Zero bolt failure in steel making

ROLL- NO:-11115175

B.TECH(ME)
BY DIPANKER JHA

Q.1 How to make iron in the

blast furnace.?

1.
2.
3.

1.

Ans : - For making the iron there are three raw materials are used.
Hematite
Lime stone
Coal
Hematite :Hematite is themineralform ofiron oxide(Fe2O3), one of
severaliron oxides. Hematite crystallizes in therhombohedra lattice
system, and it has the samecrystalstructure aslimoniteandcorundum.
Hematite and limonite form a completesolid solutionat temperatures
above 950C (1,740F).
Hematite is a mineral, colored black to steel or silver-gray, brown to
reddish brown, or red. It isminedas themain ore of iron.

2. Limestone :Limestone is asedimentary rockcomposed largely of

themineralscalciteandaragonite, which are differentcrystal
formsofcalcium carbonate(CaCO3). Most limestone is composed of
skeletal fragments of marine organisms such ascoralorforaminifera.
Limestone makes up about 10% of the total volume
of all sedimentary rocks. Limestone has numerous uses: as abuilding
material.

3.

Coal :coalis acombustibleblack or brownish-blacksedimentary

rockusually occurring inrock stratain layers or veins calledcoal
bedsorcoal seams. The harder forms, such asanthracite coal, can be
regarded asmetamorphic rockbecause of later exposure to elevated
temperature and pressure. Coal is composed primarily ofcarbonalong
with
variable
quantities
of
other
elements,
chieflyhydrogen,sulfur,oxygen, and nitrogen.
Coal has been used as an energy resource. Coal is the largest source of
energy for thegeneration of electricityworldwide, as well as one of the
largest worldwideanthropogenicsources ofcarbon dioxide releases.

Iron making process in the

blast furnace .
Working :
When we supply the raw material (hematite,
lime stone, coal ) continuosly through the
top of the blast furnace.

Then oxygen is blown into the furnace then

the coal is completely burnt into carbon
dyoxide due to carbon percentage is
available into the coal, it is known as
exothermic reaction therefore lots of heat
energy is produced that is almost 1700.

when the carbon dioxide (CO) is raises up it reacts with the carbon
percent in the coal which is being fed from the top of the furnace and
this carbon dioxide (CO) is converted into carbon monoxide (CO) .
And two more reaction also taking place in the middle zone of the
furnace.

Now the calcium carbonate (CaCO) or lime stone is decomposes

into lime and CO.

Now this lime reacts with the silica percent in the hematite or iron
ore as impurity to form calcium silicate (CaSiO).so therefore in the
middle zone calcium silicate is formed.

Carbon monoxide is reacts with the iron ore(CaSiO) then it reduces

the iron oxide from the iron ore into the iron and it self get oxidized to
CO.

Now then we collect the molten iron because molten iron is densor so
it sinks to the bottom of the furnace.

Now being a CO gas is goes out through the chimney.

Now the molten iron is collected through the outlet of

the bottom which is called pig iron.

Now the calcium silicates which floats on the surface of

the molten iron is collected through the slag outlet pipe.

Bottom zone reaction

C + O CO
Middle zone reaction
C + CO 2CO
CaCO CaO + CO
Cao + SiO CaSiO

Upper zone reaction

3FeO + CO 3Fe + CO

ZERO BOLT FAILURE CAMPAIGN:

Area Selection
Consumption across the
Plant in last 3 FY 32.8
Cr
Every year more than
10Cr is consumed on
Most&contributing
bolt
fasteners a
Area
1. LD
2. Blast furnace
3. Mill Section
Total consumption 23.2
Cr.

Area Selection
Steel Making

Mills Area

Blast furnace & PP

Four most contributing Dept.

1. LD2& LD1
2. HSM, TSCR
3. P PLANT
Plan for next three month.(Apr to
June 14)
1. Formulation of Cross functional
team
2. Data collection as per ground
reality & target setting.
3. Action point (Analysis &
recomm)

Analysis
Span of Analysis-Failure reports of 6 Years(2008-2013)
Source of Data- Sc. Services Archived report and Field failure reported by
Scope of study- Tata Steel Jamshedpur works
Data capturing Format:

Analysis:
Reason of Failure

40
35
30
25
20
15
10
5
0

Quality

Overloading

Design

Overtorquing

Fatigue

maintenance

*Quality related failure and Overloading during operation are the

two major reason of failure

FOLLOWINGS WERE THE FINDINGS:

WRONG SPECIFICATION IN PO TEXT

WRONG SPECIFICATION IN PO TEXT

54

34
22

19

16
6

GRADE WISE FAILURE:

Means and Strategies:

RECOMMENDATIONS:

Inspection of standard bolts supplied by the

approved vendors to eliminate the field failure
due to quality related reasons like improper
hardness or chemistry.
Tagging of material in SAP as Critical, supplied
by the vendors procured through drawing route.