feed water:
Flow rate - 13m3/hr
Temperature - 105C
Pressure available - 23.5 bar
Steam at drum inlet:
Flow rate - 4.5 to 9 T/hr
Temperature - 201 to 207C
Pressure in drum - 15 to 17 bar
Available steam pressure - 12 to 15 bar
ECS DRUM:

Fig-29
DMDA STATION FOR MMSM:
 Fig-30

DMDA (De Mineralization and De Aeration) PLANT:

The De mineralized and De aerated water required by the Evaporative Cooling System
(ECS) in rolling mills is supplied from DMDA plant. The plant also serves the needs of other
departments like Thermal Power Plant (TPP), Coke ovens and Steel Melting Shop (SMS).
REQUIREMENT FOR FEED WATER AND BOILER WATER:
Feed water:
General requirement - Clear and colourless
PH value (at 25C) - 8.3 to 9.5
Total hardness - < 1mg/kg (as CaCo3) = 0.02 mval/kg
Oil - < 0.5 mg/kg
Oxygen - < 0.02 mg/kg
CO2 (combined) - < 25 mg/kg
CO2 (free) - undetectable
Fe (total) - < 0.05 mg/kg
Cu (total) - 0.01 mg/kg
KMnO4 (consumption) - < 10 mg/kg
Conductivity (at 20 C) - < 130 mg/kg (as NaCl) =250 mho/cm
Cl- - < 10 mg/kg
SiO2 - < 1 mg/kg
Boiler water
P value - < 90 mg/kg (as CO32-) = 3 mval/kg
SiO2 - <10 mg/kg
PO43- - < 15 mg/kg
Conductivity (at 20C) - < 1300 mg/kg
Cl- - < 100 mg/kg
The continuous blow down is assumed as 10 %. If demineralised feed water is used, the
continuous blow down may be zero.
ECS STATION PUMP WITH MOTOR:

Fig-31
Collection of pump data:
No of stages : 1
Pump size & type : 8 HNN 194(Centrifugal pump)
Speed : 1460 rpm
Max head : 87 m
Suction pressure : 18 bar
Discharge pressure : 22.5 to 24.5 bar
Differential head : 77 m
Differential Pressure : 6.5 bar
Pumping temp : 201 to 2070C
Liquid type : Boiler feed water
Discharge rate : 480 to 600 m3/hr
Pump supplier : Flow Serve, France
ECS STATION PUMP WITH STEAM TURBINE:

Fig-32
Collection of Turbine data:
Pump supplier : Dresser, France
Turbine model : 703 T
Speed governor : Mechanical /Wood ward
No of stages : 1, Curtis model (Impulse turbine)
Normal turbine power : 134 KW
Speed : 1470 rpm
Pressure (inlet) : 15 bar
Temperature at inlet : 180 to 3000C
Exhaust pressure : Atmosphere

This turbine used during the no electrical power condition and during start and stop of the
furnace (heating up to 8000C or below 8000C water and vapour got more load on the motor). But
this turbine can handle the same load. Later existing motor capacities were increased from 132
KW to 160 KW for better working of the system.
 CHAPTER - 7
DATA COLLECTIONS
PUMPS:
Pumping is the process of addition of kinetic and potential energy to a liquid for the
purpose of moving it from one point to another. This energy will cause the liquid to do work such
as flow through a pipe or rise to a higher level.
A centrifugal pump transforms mechanical energy from a rotating impeller into a kinetic
and potential energy required by the system. The most critical aspect of energy efficiency in a
pumping system is matching of pumps to loads.

TYPES OF PUMPS:

1) Positive displacement
2) Non positive displacement
1) POSITIVE DISPLACEMENT:
Positive displacement is defined as the pump that which dont have any minor losses for
example gear pump, vane pump, piston etc.,
2) NONE POSITIVE DISPLACEMENT:

Non positive displacement is define as the pump that which has minor losses is called as
none positive displacement. For example centrifugal pump

CENTRIFUGAL PUMPS:
A centrifugal pump is of a very simple design. The two main parts of the pump are the
impeller and the diffuser. Impeller, which is the only moving part, is attached to a shaft and driven
by a motor. Impellers are generally made of bronze, polycarbonate, cast iron, stainless steel as well
as other materials. The diffuser (also called as volute) houses the impeller and captures and directs
the water off the impeller.
Water enters the center (eye) of the impeller and exits the impeller with the help of
centrifugal force. As water leaves the eye of the impeller a low-pressure area is created, causing
more water to flow into the eye. Atmospheric pressure and centrifugal force cause this to happen.
Velocity is developed as the water flows through the impeller spinning at high speed. The water
velocity is collected by the diffuser and converted to pressure by specially designed passageways
that direct the flow to the discharge of the pump, or to the next impeller should the pump have a
multi-stage configuration.

Fig-33
The pressure (head) that a pump will develop is in direct relationship to the impeller
diameter, the number of impellers, the size of impeller eye, and shaft speed. Capacity is
determined by the exit width of the impeller. The head and capacity are the main factors, which
affect the horsepower size of the motor to be used. The more the quantity of water to be pumped,
the more energy is required.

A centrifugal pump is not positive acting; it will not pump the same volume always. The
greater the depth of the water, the lesser is the flow from the pump. Also, when it pumps against
increasing pressure, the less it will pump. For these reasons it is important to select a centrifugal
pump that is designed to do a particular job.
Since the pump is a dynamic device, it is convenient to consider the pressure in terms of
head i.e. meters of liquid column. The pump generates the same head of liquid whatever the
density of the liquid being pumped. The actual contours of the hydraulic passages of the impeller
and the casing are extremely important, in order to attain the highest efficiency possible. The
standard convention for centrifugal pump is to draw the pump performance curves showing Flow
on the horizontal axis and Head generated on the vertical axis. Efficiency, Power & NPSH(Net
positive Suction Head) required (described later), are also all conventionally shown on the vertical
axis, plotted against Flow, as illustrated in Figure
PUMP PERFORMANCE CURVE:

M
E
T
S
Y
S

Fig-34
Given the significant amount of electricity attributed to pumping systems, even small
improvements in pumping efficiency could yield very significant savings of electricity. The pump
is among the most inefficient of the components that comprise a pumping system, including the
motor, transmission drive, piping and valves.
Field testing for determination of pump efficiency:
To determine the pump efficiency, three key parameters are required: Flow, Head and
Power. Of these, flow measurement is the most crucial parameter as normally online flow meters
are hardly available, in a majority of pumping system. The following methods outlined below can
be adopted to measure the flow depending on the availability and site conditions.
Determination of total head (H):
Suction head (hs):
This is taken from the pump inlet pressure gauge readings and the value to be converted
2
in to meters (1kg/cm = 10. m). If not the level difference between sump water level to the
centreline of the pump is to be measured. This gives the suction head in meters.
Discharge head (hd):
This is taken from the pump discharge side pressure gauge. Installation of the pressure
gauge in the discharge side is a must, if not already available.
Measurement of motor input power:
The motor input power Pm can be measured by using a portable power analyser.

Pump Efficiency:
Fluid power and useful work done by the pump divided by the power input in the pump shaft.

Hydraulic power (P )
Pump Efficiency = h X 100
Power input to the pump shaft (PS)

Where:
Hydraulic power Ph (KW) = Q x (hd - hs) x x g / 1000
3
Q = Volume flow rate (m /s),
3
= density of the fluid (kg/m ),
2
g = acceleration due to gravity (m/s ),
(hd - hs) = Total head in metres

PUMP OPERATING POINT:

When a pump is installed in a system the effect can be illustrated graphically by
superimposing pump and system curves. The operating point will always be where the two curves
intersect.

Fig-35
 If the actual system curve is different in reality to that calculated, the pump will operate at
a flow and head different to that expected. For a centrifugal pump, an increasing system resistance
will reduce the flow, eventually to zero, but the maximum head is limited as shown. Even so, this
condition is only acceptable for a short period without causing problems. An error in the system
curve calculation is also likely to lead to a centrifugal pump selection, which is less than optimal
for the actual system head losses. Adding safety margins to the calculated system curve to ensure
that a sufficiently large pump is selected will generally result in installing an oversized pump,
which will operate at an excessive flow rate or in a throttled condition, which increases energy
usage and reduces pump life.
 CHAPTER - 8
CALCULATIONS OF PUMP EFFICIENCY
FORMULA:
Hydraulic power (P )
Pump Efficiency = h X 100

Power input to the pump shaft (PS)

Motor Input Power (PS) = x Vx I x cos

For furnace 1:
Total flow (Q) = walking beam flow + fixed beam flow
3
= (294.5 + 275.3) m /h---COLLECTED FROM CONTROL PULPIT
3
= 569.8 m /h
3
= 0.1582 m /s
3
Density of the fluid (p) = 856 kg/m
2
Acceleration due to gravity (g) = 9.81 m/s
Total Head (H) = 77 m (Given)
Motor Current (I) = 215 A (Collected)
Motor Input Power(Pm) = 160 KW (Given)
Voltage (V) =440 V
Power Factor/ cos = 0.8

Motor Input Power (PS) = x Vx I x cos

Efficiency of Motor Motor = 88 %

Now,
Hydraulic power (Ph) = Q x (hd hs) x x g / 1000
= 0.1582x77x856x9.81 /1000
= 102.29 KW

Motor input power (PS) = x Vx I x cos

= x 440 x 215 x 0.8

= 131 KW
 Hydraulic power (P )
Pump Efficiency = h X 100

Power input to the pump shaft (PS)

Pump efficiency =

= 78 %
For furnace 2:
Volume flow rate (Q) = walking beam flow + fixed beam flow
3
= (274.4 + 239.3) m /h--- COLLECTED FROM CONTROL PULPIT
3
= 513.7 m /h
3
= 0.1426 m /s
3
Density of the fluid (p) = 856 kg/m
2
Acceleration due to gravity (g) = 9.81 m/s
Total Head (H) = 77 m (Given)
Motor Current (I) = 210 A (Collected)
Motor Input Power (Pm) = 160 KW (Given)
Voltage (V) = 440 V
Power Factor/ cos = 0.8

Motor Input Power (PS) = x Vx I x cos

Efficiency of motor Motor = 88 %

Now,
Hydraulic power (Ph) = Q x (hd hs) x x g / 1000
= 0.1426x77x856x9.81 /1000
= 92.2 KW

Motor input power (PS) = x Vx I x cos

= x 440 x 210 x 0.8

= 128 KW
Hydraulic power (P )
Pump Efficiency = h X 100
 Power input to the pump shaft (PS)

Pump efficiency =

= 72 %
As per above calculation we found furnace-1 is running better than furnace-2. It may be
due to life of the pump and other losses in the pipelines.

CHAPTER - 9
CONCLUSIONS
During our study of mill furnace cooling system i.e. water cooled and evaporative cooling
system it was found that both the systems have their own advantages and disadvantages. In our
pump performance calculation shows that both the furnace ECS systems are running well.
However some difficulties arise while handling the Evaporative Cooling System (ECS), they are
as follows.
1) The generated steam in ECS system is of poor quality due to the presence of moisture.
Hence it cannot be directly used to run the prime movers such as turbines.
2) From maintenance point of view handling steam and other machines such as turbines is
very complicated. Spare used for this system fallow the Indian boiler act.(IBR)
3) A highly skilled operator with sound knowledge of the systems is needed to handle ECS.
4) The initial cost of setup is very high and the cost of spares is very high due to Original
Equipment Manufacturer (OEM).
5) Frequent interruptions due to steam leakages.
As per our study, if all the factors like DMDA station maintenance, ECS system
maintenance, utilisation and generated steam and lesser space consumption may result in a better
use of ECS rather than Indirect Cooling Water (ICW) system.
Finally we conclude that in the present industrial environment ICW system is much more
feasible. So we are suggesting that ECS system to be converted into ICW to solve the above
mentioned difficulties.
 CHAPTER - 10
BIBLIOGRAPHY

1) Stein Hurtey Manual OEM of RHF, France

2) Literature of Energy Management Dept.VSP
3) Operator manual of K-3 pulpit ,MMSM Dept
4) Log books of mechanical shift/In charge, MMSM Dept
5) Er. R.K. RAJPUT, A Textbook of Thermal Engineering, Published by Laxmi Publications
(P) Ltd. In the year 2013.