Building on the success of JSW Steel’s blast furnaces No. 3 and No. 4, Primetals Technologies faced the challenge of delivering the largest blast furnace ever constructed (at the time) in India for JSPL (Jindal Steel and Power Limited). This project marked a significant milestone, as it required not only advanced technological solutions but also an in-depth understanding of the unique requirements and production capabilities of JSPL. The task was to design and install a furnace that would not only enhance the efficiency of the steelmaking process but also support JSPL's strategic goal of increasing production capacity to meet growing demand.
Challenge
Following on from the success of JSW Steel’s blast furnaces No. 3 and No. 4, the challenge for Primetals Technologies was to provide JSPL with the largest furnace yet built in India.
JSPL Angul Blast Furnace No.1
Solution
Primetals Technologies' solution included the design, equipment supply, and erection/commissioning supervision of the furnace, which was installed at Angul in the state of Orissa, India. This furnace was an extension of the family of Gwangyang large blast furnaces provided by Primetals Technologies. Primetals Technologies designed a blast furnace capable of producing 11,000 tHM/day based on an inner volume of 4,554 m³. The furnace profile and cooling system allowed operation with a variety of ferrous burden qualities, with a pulverized coal injection potential of up to 250 kg/tHM. Construction commenced in October 2013, and Primetals Technologies worked closely with a number of contractors to bring the project to a successful conclusion. The blast furnace was successfully blown-in on 27 May 2017 with zero lost time incidents. The furnace is complemented by the Primetals Technologies sinter plant and incorporates Primetals Technologies' level 2 automation systems, ensuring that JSPL has the capability to produce a consistently high-quality product for many years to come.
Technology Supplied
Blast Furnace
- Furnace profile based on Primetals Technologies' worldwide success with copper staves
- Carbon hearth with deep sump and ceramic pad for long life
- Closed circuit cooling using 5 closed-water circuits
Hot Blast Stove System
- 3 internal combustion chamber stoves providing 1,250 °C hot blast to minimize coke consumption, incorporating waste heat recovery to minimize enrichment fuel costs
Process Gas Cleaning System
- Tangential single-entry cyclone to maximize dry dust recycle
- Triple-cone wet scrubber
Stockhouse
- Twin stockhouse with two gathering conveyors for various burdens containing a wide range of sinter, lump ore, and/or pellets, plus use of center coke
- Belt conveyor feeding a parallel hopper top
Casthouse
- 4 taphole flat-floor casthouse for optimum ease of operation, incorporating Primetals Technologies' taphole equipment
Screw-Dewatering Slag Granulation System
- Heavy-duty screw-dewatering system copes with slag surges
- Quality granulated slag generating high-value product for the cement industry
Automation
- Primetals Technologies' level 1 and level 2 systems
JSPL Angul Blast Furnace No.1
Results
Furnace Design Parameters
- Average production: 11,000 t/d
- Peak production: 12,000 t/d
- Furnace hearth diameter: 13.9 m
- Furnace working volume: 3,803 m³
- Furnace inner volume: 4,554 m³
- Top gas operating pressure: 2.60 bar g
- Blast pressure at furnace: 4.30 bar g
- Normal productivity on inner volume: 2.42 tHM/d/m³
- Normal productivity per hearth area: 72.5 tHM/d/m²
- Number of tuyeres: 38
- Number of tapholes: 4
JSPL Angul Blast Furnace No.1
Benefits
- Blast furnace capable of producing 11,000 tHM/day based on an inner volume of 4,554 m³
- Pulverized coal injection potential up to 250 kg/tHM
- Level 2 automation systems ensure JSPL has the capability to produce a consistently high-quality product for many years to come
Conclusion
- Largest furnace in India when blown-in, with a 4,554 m³ inner volume to produce 3.85 million tonnes per annum
- State-of-the-art blast furnace technology
- Process gas cleaning using cyclone technology to maximize cost-effective recycling of process dusts
- Level 1 PLC system for the complete furnace, including auxiliary plant, with Primetals Technologies' level 2 system
