(India) Durgapur Local Centre

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

33 rd National Convention of Metallurgical and Materials Engineers

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33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

National Advisory Committee

Chairman Dr T M Gunaraja, FIE, President, IEI Co-Chairman Prof N R Bandyopadhyay, FIE, Chairman, MMDB, IEI Convenor Dr.Debasish Ghosh, FIE ,Sr. Principal Scientist, CSIR-CMERI, Durgapur

Members : Mr K KMehrotra, FIE, Member, MMDB, IEI Mr V Parthasarathy, FIE, Member, MMDB, IEI Mr Asish Gupta, FIE, Member, MMDB, IEI Mr. P. K. Pradhan, FIE, Executive Director, SAIL- DSP , Durgapur Mr. M K Biswal,Honorary Secretary, IEI, Durgapur Local Centre Technical Committee Chairman Prof. H.B. Goswami, FIE, Council Member, IEI Convenor Mr.Lohitendu Badu, General Manager, SAIL-DSP, Durgapur Jt. Convenor Mr. P. S. Banerjee, MIE, Committee Member, IEI, Durgapur Local Centre

Technical Advisors Dr. Amit Ganguly, Former Steel Chair Professor Mr Rajeev Kumar, Chief General Manager, SAIL-DSP, Durgapur Mr R K Bhattacharyya, Jt. General Manager, MECON Limited, Durgapur Shri B BMajumder,GeneralManager,MECON Ltd., Burnpur Dr Siddhartha Mukherjee, Former Director, School of Mines & Metallurgy, KNU Dr. P. K. Sinha, Principal, DIATM, Durgapur

Members Mr. R K Roy, FIE, IEI, Durgapur Local Centre Dr P Adhvaryyu, FIE, Principal, SIT, Techno India Group Dr. C Bhattacharya, Dy. Director, NPTI (ER) Mr.Tilok Roy, FIE, Past Chairman, IEI, Durgapur Local Centre Dr.Abhiram Hens, MIE, Asst Professor, NIT, Durgapur Dr.Samik Dutta, AMIE, Sr. Scientist, CSIR-CMERI, Durgapur Mr.RajatMalakar, AMIE, Executive, SAIL-DSP, Durgapur Mr. S K Thakur, AMIE, Executive, DVC, Durgapur

Organising Committee Chairman Prof K C Ghanta, FIE, Chairman, IEI, Durgapur Local Centre Organising Secretary Mr. Safikul Islam, MIE, Member, IEI-WBSC Jt.Organising Secretary Mr. M.K. Biswal, MIE, Hony. Secretary, IEI, Durgapur Local Centre

Members Mr. P. Shaw, FIE, IEI-DLC Mr. A. K. Mukherjee, FIE, Member, IEI-WBSC Mr. M. N. Bandyopadhyay, MIE, IEI-DLC Mr M Majumder, FIE, IEI-DLC Mr M Nandi, MIE, IEI-DLC Dr N B Hui, MIE, IEI-DLC Mr SurajitDey, AMIE, IEI-DLC Mr B N Sain, AMIE, IEI-DLC Mr R Bhattacharjee, AMIE, IEI-DLC Mr S K Dey, FIE, IEI-DLC Mr D P Das, MIE, IEI-DLC Mr B B Das, MIE, IEI-DLC Mr. S. Sikdar, AMIE, IEI-DLC Mr.SarojSahoo, AMIE Mr.RajibChakrborty, MIE Mr. P.K. Roy, MIE Mr.Arun Kr Mukhopadhyay, FIE Mr. S K Bhakat, AMIE Mr. Amit Pal, AMIE Mr.IshanChattaraj, AMIE Mr.KoushikChaterjee,AMIE 1

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

INDEX

Sl. No Details Author /Speaker Page Messages No.

1 Message from President IE(I) Er. NarendraSingh,FIE 4 2 Message from Chairman,MMDB, IE(I) Prof N R Bandyopadhyay 5 3 Message from Director, CSIR-CMERI-Durgapur Prof.Harish Hirani 6 Message from Chief Executive officer, SAIL -ISCO, Mr.A.V.Kamlakar 4 DSP&ASP 7 Message from Chief Engineer & Head of Project, DVC - Mr.Manabendra Debdas 5 Durgapur Steel Thermal Power Station 8

6 Programme Schedule 09-10 Mr A V Kamlakar Mr Kanak Kumar Ghosh 7 Bio-data of Eminent Engineering Personalities Prof B K Mishra 12-14 Dr Aritra Sarkar Mr K Prakash 8 Bio-data of Young Engineers Dr (Ms) Indu Elizabeth 15-16 Shri V Subramony Memorial Lecture Dr Debasis Mukherjee, Steel ChairProfessor, “Options for Lowering Carbon Footprint and NIFFT Ranchi 18-19 9 Improving Sustainability in Indian Steel Plants”. 10 Bio -data of Dr Debasis Mukherjee 20 11 Improved Understanding On Steel Quality Prof. Santanu K. Ray, Former Steel Chair Professor , IIT Madras 21-25 Climate Responsive Technologies vis -a-vis Iron and Mr Birupakshya Sanyal, Consultant, Steel Production Scenario an Approach towards M.N.Dastur& Co(P) Ltd,Kolkata 12 Pollution and Waste Management 26 Prof Amit Ganguly, Ex. Chief of Business 13 Clean Development Mechanism for The Steel Sector Excellence- Mukand Group 27 Some glimpses on the developments of advanced 14 steels for reducing CO2 emission Prof K K Ray, Former Professor , IIT Kharagapur 28 Waste To Wealth - Recycle Steel Plant Waste Er. Pawan Verma, CEO, The Deailed Study On Application Of Ld Sludge + Mill Techno Enviro Services Pvt Ltd 29-33 15 Scale Briquettes Use In Convertor 16 Advertisement 34 Papers Development of amorphous Mg -Ca -Zn a lloys by Melt Sudeep Paul& Others 17 spinning route CSIR-CGCRI,Kolkata &, NIT-Durgapur 36 18 Improvement in balling efficiency of mixing and S Sudershan, M Roy, SA Balaji, Dr. SK Dhua,RDCIS nodulizing drum for sinter making Burnpur Centre, SAIL, INDIA. 37-42

19 Global Steel industry scenario in the face of new Lohitendu Badu, General Manager, DSP -SAIL challenges 43 Butt friction stir welding of aluminium to steel - a AbhijitDatta, Dr.Sitanshu Shekhar Chakraborty 20 review ,CSIR -CMERI, Durgapur 713209 44-49 21 Effect of Molasses and Lime on Strengthening Soumya Mukherjee & Siddhartha Mukherjee Property of Chromite Briquettes KaziNazrul University & M. N. Dastur School of Materials Science and Engg., IIEST 50 AbdurRouf, Dr. S K Dhua, Kumar Abhishek and B 22 Improvement in steel ladle life at ISP: A case study K Sinhamahapatra ; RDCIS, Burnpur 51-56 Refractories Engineering Department, IISCO Steel Plant, Burnpur 2

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

S Ray ,Sr.Technical Officer ,ISR group, CMERI, Non Destructive testing( NDT) a useful tool for Durgapur-713209 23 damage assessment of industrial Component 57 Role of in-situ Metallography for damage assessment A.Mondal, H Roy and D Ghosh of critical high temperature thermal power plant CSIR-CMERI 24 components 58 Cleaner S teel Making Technology for Green House D Ghosh and U Bhattacharyya 25 Gas Emission Reduction – a review CSIR-CMERI, and SAIL- DSP, Durgapur 59 Development of High Speed Wheel & Axle a Make in 26 India Approach at WAP, SAIL, DSP S K Behera, DGM, SAIL, Durgapur Steel Plant 60 27 Li ion batteries (LIBs): Technology of the Green World Dr.Indu Elizabeth, CSIR-NPL, Delhi 61 Molecular Dynamics Based Design And Development D. Banerjee and M.M. Ghosh Of Surface Nanostructured Ti-Al Alloy For Advanced Department of Metallurgical and Material 28 Structural Applications Engineering,NIT-Durgapur 62 Crack propagation and fracture characteristics of Ajay Kumar Mishra, Krishnan Bandyopadhya y copper-nickel single crystal alloy nano-particles: A and M.M. Ghosh, NIT-Durgapur 29 molecular dynamics study 63 Design of tungsten nanoparticles with enhanced Krishnan Bandyopadhyay, S. Banerjee, H. nano-mechanical properties for advanced structural Kumar, A.K. Mishra, K.S. Ghosh and M.M. Ghosh 30 applications using MD based modelling approaches , NIT-Durgapur 64 Development of Welding Procedure for High Strength Suvam Chatterjee, Pawan Agrawal C-Mn-Si (SA299 Gr.B) Steel through Optimization of GE Power , Durgapur 31 Normalizing and PWHT Cycles 65 Use of Fly Ash and Flue Du st in Agglomeration: A Ritwik Das, Manas Kumar Mondal, Susanta 32 Sustainable Technology for Waste Recycling Pramanik ; NIT-Durgapur 66 Mechanical, Degradation, Biocompatibility study of Sudeep Paul, Ramasa my Parthiban, Mitun Das, Mg-Ca-Zn alloys prepared by Melt spinning route Durbadal Mandal, Mariana Calin, 33 Jürgen.Eckert,, Supriya Bera 67 34 Extraction of Metals from Industrial Wastes by Using Ramesh Kumar Mittal, Arup Kumar Mandal, Transferred Arc Plasma Om Prakash Sinha NIT Durgapur IIT(BHU), Varanasi 68

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

The Institution of Engineers (India) (ESTABLISHED 1920, INCORPORATED BY ROYAL CHARTER 1935) 8, GOKHALE ROAD, KOLKATA – 700020

“““100“100 Years of Relentless Journey Towards Engineering Advancement for NationBuilding”

Professor N. R. Bandyopadhyay, FIE, FAScT Telephone: 40106299 + 91-33- 2223-8311/14/15/33/34 Chairman, Metallurgical & Materials Engineering Chairman, Metallurgical & Materials Engineering Fax: + 91-33-2223 8345 Division Board (MMDB) Telegram: ENJOIND Web : http://www.ieindia.org

Ref: Date: December 20,2019 M e s s a g e

I am glad to know that The Institution of Engineers (India), Durgapur Local Center is organizing 33rd National Convention of Metallurgical and Materials Engineers and National Conference on ‘Climate RResponsiveesponsive Technologies visvis----aaaa----visvis Iron and Steel Production Scenario’ during January 17-18, 2020 at IEI, at Durgapur, under the aegis of Metallurgical & Materials Engineering Division Board (MMDB) of IEI

I appreciate the move taken by the organizer to address such an important topic of contemporary and societal interest. I sincerely believe that all the relevant and pertaining issues will be discussed in the National Conference in its right perspective and this conference will facilitate professionals & experts, researchers, prospective producers to interact between them for the benefit of the industry, research organization and academia in all respect.

I wish the National Convention of Metallurgical and Materials Engineers and National Conferencea grand success.

20-12-2019 (N. R. Bandyopadhyay)

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

DAMODAR VALLEY CORPORATION DURGAPUR STEEL THERMAL POWER STATION P.O.: ANDAL - 713321 : DIST.- BURDWAN

MESSAGE

Welcome to the Institution of Engineers (India) - Durgapur Local Centre, to organize the 33 rd National Convention of Metallurgical and Materials Engineers and National Conference on “Climate Responsive Technologies vis- à-vis Iron & Steel Production Scenario” On behalf of DSTPS, DVC I hope that this year’s conference will be interesting and informative. The national conference is structured to provide a broad range of information across the entire Steel industry eco system and its Support Technology spectrum. The focus is on practical explanation and application of existing technologies. To date the Conference Program has focused on productivity through the adoption of more efficient and cleaner technologies in the manufacturing sector will be effective in merging economic, environmental and social development objectives. I like to congratulate all National committee, Technical Committee and Organising committee for bringing together quality research papers and participants from both Academia and Industries to make this National conference a grand success. I hope this convention will be a good forum for researchers to exchange their ideas and get direction in area of Metallurgical and Materials Engineers.

I wish the National Convention &National Conference a grand success.

( ManabendraDebdas) Chief Engineer & Head of Project

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

333333 RDRDRD NATIONAL CONVENTION OF Metallurgical & Materials ENGINEERS Theme: Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario

January 17-18, 2020 Venue: The Institution of Engineers (India), Durgapur Local Centre, Visvesvaraya Auditorium, Nehru Avenue, B-Zone, Durgapur 713205 Technical Programme

Day 1: January 17, 2020 0930 hrs -10 30 hrs REGISTRATION 10 30 hrs -120 0 hrs INAUGURAL SESSION & AWARD PRESENTATION

Welcome Address Prof K C Ghanta Chairman, IEI - Durgapur Local Centre About the Theme Dr Debasish Ghosh Convener, National Convention Address By Prof N R Bandyopadhyay , FIE Chairman, Metallurgical & Materials Engineering Division Board, IEI Address by Guests -of -Honour Mr Sisir Kumar Banerjee, FIE Past President, The Institution of Engineers (India) Mr Manabendra Debdas Chief Engineer & Head of Project, DVC, DSTPS, Andal Releasing of Proceeding / Souvenir of the Convention Felicitation of Eminent Engineering personalities • Mr A V Kamlakar, Chief Executive Officer, IISCO Steel Plant, Burnpur, SAIL- Durgapur Steel Plant • Mr Kanak Kumar Ghosh, Director (Projects), Rashtriya Ispat Nigam Limited, Visakhapatnam Steel Plant, Visakhapatnam • Prof B K Mishra, Director, Indian Institute of Technology Goa

Felicitation of IEI You ng Engineers Awardees • Dr Aritra Sarkar, Scientific Officer-E, Indira Gandhi Centre for Atomic Research Kalpakkam, Tamilnadu • Mr K Prakash, Welding Engineer, Larsen & Toubro Ltd., Kanchipuram, Tamilnadu • Dr (Ms) Indu Elizabeth, Scientist, CSIR- National Physical Laboratory, New Delhi Address by the Chief Guest Mr Prem Sagar Mishra Chairman and Managing Director, Eastern Coalfields Ltd Address by Eminent Engineer Mr A V Kamlakar, Chief Executive Officer, IISCO Steel Plant, Burnpur, SAIL - Durgapur Steel Plant Vote of Thanks Mr M K Biswal Honorary Secretary, IEI- Durgapur Local Centre

120 0 hrs –1215 hrs TEA BREAK 1215 hrs -1345 hrs V SUBRAMONY MEMORIAL LECTURE AND INVITED LECTURE 1215 hrs -1300 hrs V Subramony Memorial Lecture Dr Debasis Mukherjee [Session Chairman: Prof N R Bandyopadhyay] Chair Professor, Ministry of Steel, National Institute of Foundry & Forge Technology, Ranchi 130 0 hrs -133 0 hrs Invited Lecture Prof Santanu K Ray , former Steel Chair Profess or, IIT Madras [Session Chairman: Prof N R Bandyopadhyay] 13 45 hrs - 1430 hrs LUNCH 1430 hrs -1700 hrs TECHNICAL SESSION –I Chairman Prof Santanu K Ray , former Steel Chair Professor, IIT Madras 1430 hrs -1500 hrs Invited Lecture: Mr Birupakshya Sanyal, Consultant, M N Dastur & Co. (P) Ltd., Kolkata 1500 hrs -1530 hrs Address By Mr Kanak Kumar Ghosh, Director (Projects), Rashtriya Ispat Nigam Limited, Visakhapatnam Steel Plant, Visakhapatnam 1530 hrs -1600 hrs Invited Lecture: Prof Amit Ganguly, former Chief of Business Excellence, Mukand Group 1600 hrs -1630 hrs Prof.Sidhartha Mukherjee,IIEST / Dr Soumya Mukherjee, Nazurl University 1630 hrs -1700 hrs Discussion 1700 hrs -1800 hrs PANEL DISCUSSION ON FUTURE OF METALLURGICAL & MATERIALS ENGINEER ING Chairman – Mr K K Mehrotra , Member , MMDB, IEI

1800 hrs onwards BREAK 9

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

333333 RDRDRD NATIONAL CONVENTION OF Metallurgical & Materials ENGINEERS

Day 2: January 18, 2020 103 0 hrs -1200 hrs TECHNICAL SESSION – II Chairm an Dr Debasish Ghosh , Senior Principal Scientist, CSIR - Central Mechanical Engineerin g Research Institute (CMERI) , Durgapur

1030 hrs -1100 hrs Invited Lecture: Mr Pawan Varma on "Cost Effective Recycling of High Iron Containing solid waste" 1100 hrs -1115 hrs Mr Satyendra Sudershan, Deputy Manager, Research & Development Cent re for Iron & Steel (RDCIS)

Speakers 1115 hrs -1130 hrs Mr Lohitendu Badu, General Manager, SAIL -DSP, Durgapur 1130 hrs -1145 hrs Mr S K Behera , Deputy General Manager, SAIL 1145 hrs -1200 hrs Mr Abdur Rouf, Manager, RDCIS , Burnpur Centre 120 0 hrs -1215 hrs BRE AK 1215 hrs -1345 hrs TECHNICAL SESSION – II I Chairman Mr V Parthasarathy, Member, MMDB, IEI

12 15 hrs -1245 hrs Invited Lecture: Prof Kalyan Kumar Ray , IIT Kharagpur Speakers 1245 hrs -1315 hrs Invited Lecture: Prof Suddhasatwa Basu, Director, CSIR - Institute of Minerals & Materials Technology, Bhubaneswar 1315 hrs -1400 hrs LUNCH 1400 hrs -1530 hrs TECHNICAL SESSION – IV Chairman Prof N B Hui , NIT -Durgapur / Mr Lohitendu Badu , General Manager, SAIL -DSP , Durgapur 1400 hrs -1410 hrs Dr ( Ms) Indu Elizabeth, Scientist, CSIR - National Physical Laboratory, New Delhi 1410 hrs -1430 hrs Dr Debasish Ghosh, Senior Principal Scientist, Mr A Mondal CSIR -CMERI, Durgapur ,

Speakers 1430 hrs -1440 hrs Mr K Prakash, Welding Engineer, Larsen & Toubro Ltd., Kan chipuram, Tamilnadu 1440 hrs -1450 hrs Dr S Chakraborty / Mr S Ray CMERI 1450 hrs -1500 hrs Dr Arup Mandal , Asst Prof.& Team , NIT Durgapur 1500 hrs -1510 hrs Mr Sudeep Paul & Team , NIT / CGCRI 1510 hrs -1530 hrs Discussion 1530 hrs -1600 hrs BREAK 1600 hrs -1700 hrs VALEDICTORY SESSION Welcome Address Prof K C Ghanta , Chairman, IEI - Durgapur Local Centre

Reporting on the Technical Sessions Mr Lohitendu Badu , Convener -Technical, National Convention Guests -of -Honour Mr K K Mehrotra , Member, MMDB, IEI Prof Kalyan Kumar Ray , IIT Kharagpur Mr V Parthasarathy, Member, MMDB, IEI Finalization of Recommendations by Prof H B Goswami, Chairman, Technical Committee

Vote of Thanks Mr S Islam, Organizing Secretary , National Convention

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Eminent Engineering Personalities & Young Engineers

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Er A V Kamlakar Chief Executive Officer IISCO Steel Plant, Burnpur SAIL- Durgapur Steel Plant

Mr A V Kamlakar , CEO, IISCO Steel Plant (ISP) has assumed the additional charge of Chief Executive Officer, Durgapur Steel Plant & Alloy Steels Plant (DSP & ASP) in 2019. Prior to his current responsibilities, Mr Kamlakar worked as Executive Director of Salem Steel Plant (SSP) and was also vested with the additional charge as Executive Director of VISL. He was thereafter posted as OSD at IISCO Steel Plant (ISP) from 2019 onwards. Having done graduation in Metallurgy from Ravishankar University, Raipur, MrKamlakar joined SAIL at Bhilai Steel Plant (BSP) in 1987. He has worked for about 25 years in Rail & Structural Mill in Bhilai Steel Plant, where as an Operations man, he played a key role in production and supply of desired grade, quality and length of prime rails for Indian Railways. During his tenure at RSM of BSP, Mr Kamlakar was also involved in the design and development of thick web asymmetric rails that are used in switch points of tracks. He rose through the ranks at Bhilai Steel Plant to head the Mill as General Manager in 2013. As Head, he was deeply involved in various HRD initiatives for turnaround of Rail & Structural Mill including “Apeksha” - a departmental level communication and involvement initiative started by Rail and Structural Mill in 2015 that continued to energize the workforce to meet the challenges and expectations of SAIL-BSP from the Mill. Another novel initiative that he took as Head was celebrating the birthday of mentally handicapped children at a local school named Muskan at Bhilai, a tradition that still continues at Rail Mill. Mr Kamlakar was also instrumental as a Project Owner in finalizing design of Modex unit, Universal Rail Mill, which is equipped with the first walking beam furnace that became operational in 2017 and rolls out the world’s longest 130 m rail. In 2016, he joined DSP as an expert for stabilization of Medium Structural Mill (MSM) and assumed the charge of General Manager In-charge (Mills). During his tenure at DSP, Mr Kamlakar played a key role in switching over the process of production of TMT Bars from 100 mm 2 billets to 125 mm 2 ones at Merchant Mill including stabilization of operations at MSM and also initiating production of 100 x 50 channels at MSM.

In recognition of his valuable contribution in the field of Metallurgical and Materials Engineering, The Institution of Engineers (India) is proud to felicitate Mr A V Kamlakar as an Eminent Engineering personality on this auspicious occasion of Thirty-third National Convention of Metallurgical and Materials Engineers here at Durgapur during January 17-18, 2020.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Er Kanak Kumar Ghosh Director (Projects) Rashtriya Ispat Nigam Limited, Visakhapatnam Steel Plant, Visakhapatnam

Mr Kanak Kumar Ghosh is a Metallurgical Engineer from Govt. College of Engineering & Technology, Raipur, (presently NIT, Raipur) in 1982. He joined Visakhapatnam Steel Plant as Management Trainee (Technical) in 1983 and elevated to the post of Director (Projects) at RashtriyaIspat Nigam Limited (RINL), which is a Corporate entity of Visakhapatnam Steel Plant (VSP), a shore based 7.3MT capacity integrated steel maker. Mr Ghosh is having 37 years of insightful exposure in RINL with a sharp focus on the top and bottom line performance. During this long tenure, he gas got rich experience to the Engineering, erection, testing & commissioning and Operations of Installations in the Steel plant. He has done lot of collaborative projects with several consultants & EPC contractors for smooth testing and commissioning of various units. Mr Ghosh is one of the officers having seen growing this company since inception and actively involved in all stages starting from design, Installation, testing, commissioning & fully operationalize of 3.0MT units and also 7.3MT units. He has Strong credentials in crafting strategies and orchestrating resources to achieve operational excellence. In his capacity as Head of the Department & functional head, several transformational changes were brought by him resulting in substantial benefits to the plant. Rolling Mill Zone Special award is awarded to him by Joint Committee on Safety in Steel Industry (JCSSI) for NO FATAL ACCIDENT for consecutive Three years in 2018-19. Owing to his rich exposure he was involved in Erection, testing and commissioning of reheating Furnaces and Rolling mills, Stabilization of Mill and increasing output up to the level of 120%. Mr Ghosh has also handled greater responsibility of commissioning & stabilization of units under 6.3 and 7.3 MT stage i.e. Wire Rod Mill - 2 , Special Bar Mill and Structural Mill. He is also part of core team for finalising the concept report for 11.0/12MT expansion. Working with RINL-VSP since inception Mr Ghosh has honed his skills in strategic planning, commissioning, resource optimization and ramping up production in Mills to beyond rated capacities. Even in Newly commissioned mills of Wire Rod Mill 2, the monthly production of 118% in March 2019 has been recorded during his tenure. As functional Head in Rolling Mills, he had taken keen initiative in developing new products like, Spring steel flats for Automobile sector, Spring steel rounds for Railway sleeper clips and higher size rounds for forging industries from newly commissioned mills, which are presently fetching the highest Net Sales Realization. Mr Ghosh has facilitated in increasing the bottom line of the company by making revision in Wagon unitization material specification that resulted in saving of more than Rs.50 lakhs per annum. He has also worked as Chief Management Representative for all four ISO management systems on Quality, Safety & Health, Environment and Energy (QSHEE). He has taken many innovative initiatives such as, modifications in cooling of wire rods for production & subsequent stabilization of Fe500 & Fe500D grade TMT bars, developed Boron grade steel for high tensile fasters and CO 2 grade wire rods for welding from newly expansion facilities, continuously winning Safety & housekeeping Awards with Zero fatal accidents & ZERO fire accidents.

In recognition of his valuable contribution in the field of Metallurgical and Materials Engineering, The Institution of Engineers (India) is proud to felicitate Mr Kanak Kumar Ghosh as an Eminent Engineering personality on this auspicious occasion of Thirty-third National Convention of Metallurgical and Materials Engineers here at Durgapur during January 17-18, 2020.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Prof B K Mishra Director Indian Institute of Technology Goa

Prof B K Mishra is a Metallurgical Engineer from NIT Rourkela, obtained Masters from Wayne State University Michigan, USA and PhD from University of Utah, Salt Lake City, USA. Prior to IIT Goa, Prof Mishra was the Director of CSIR-Institute of Minerals & Materials Technology, Bhubaneswar, Chairman of Recruitment & Assessment Board at CSIR, New Delhi as well as Professor of IIT Kanpur. He is the recipient of prestigious Vividhlaxi Audyogik Samshodhan Vikas Kendra (VASVIK) Award for the development of software for designing tumbling mills, the iron ore jigging system for a close separation of the constituents, bioleaching process for copper recovery and biopolymerisation technology. Due to his outstanding achievement, Prof Mishra has received National Mineral Award in 2007. He has published many research articles in various national and international reputed journals.

In recognition of his valuable contribution in the field of Metallurgical and Materials Engineering, The Institution of Engineers (India) is proud to felicitate Prof B K Mishra as an Eminent Engineering personality on this auspicious occasion of Thirty-third National Convention of Metallurgical and Materials Engineers here at Durgapur during January 17- 18, 2020.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

YOUNG ENGINEERS

Dr.Indu Elizabeth working as a Scientist in CSIR-National Physical Laboratory, New Delhi in the Force and Hardness Metrology Division. Research activities include the development of carbon based force sensors for artificial intelligence and biomedical applications, development of high capacity anode materials for Li ion batteries etc. She have worked towards the technology transfer of Indigenous Li ion batteries to industries during my PhD. She have done my PhD in Engineering in the field of Li ion batteries under the Prime Minister Fellowship for Doctoral Studies in the year 2018. The thesis has won the “Best PhD thesis award “of AcSIR and in National Carbon Conference (CCM-2019). She have done M.Tech in Advanced Material Science & Engineering from AcSIR and ranked 1 st in the University. She was B.Tech was in Electronics &Communication from College of Engineering, Trivandrum in 2011. She was National Level 2 nd in the Xth CBSE board exams in the year 2004.

Dr. Aritra Sarkar

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Mr.PRAKASH K

Qualified International Welding Engineer (IWE) awarded by International Institute of Welding and Postgraduate diploma in welding and Quality engineering (Welding Research Institute). Beginner as a welding engineer at Welding Technology Center- M/S. Larsen&Toubro Limited, Heavy Engineering Division, Powai, and now welding manager at M/S. Larsen&Toubro Limited, Engineering workshop, Kanchipuram.

Certified for specializes in Welding-Design-fabrication-analyses, Non- destructive testing (ASNT NDE Level-II), Quality management systems (Diploma in Quality Management), and Advanced fabrication systems (Master’s degree in computer-integrated manufacturing).

Prior Experience

Eight years of total experience in ferrous steel fabrication like structural, Equipment, pressure vessels, railway bridges, General fabrication, Welding technology upgradation, and Research & innovation methods

Research articles

Presented eight no’s of research papers as on August 2019 in International and National Conferences and published two papers on international journal.

Major achievements

Awarded “ Best Outgoing Student of Mechanical Engineering Student ”, Awarded “Young Welding Engineer Award” weldfab tech awards Best Paper Award for “ Recent Trends in Industrial Automation ” RULA-Young Engineer Award

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

KEPT IT BLANK

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Shri V Subramony Memorial Lecture

Options for Lowering Carbon Footprint and Improving Sustainability in Indian Steel Plants

Date and Venue: 17 th January, 2020; Visveswaraya Auditorium, Nehru Avenue, B Zone, Durgapur

Dr Debasis Mukerjee Former Chair Professor, Ministry of Steel, Dept. of Metallurgy and Materials Engineering, National Institute of Foundry and Forge Technology, Ranchi-834003 and Former Executive Director and In-Charge, R&D Centre for Iron and Steel, SAIL, Ranchi-834002

SYNOPSIS OF LECTURE

Alarming increase in greenhouse gas (GHG) emission worldwide, presently in excess of 415 ppm, is an area of concern for sustainable development. The CO 2 emission is likely to breach 450 ppm concentration level by 2030 primarily due to over dependence and usage of fossil fuels for energy generation.

The fall out of such unacceptably high CO 2 concentration is already having catastrophic effect in terms of climate change by way of melting of glaciers, rising sea water levels and higher ambient temperatures. Such unabated and irreversible global warming will lead to a ‘domino or cascade effect’ that will eventually threaten human existence. Our planet has ‘already reached climate change tipping points’. Scientists have identified the need to reduce greenhouse gas emission, one of the primary tipping point, as other key tipping points that have not yet been activated could soon be hit. Other tipping points not currently activated include heating up of deep water in the Antarctic, and the release of methane stored in the Ocean in polar regions, reduction in rainfall in the Indian monsoon, and a major loss of oxygen in the ocean, reductions in the size of the Amazon rainforest and the great ice sheets of Antarctica etc.

The global steel industry is estimated to account for around 6-7% of the total anthropogenic CO 2 emission. According to International Energy Agency (IEA), global iron and steel industry is one of the most energy intensive industry and accounts for the largest share, approximately 27%, of the CO 2 emissions amongst all global manufacturing sectors. The iron and steel industry, per force, has to be sensitive towards curtailment of CO 2 emission in order to facilitate sustainable development.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

India and China have maintained continuous growth in steel production and are under intense global scrutiny for reducing emission norms in their manufacturing streams. India has surpassed Japan in becoming the second largest steel producer after China, and shortly is expected to be the second largest steel consumer surpassing USA. Steel industry, in India, is the fifth largest emitter of CO 2 equivalent after electricity, transport, residential and cement as per the report published in May 2010 by Indian Network for Climate Change Assessment (INCCA).

Towards lowering the carbon footprint in the steel industry, it is imperative to seriously consider and implement technological measures for energy efficiency. The approach to be adopted by Indian steel industry hinges on innovating and incorporating technologies to realise energy conservation and emission reduction in steel plant operations along with development of high strength/advanced high strength steels that support energy reduction in downstream industries like automobiles, construction, oil and gas, space etc. In the Indian context, beneficiation of input raw materials, incorporation of waste/sensible heat recovery systems, adoption of commercially available energy efficient technologies across the entire domain of the manufacturing spectrum, ensuring materials efficiency and evaluation of emerging green technologies utilising iron ore fines and non coking coal, rapid assimilation of high end process and product models, automation, IT and expert systems besides development of ultra high strength steels will hold significance not only for ensuring energy efficiency and a cleaner environment but also reduce production cost as well.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Professor Debasis Mukerjee – Personal Resume

After graduating in Metallurgical Engineering in 1974, from Bengal Engineering College, University of Kolkata, India, Dr. D. Mukerjee completed his Ph.D. in 1978 from University of Birmingham, U.K. He thereafter joined the R&D Centre for Iron & Steel (RDCIS), Ranchi under Steel Authority of India Limited (SAIL), in 1978. With his Physical Metallurgy background, he has worked initially in the area of Product Development and Product Application. He has made significant contribution in development and commercialisation of a large number of value added special steel products from SAIL. Towards promotion of special steels from SAIL in the Middle East, Dr. D. Mukerjee made technical presentations in Dubai. He has also provided consultancy services to Mobarakkeh Steel Company, Iran for setting up of a R&D Centre besides identifying product development and application engineering programmes.

Dr. D. Mukerjee has published 92 nos. of technical papers in national and international journals. He has 19 patents to his credit. He has represented India in the meeting organised by International Standards Organisation for Continuous Mill Flat Products. He has undergone Specialised Management Training Programme in UK, France and Germany. For his contributions, he has received several national level awards in India, including SAIL Gold Medal given by Institution of Engineers (India); Metallurgist of the Year given by Ministry of Steel, Government of India; Indranil Award for Metallurgy given by Mining, Geological and Metallurgical Institute (MGMI), India etc. He is a Fellow of the Indian Institute of Metals and a Member of The Mining, Geological andMetallurgical Institute of India.

He has been involved in overall coordination in respect of selection, execution and utilisation of R&D projects in various steel plants under SAIL as well as sponsored research projects funded by various Ministries under Government of India. Under his leadership, a number of technology development initiatives led to successful fruition.

Dr.Mukerjee retired from RDCIS, SAIL, Ranchi, in April, 2012, as its head in the capacity of Executive Director and Incharge. Post retirement he had been a consultant to Oman Oil Corporation (OOC), Muscat for one year (2013) for improving their operational efficiency besides planning for expansion in the iron and steel sector. Since July 2014 he was engaged in teaching B.Tech and M.Tech students as Ministry of Steel Chair Professor in the Department of Metallurgy and Materials Engineering (MME), National Institute of Foundry and Forge Technology (NIFFT), Ranchi.Later from January 2019 till July 2019 he taught B.Tech and M,.Tech students in Dept. of MME, NIFFT in the capacity of an Adjunct Faculty Professor.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

IMPROVED UNDERSTANDING ON STEEL QUALITY Dr.Santanu Kr. Ray ( [email protected] )

Steel cannot be absolutely free from residuals or trace Introduction elements. It is therefore important to make a realistic

Quality of a steel product is understood as the totality of judgement on the limits of the impurity contents and the its attributes which would impart the desirable critical size of NMIs with respect to specific quality application requirements. Quality is therefore essentially requirements of steel products. It has been observed that related to the end use of the product. inclusions, particularly the large exogenous entrapments, are responsible for causing different types of visible Genesis of Undesirable Surface Quality defects in steel products. The role of inclusions on defects becomes more prominent in products of thinner Metallographic investigation of defects and correlating gauges for both flat and long varieties. them with the process parameters has been helpful in identifying the stages of occurrence of quality problems. Low-carbon aluminium-killed (LCAK) steel coils of very These are either inherited from i] parent cast material, or thin (< 0.5 mm) gauge used for automotive and food ii] imparted during subsequent processing operations. processing applications are sometimes plagued with thin The quality problems owing their genesis to the parent surface lines. Fine NMIs of aluminium oxide or complex cast material is termed as “material defects”. The material defects have been found to be again associated oxides and silicates with size range of about 20 to 25 μm with two different origins : i] level of steel cleanliness , and above have been found to be associated with the particularly with respect to large exogenous NMIs cracks and / or entrapments constituting these unseemly entrapped from steelmaking or casting, ii] surface or surface defects. Similarly long products such as thin subsurface irregularities existing in the cast material. wires, tyre cords or bearings cannot tolerate oxide Steel cleanliness has a profound influence on the inclusions of even as low as 15 to 20 m size. properties and quality of the final product. The cleanliness requirements for the various steel grades

Facets of Steel Cleanliness are therefore application-specific. The amount, size distribution and the morphology of the NMIs which The different aspects of cleanliness and their distinct cannot be tolerated for the different applications have influence on product quality need to be understood. The been debated over the years. The following Table shows following attributes are generally expected in a clean a broad consensus on the cleanliness requirements of steel: different steel products. • Restricted amount and size of NMIs of mainly complex oxides, sulphides, nitrides etc. Cleanliness requirements reported for various steel products • Low content of residual impurity elements such as S, P, O, N, H etc. Product Max. impurity content Max. inclusion • Absence or low amount of trace elements like size [ m] Total [O] [N] As, Sn, Sb, Cu, Pb, Bi etc The undesirable impurities are present in steel products Line pipe 30 ppm 30 ppm 100 either in the form of elements in solid solution or as Deep drawn - 30 ppm 100 simple or complex compounds depending upon their sheet content and thermodynamic stability. Heavy plate 20 ppm 30 ppm Cluster 200; Application-specific Requirements single 20

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Drawn & 20 ppm 30 ppm 20 ironed can Total Oxygen in steel is present in two forms. Free oxygen is essentially present in dissolved form, and Wire 30 ppm 60 ppm 20 combined oxygen as non-metallic inclusions. Free or Tyre cord 15 ppm 40 ppm 15 active oxygen is controlled by equilibrium Bearing 10 ppm - 15 thermodynamics. Steel, after being suitably killed by Al, has a dissolved oxygen content of about 3-5 ppm. This is

Critical Size of Inclusion governed by the equilibrium constant of the reaction between Al and O. The free oxygen content in steel It has generally been observed that only large inclusions normally remains in a very close range. Total oxygen greater than 100 µm size result in visible surface defects can therefore be taken as a reasonable indirect in normal steel products. Increase in extent of measure of the total amount of different oxide deformation for processing of the final product from the inclusions present in steel . parent cast material makes the inclusions longer, or impart a chain-like distribution. It has been found that It has been demonstrated that presence of macro- even 30 µm inclusions produce very fine visible defects inclusions of complex oxides or silicates of size larger along the brighter surface finish of stainless steels meant than 50 µm generally increases when total oxygen for food processing application. Likewise, smaller content goes beyond about 40 ppm. It can therefore be inclusions of about 20 µm size have been found to be generalised that the probability of having harmful responsible for the generation of very thin line defects in exogenous large NMIs goes up with increase in total softer products like DI ( drawn and ironed ) cans. oxygen of steel. Some investigators have found a correlation of undesirable surface quality of steel product Inclusion size distribution has therefore assumed with its total oxygen content. significance with respect to steel cleanliness in general, and particularly for application-specific product quality. Operating Practice for Improved Cleanliness It has been postulated and observed that one kg of a typical clean steel contains about 10 7 to 10 9 inclusions. Secondary refining process and casting operation have Out of these, only very few are really large inclusions. profound influence on improving steel cleanliness, both Four hundred are of 80 to 130 µm size, ten are having in terms of quantity, and size of inclusions. The different 130 to 200 µm dimension, and the possible number of processing stages have to ensure more and more removal inclusion in 200 to 270 µm size range is less than one. of inclusions already existing in liquid steel, and at the same time prevent entrapment of new ones from The large inclusions are therefore far outnumbered by the exogenous sources. Systematic study has revealed that small ones, and the volume fraction of the former is selection of suitable refining processes and adequate much less as compared to the latter. It is thus important preventive measures has effected the following relative to note that the volume fraction of inclusion cannot be improvement in cleanliness in terms of total oxygen taken as the only criterion for steel cleanliness. Rather, content. large inclusions beyond critical size have to be avoided for ensuring good surface finish in the final product. • Maximum benefit to the tune of ~ 70% removal of NMIs is normally achieved through ladle treatment. Cleanliness Evaluation • About ~ 25% improvement is achievable through suitable measures in tundish, if possibility of

Fast and reliable methods of measurements are useful reoxidation can be prevented. forevaluation and control of steel cleanliness. The direct • Only ~ 5% improvement is possible in mould, and methods for cleanliness evaluation, such as, observation possibility of quality deterioration through under microscope, or through electrolysis, or ultrasonic entrainment of mould slag has to be taken care of. technique are accurate, but time-consuming, and sometimes expensive. The indirect methods of evaluation The following observations have been are therefore gaining popularity in steel industry. consolidated from the extensive evaluation of total Measurement of total oxygen in liquid steel is one of oxygen content at different stages of steelmaking, and its correlation with surface quality of product. the prominent indirect methods, which has been accepted by most of the modern steel producers and users. 22

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

• Total oxygen content from tundish sample is An important factor contributing to exogenous generally taken as indicative of steel cleanliness, and macroinclusion immediately before and after a change of is used to decide disposition of cast slab for further ladle is the carried-over ladle slag. Attempt to completely processing, or downgradation. discharge the liquid steel from the ladle leads to this • Total oxygen in the commonly used Al-killed low- problem. Carry-over of the slag can be prevented either carbon steel has steadily decreased over the years by retaining a minimum amount of steel in the ladle, or from about 50 ppm in the 1970s to about 25 ppm in by using suitable slag detection system. The latter recent time, with the advent of secondary metallurgy ensures restriction of ladle slag carry-over to as low as 0.3 kg per ton of steel in the tundish. technologies . • Total oxygen generally drops after every processing Refractory shroud made of alumina and graphite is used stage of steelmaking : to protect the steel flow between ladle and tundish. This is connected with the ladle slide gate system, and Ladle : 40-45 ppm submerges into liquid bath in tundish. Prevention of Tundish: 25-30 ppm reoxidation is possible only when the gap between the tip Mould : 20-25 ppm of slide gate and the shroud is adequately covered or

• It is possible to achieve lower total oxygen content shielded. An argon-shield restricts surrounding air from of about 20-30 ppm in the final liquid steel if RH flowing in, and restricts reoxidation. The extent of degasser is used as compared to ladle gas stirring reoxidation can be measured by way of nitrogen pick-up, (30-40 ppm) or oxidising loss of dissolved aluminium in liquid steel. An experimentation with the flow rate of argon has • Steel products meant for demanding applications, demonstrated that 80 lpm is necessary to restrict the having total oxygen level of 30 ppm max. intundish, quantum of nitrogen pick up to 2 ppm. are normally sent to customers without special inspection. Critical inspection is required for 30-50 Examples of Cleanliness Enhancement ppm range, and heats above 50 ppm level are normally downgraded. Some examples on improving cleanliness of different high value steels are being mentioned here. Control of Carry-over Slag The relative influence of refractory shroud and argon An important source of reoxidation in ladle is the carry- shielding on the incidence of surface lamination defect in over slag from the primary furnace. Higher content of cold rolled (CR) products of stainless steel is evident in FeO and MnO in this slag are known to be responsible Fig. 1. for reacting with dissolved Al in liquid steel and generating alumina. In fact higher contents of FeO and It has been revealed that incidence of surface lamination MnO in ladle slag have been correlated with poor increases with reoxidation. Absence of argon shrouding cleanliness in terms of higher total oxygen. has led to about 3% deterioration in product quality. An additional increase in defect incidence to the tune of Ladle Refining about 12% has been registered when refractory shroud was not used between ladle and tundish. The extent of It has been observed that simple argon stirring operation quality deterioration has been indirectly assessed from in ladle has limitation in promoting inclusion growth and the quantum of total oxygen increase measured during their subsequent floatation. It is considered to be reoxidation. adequate for grades which do not have stringent quality requirements. However, the full potential of cleanliness improvement can be attained through RH treatment. Vacuum treatment for degassing used in this process has been found to be very effective. Calcium-based powder injection has also been proved to be useful. It combines the benefit of deoxidation, liquefying inclusions, and stirring effect.

Discharge from Ladle to Tundish

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

• Start of casting sequence ( casting length of five metre ) • Steady-state casting during first heat (casting length of twenty five metres) • Subsequent to change of ladle at the start of second heat ( casting length of 5 metres ) • Steady-state casting during second and third heats (casting length of fifty metres) • End of sequence ( casting length of five metre ).

The following observations have emerged with respect to the type of defect and their origin across the casting length, and the influence of product thickness.

• Only surface lamination has been observed in thicker Fig.1 :Effect of reoxidation owing to absence of (> 3 mm) gauges of rolled products. Reoxidation shroud or argon on incidence of lamination defect and appears to be the major cause of this defect. total oxygen content Entrapment of mould flux has also contributed to a Free-opening of Ladle lesser extent.

Opening of the ladle sometimes poses problem. In case • Sliver or slag line defect is predominant only in the ladle does not open on its own, it has to be lanced. thinner (< 1 mm) gauges. Emulsified slag entrained The shroud has to be removed during the use of lance to either in tundish or in mould has been found to be open the ladle. The liquid steel coming out from the ladle only source of this defect. to the tundish during this period is thus left unshrouded. • Cleanliness is least and consequently defect The initial portion of the cast for the heats, which are incidence is maximum at the start of sequence. opened through lancing, are therefore found to be inferior Defect incidence is minimum during steady-state in quality. It has been observed that the total oxygen casting. Transition between two heats and end of content of the initial one or two meters of the cast sequence has also registered relatively higher level of entrapment of NMIs. product from such heats is about 10 ppm higher than that from self-opened heats. Sand used for ladle opening has It is thus necessary to process only the cast material been carefully packed to avoid this eventuality. corresponding to the steady-state of casting for product

Defects along Casting Sequence applications having stringent quality requirements. The material from transient stages such as start or end of Cleanliness distribution in cast steel and consequently in sequence, or corresponding to change of heat, should be rolled product has been found to be non-uniform along used only for the applications conforming to less casting duration or length. The start of casting, transition exacting quality standard. between two heats, and the end of sequence are particularly prone to relatively higher incidence of Importance of Knowledge NMIs. The distribution of shell-type surface lamination It is essential to develop knowledge-base on the different and sliver or slag line defects in thicker ( > 3 mm ) hot aspects of process variation which result in undesirable rolled and pickled and thinner gauges ( < 1 mm cold steel cleanliness and consequent surface defects in rolled rolled ) of stainless steel products have been carefully products. The process aberrations during steelmaking monitored during three-heat casting sequence. The and continuous casting is the cause , and the undesirable origins of defects have been traced essentially to product quality is the end result. Consolidation of all the reoxidation product and entrained slag. Metallography possible clues associated with specific quality issues is investigation and careful correlation with process essential to clearly identify the genesis of the defects. parameters have been helpful in identification of the The following tools are used for such investigation : origin of defect. The variation in the incidence has been observed in both thicker and thinner gauges of rolled • Metallographic study using optical and scanning products processed from the following categories of cast electron microscopes to observe the material :

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

microstructural variation associated with different defects. • Identification of the nature and size of cracks and / or exogenous NMIs with the help of elemental microanalysis using energy-dispersive X-ray ( EDX ) or wavelength-dispersive X-ray ( WDX ) technique.

Methodology of Defect Investigation

Identification of the genesis of quality problems in steel product is normally accomplished through metallographic investigation. It is prudent to know its limitation. A specific cause may result in different symptoms depending on the type of product , or the process variation. Likewise , different sources may lead to a similar manifestation of defect. It is therefore difficult to diagnose the root cause simply by looking at the symptom manifested on a small surface area.

Investigation should start from a detailed inspection of the location , frequency , size and shape of a specific defect with respect to the product dimension. Cutting of a small piece from the defect region has to be decided based on these observations. Another essential aspect is correlation of the defect incidence with undesirable process variation.

Once the possible factors responsible for a quality problem are identified , a decision has to be taken on implementing the remedial measures. This may be expensive and time-consuming. Depending on the seriousness of the issue , the product can either be downgraded for less-stringent application , or a time- bound action plan for process improvement has to be implemented by the steel industry.

Bibliography

1. Book on “ Surface Quality of Steel Products” - Dr.Santanu Kr. Ray, Allied Publishers Pvt. Ltd, 2005.

2. L. Zhang, W. Pluschkell& B.G. Thomas, Steelmaking Conf. Proc., Vol.82, 2002, p.463 .

3. M. Goransson, F. Reinholdsson& K. Willman, Iron and Steelmaker, Vol.26(5), 1999, p.53.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’

Brief Outline of Presentation.

The steel plant uses around 4.939X106 to 5.487X106 Kcal of energy for making a ton of crude steel from iron ore. Of the above quantity of energy, around 56.8% energy comes from coke, 12.1 % from oil and gas, 18.6 % from electric, 2.7 % from oxygen and 10.8% from other sources. These figures vary according to process route selected and efficiency of logistics of the plant. However these figures have been further improved upon by adopting various energy saving practices and technological interventions. Such huge transaction of energy together with high temperature operation which is imperative for sustaining plant operation, results in emission of carbon dioxide (CO 2), nitrogen oxides (NOx ) and sulphur dioxide (SOx ) along with some other detrimental gases present in small quantity. The menacing effect of such gases, although minor in volume, is a challenge for the steel plant operation when viewed from environmental aspect. To mitigate such issues technological interventions involving precious capex and scarce space are needed.

Dust, another menace, is formed in most of steel industry’s processes. In the process of high temperature metallurgical process dust is formed and accompany the process gases. Dust is also formed during transfer of input materials and also during transfer / repouring of molten metal. Such dust causes work zone emissions which are controlled by efficient use of various types of filters or cyclones.

Metallurgical processes are always accompanied by waste generation and handling of the same is a formidable issue. While some of such wastes are gainfully utilized some are not. Obviously dumping of such difficult- to -utilize wastes requires careful considerations.

All such aspects have been presented in technical review. In this technical review efforts have been made to deal with technical aspects related to environment management in steel making covering air pollution, water pollution, and solid waste and noise problems associated with integrated steel plant based on classical production route.

It is to be noted that environmental protection technology in relation to steel industry is continually undergoing change and therefore no overview can be comprehensive. Hence it is to be considered that the information given in this presentation is representative of present practices.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Clean Development Mechanism for The Steel Sector Dr Amit Ganguly Ex-Steel Chair Prof., NIT Durgapur and Ex-Chief, Business Excellence, Mukand Group, Mumbai

ABSTRACT

While CDM has caught the fancy of the steel makers today what with all the Kyoto Protocol-Carbon Credits-Global warming-Emission Control hullabaloo around, our Make-in-India aspirations are in a rudimentary state of the art! With neighbour’s envy, you may cast aspersions at other sectors but even after centuries of steelmaking, there has been not a single technology worth the mention as our own. To shun such shame, the only path would be to develop and establish a new, viable and enviable process technology integrating and amalgamating the least polluting, loss-making, renewable energy- intensive, skill-based, zero-discharge, least Life Cycle Assessment(LCA)- load bearing, process route which we can boast of, as our own , for others to beg or copy. Should’nt we deliberate on these at your ambitious conferences taking place all over India , all over the years?

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Some glimpses on the developments of advanced steels for reducing CO 2 emission

K. K. Ray Professor (Former) Department of Metallurgical and Materials Engineering, Indian Institute of Technology, Kharagpur, India-721302 e-mail: [email protected]

Abstract This report aims in elucidating some glimpses on the numerous efforts by physical and mechanical metallurgists on the development of different advanced steels which can assist in reducing the carbon imprint to the environment. Amongst the different efforts towards this direction, two major ones which can considerably reduce CO 2 emission to the environment are advanced steel development for increasing efficiency of fossil fuel based power plants and weight reduction of automobiles through development of high strength formable steels with sufficient ductility and crash resistance. The current state of the art in these two directions i.e. development of steels for Advanced Ultra-Super-Critical (AUSC) coal based power plants and for Advanced High Strength Steels (AHSS) based on TRIP-TWIP effect is depicted in this report with some basic backgrounds.

The goal of improving the efficiency of fossil fuel (particularly pulverized coal) based power plants, by increasing the temperature and pressure of the steam, has been pursued for several decades with particular emphasis from 1970’s. The goal of increased efficiency has acquired special urgency due to increased concern of global warming. The major challenge in constructing AUSC power plants has been in the area of materials technology. A sketch of the development of materials for subcritical, supercritical (SC), ultra-supercritical (USC) to advanced ultra-supercritical (AUSC) power plants is depicted along with the characteristics of the materials required for these applications, Rankine cycle based definitions of these power plants and comments on their contribution towards reducing CO 2 emission to the environment. The characteristics of the materials used for AUSC power plants operating at temperatures above 700 oC/720 oC and at pressures of > 35MPa requires suitable elevated temperature strength, and appropriate resistance to creep rupture, fatigue, oxidation and corrosion resistance. These challenging demands have led to the development of carbide and nitride precipitation strengthened ferritic and austenitic stainless steels with current bias towards adopting (iron bearing) nickel based alloys for AUSC power plants.

The development of high strength steels with numerous varieties and grades has started several decades back for reducing the weight of automobile vehicles for fuel economy, and the current efforts are directed towards development of these steels having simultaneous twin induced plasticity (TWIP) and transformation induced plasticity (TRIP). The development of AHSS includes dual-phased (DP), transformation induced plasticity (TRIP), complex-phased (CP), and martensitic (MART) steels, and the current trend is directed towards medium manganese steels which can impart excellent combination of strength and ductility based on combined TRIP and TWIP effect. This can lead to steels with strength better than 1.5 GPa and ductility > 25%. An attempt will be made to make a short portrayal of these third generation steels within the time limit.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

WASTE TO WEALTH- RECYCLE STEEL PLANT WASTE THE DEAILED STUDY ON APPLICATION OF LD SLUDGE + MILL SCALE BRIQUETTES USE IN CONVERTOR

By PawanVerma, CEO, Techno Enviro Services Pvt Ltd

In India the recycle, reuse and recovery of waste generated in a BF- BOF route Integrated Steel Plant, historically has been accorded a low priority which is evident by huge mountains of solid waste around these plants.

In the past, major reasons for low priority for Recycle were

• low per capita steel consumption, • availability of abundant cheap raw materials and • lack of awareness of recycling technologies.

Surprisingly, even now, most of these plants are wasting valuable resources and dumping them in ash ponds.

In recent years, unsustainable mining practices have led to exploitation of natural resources causing extensive environmental degradation. Moreover,

• continually increasing demand for metals, • declining ore grades and • complex new deposits are all contributing to a rise in greenhouse gas (GHG) emissions from primary metal production.

The consequence of this is fact that the mineral processing and metal production sector is coming under increasing pressure to improve the overall sustainability of its operations, especially by decreasing energy consumption, GHG emissions and waste disposal.

Industrial sustainability is the ultimate goal of modern society, particularly so for the iron and steel making industries.

Kyoto Summit has laid serious concern for environmental issues and GOI under National Steel Policy 2011 and The Ministry of Environment & Forest (MOEF) has launched the Charter on

"Corporate Responsibility for Environmental Protection (CREP)" in March 2003 which in nutshell directs all steel companies that

“Industry shall not store/dump solid wastes outside the factory premises in any circumstances without prior permission of the Board. Industry shall submit a time bound action plan to reduce solid waste by its proper utilization and disposal.”

Probably the most fundamental changes are those of

• public attitude, • awareness of available technologies • acceptability with respect to waste as a resource and • most important, realisation of Waste as Wealth

These changes are increasingly applying pressure to minimize waste, encourage waste recycling and demanding waste disposal as landfill to be the last option.

Utilizing solid waste is an option today, but it’s likely to be a necessity very soon.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Taking solid waste generation in BF-BOF in around of 450 kg/t of crude steel, the industry has produced 19 MT of solid waste, of which only 12 to 18% is recycled. This is an alarming scenario.

Depending on the type of waste, it can be returned to the process as energy source or raw material for steel fabrication or else be traded as co-product to other industrial applications. The reuse of these products is of great importance for the sector regarding both economic and environmental aspects.

A limitation of dust to be fully re-used is its variable composition and the high cost of implementing new technologies of recycling. But with the changed statutory obligations, public protest/ban against landfill and high cost of disposal has made it possible to economically recycle many wastes.

The cost of storing 1 MT of dust may account for 50% of the price of 1 MT of steel. These dusts cannot be stored anymore in open landfills.

RECYCLE OF HIGH IRON BOF SLUDGE

There are high iron oxide bearing wastes which always has very lucrative return on investment, and proven technology is also available, but it is never put in practice in India for the facts better known to our past policy makers. For example, briquetting the BOF sludge and use as coolant. For example, in a Steel Plant during 2014-15, approximately 38 MT crude steel was produced in BOF, approximately 5.7 MT of GCP Sludge was generated which could have replaced almost equal or more quantity of coolants required in BOF.

This loss has amounted to very considerable proportions in the past.

There are numerous methodologies and processes developed to recycle the steel plant waste, like collecting all fine dusts, sludge and mill- scale and agglomerate into micro pellets to use in the Sintering Plant or Blast Furnace as substitute to iron ore.

However, we should not use high iron containing oxides for Micro Pelletisation and use as substitute for low value iron ore when that rich iron oxide can be recycled as high value coolant for BOF. For use in sintering, the beneficiated BF dust and sludge can result in recovering high grade fines with reasonable yield by floatation and low intensity magnetic separation techniques. Sludge + Mill Scale Briquette ("SM Briquette")

The ideal metallurgical briquette for use in the iron and steel refining processes should possess the property of resisting spalling, shattering, and decomposition and thermal disintegration at high temperatures, otherwise the disintegration of the briquettes charged to a convertor, for example, merely results in the blowing of the fine particles out through the top with an incident increase in the fine dust and sludge- waste. A satisfactory and successful briquette for commercial use should possess sufficient compression and impact strength so that it can withstand the rigorous handling to which it is subjected in conveyors, loading and charging devices. Such strength should be imparted to the briquette not only immediately upon its fabrication, but during its subsequent period of handling and storage prior to use. A satisfactory briquette ‘must also be resistant to leaching action, that its binder must be capable of withstanding the washing out action of water.

A briquette made from mix of SMS or BOF sludge, Calcium Hydroxide and Mill Scale with a binder of water- soluble molasses and silicate of soda is capable of withstanding thermal disintegration but it requires a drying period before it can be handled or stacked. The control of the moisture content of the briquette is of special importance. Not only the iron oxide waste material contains appreciable amount of moisture, but also the addition of more water to. the briquette through the medium of the binding agent increases the ‘ultimate moisture ‘content 30

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020 of the finished “product which is to be charged or fed to the BOF. If such moisture content is too high, difficulty will be encountered in molding the briquettes, and also in the use of the briquettes due to the generation-of an excessive amount of steam. It is found that if a mix of High Iron Oxide Sludge (total Fe +60% or more and dried to less than 8% moisture), mill-scale, quick lime fines and suitable binders is briquetted, cured over 110 0C over a desired period has given a very good results to substitute it as coolant for the BOF.

Sludge + Mill Scale Briquette ("SM Briquette") cannot replace steel scrap 100% in Convertors. Usage limits are not very clear due to slopping problems. One expert says that normally SM Briquette can replace steel scrap up to 30% ~ 50% but will depend on many factors including Slag Characteristic(SiO2), Convertor Dimension, Operation Technology and Blowing Pattern (Hard or Soft) etc. In my judgment, in a 6 millionton steel plant without much difficulty, 200,000 tons per yearcold SM Briquette can be consumed.

The process of briquetting technology is a simple; environmentally friendly method of agglomeration, some difficulty is there in dewatering of sludge to less than 8% and selecting the appropriate binding media.

ADVANTAGES

• An economic solution enabling to avoid the loss of product under dust shape, uniformity of product obtained, reduction of dust volume, recycling of a product at high value added. • An ecologic solution, accepted on the environment level, consisting of the problem solution associated to the production and dispersion of dust and therefore to the atmosphere and ground pollution. • There are many examples World over where the BOF Sludge has been briquetted and charged successfully as coolant. • Many Steel Companies in World including POSCO has been using Sludge + Mill Scale Briquette ("SM Briquette") as substitute to steel scrape also for long. • The reduced oxygen consumption is another benefit; as the presence of oxides is high in the GCP sludge. • Further, the converter sludge briquettes, having high percentage of lime, would also reduce lime consumption. • The bio mass binder, molasses, may add heat value.

In India good efforts has been put in by JSW and Bhushan Steel for Sludge + Mill Scale Briquette ("SM Briquette") to recycle and value addition by using in convertors.

Thus, there is successful, proven and tested technology available to deliver a Sludge + Mill Scale Briquette Plant to replace coolant materials.

STUDY ON APPLICATION OF LD SLUDGE & MILL SCALE BRIQUETTE US IN CONVERTOR The use of mill scale briquettes as coolant in place of steel scrap/sized ore /Sinter in LD converter steel making process with following scope and available conditions: - • Scrap is 12 to 15 Ton per charge • Sinter is charged @ 4 t0 6 Ton per heat whenever hot metal comes in Torpedo ladle to reduce higher temperature • Total Fe in the Briquettes manufactured of available waste mix 58.13%a.

SCOPE OF STUDY

• Technical suitability of using mill scale briquettes in place of steel scrap / sized iron ore / Sinter as coolant in LD converters. • Material and energy balance with the use of mill scale briquettes. • Logistics of conveying of the material to LD converters. • Cost economics of the proposal

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

SUMMARY OF STUDIES • As a coolant Mill Scale briquettes (MS) can be considered on par with Iron ore and Sinter and with respect to steel scrap it is 2-3 times more effective. • Metallic content being low (58%~62%), yield of liquid steel will be lower in comparison to scrap usage. However, due to higher cooling effect, quantity of scrape replaced is higher which results in more available volume for additional Hot metal charge. • Mainly being oxide bearing material, addition shall be done with continuous feeding type. • Trial conducted with an initial quantity of 500 tons. • Handling was done through Conveyors from ground hopper to Bunkers at SMS, Converters for continuous feeding. • However, increasing hot metal consumption in place of reduced scrap cannot be envisaged in where TLC capacity of exactly caters to heat size. • Briefly the thermal balance equations show that 1 ton of SM briquettes can replace 2 tons of scrap and for iron ore and sinter the replacement will be 1:1. • Cost economics are favourable. • No change in blowing temperature. • Main objective of waste recycles and sustainability/conservation of virgin minerals achieved. • Generally, the cooling efficiency of coolant used during steel making is evaluated through observations while in actual practice / trials. In case of mill scale usage as coolant / replacement of steel scrap, the following are the most probable cases which can be further clarified by the actual observation. • The heat balance calculation shows that, the thermal efficiency of mill-scale as a coolant in BOF Steel making is similar to that of iron ore subjected to composition of mentioned earlier, therefore the addition of briquette as a coolant behaves similar to that of addition of iron ore in the BOF vessel during the commencement of a heat. Briquettes also gives surplus oxygen of 170-180Nm 3 (∼178Nm 3) per ton of its addition. • Influence on addition of briquette at start of the blow,in this case, if the total amount of briquette is added at the beginning of the blowing, the bath will get chilled and slag formation / lime dissolution will be delayed affecting the desired removal of phosphorus in the steel. Therefore, the amount of briquette must be added judiciously depending on the hot metal silicon content. For lower HM Silicon levels (if silicon<0.4 wt.% ), initial addition is favourable in slag formation. However, it is recommended to add approximately 60% of the total amount of briquette by 4-5 minutes of the blow along with lime to increase the lime dissolution. Rest amount must be added according to the prevailed situation in the blow. • Influence on addition of briquette at middle part of the blow , since it is well known that, during middle part of the blow decarburization reaches its peak, consuming all the oxygen for decarburization and also a significant amount of heat is generated, which helps the carbon removal in the forward direction. If at all, Briquettes is added in this period it may not give the actual thermal energy to propel the decarburization process by cooling the system and also the cooling efficiency of mill-scale will deteriorate and the oxygen generated from it will be available for decarburization also. • Influence on addition of Briquette at end part of the blow, if a greater number of briquettes is added at end part of the blow, the heat will be cooled and the desired opening temperature of the blown heat will be affected. Therefore, from the above it can be inferred that with its role as oxide as well as coolant, the quantity that can be used depends on actual chemistry and temperature of hot metal and clubbing with other additions like Sinter or iron ore. In all probability continuous feeding of mill scale is a practicable solution for which shop logistics are to be considered. SM briquettes can be charged through bunker only as we cannot add mill scale briquettes before the start of the blow. From the starting of the blow and within first 4-5 minutes blow, 60-70% of the mill scale briquettes was charged. After completion of about 4600 Nm 3 oxygen blowing, balance 30% mill-scale was charged along with balance lime in a phased manner to enhance de-phosphorisation and till completion of the blow.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

TRIAL CHARGE INPUT PER HEAT

PRESENT REVISED PRESENT REVISED (LD 1) (LD 2) HEAT WEIGHT 145 145 153 153 HOT METAL 145 149 153 158 SCRAP 12 6 18 12 SINTER 2.5 3 4 3 BRIQTS 2.75 3 MET.INPUT 151 151 165 165

CONCLUSION

The Mill Scale + BOF Sludge Briquettes successfully can replace up to 40% of the present quantities of scrape addition.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

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33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Development of amorphous Mg-Ca-Zn alloys by Melt spinning route

SudeepPaul a,b,* , RamasamyParthiban c, MitunDas b, Durbadal Mandal a, Mariana Calin d, Jürgen.Eckert c,e , SupriyaBera a aDepartment of Metallurgical and Materials Engineering, National Institute of Technology, Durgapur - 713209, India bBioceramics and Coating Division, CSIR-Central Glass & Ceramic Research Institute, 196 Raja S C Mullick Road, Kolkata-700032, India cErichSchmid Institute of Materials Science, Austrian Academy of Sciences, Jahnstraße 12, A-8700 Leoben, Austria dIFW Dresden, Institute for Complex Materials, P.O. Box 27 01 16, D-01069 Dresden, Germany eDepartment Materials Physics, Montanuniversität Leoben, Jahnstraße 12, A-8700 Leoben, Austria

*[email protected] (Presenting Author)

ABSTRACT

In the present work, two new Mg-based alloys were synthesized using melt spinning route and compared with the existing Mg 60 Ca 5Zn 35 alloy. The Differential scanning calorimetry (DSC) and x-ray diffraction (XRD) analysis clearly shows the formation of glassy structure in all the alloys.

The elastic modulus and hardness of the new alloys are lower as compared to Mg 60 Ca 5Zn 35 alloy. The degradation of new alloys was lower than existing alloy. In addition, the degradation products such as hydroxyapatite (HAp), Mg(OH) 2 were biocompatible to living body. Invitro biocompatible study with MC3T3-E1 cell line clearly demonstrates the non-toxicity of the alloys.

Keyword: Mg-based alloy, elastic modulus, degradation, non- toxicity

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Improvement in balling efficiency of mixing and nodulizing drumfor sinter making

S Sudershan 1, M Roy 2, SA Balaji 3, Dr. SK Dhua 4

1,4 RDCIS Burnpur Centre, SAIL, INDIA. (E-mail: [email protected] ) 2RDCIS Ranchi, SAIL, INDIA. 3RDCIS Durgapur Centre, SAIL, INDIA

ABSTRACT

Ball formation in Mixing and Nodulizing Drum (MND) is an important phenomenon in sinter making. Mixing homogenizes the base mix materials , whereasnodulizing of sinter mix improves the permeability of sinter machine. A state of the art sinter plant complex comprising of two sinter machines with 204 m 2 area each along with associated facilities have been commissioned at ISP, SAIL to produce 3.88 Mt/yr gross sinter. Both sinter machines are designed for1.2 t/m 2/hr.

An elaborate study of various input raw materials and preparation of base mix has been conducted at RDCIS, Ranchi. ISP receives iron ore fines from the captive mines of SAIL, viz., Bolani, Gua, Kiriburu and Meghahatuburu mines. Goethitic ore have low bulk density and high porosity which is the main constraint in increasing the sinter plant productivity. Higher alumina as well as very high Loss on Ignition (LOI) content (3-6 %) in these iron ore is the main constraints, which need to be taken care precisely to improve the quality sinter production.

Objective of this work was to present the variation in mixing analysis due to water addition system at MND and also the step taken to improve the efficiency of MND. The result also showed that mixing of carbon in the form of coke in the sinter mix helped in proper ignition and formation a smooth flame front during sintering.

Keywords: Sinter, Productivity, Goethite ore, Mixing analysis.

1.0 INTRODUCTION The sintering process is designed to convert ore fines into a product suitable as blast furnace feed resulting the benefits such as improved furnace control, homogenized chemical composition of the product, increase in specific furnace throughput performance, reduction of energy consumption, concentrating the essential components of the burden by the expulsion of water and loss on ignition. The sinter plants have been designed for a total output of 3.88 MTPA iron ore sinter considering an operating time of 7920 h/a. The plant availability was considered to be 90 % on an annual average. [1] Improvements in blast furnace process are achieved by technological improvements and a stable supply of high quality iron ores and sinter. However, high quality iron ore resources are being depleted due to the heavy demand, and thus it is necessary to continue improving sintering technology in order to use lower quality iron ores in raw mix along with the waste materials generated from steel industry in day to day operation. The blast furnace demands sinter with high strength, a low RDI, high RI, low fines content, good average calibrated sinter size and little variation in chemical composition in order to operate in a steady state regime. Efforts are being made to supply blast furnace operators with high quality sinter.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Sinter quality control, by means of adequate sintering, is important in order to operate blast furnaces at a low fuel rate and stable operating rate. At Sintering plant of IISCO Steel Plant (ISP), there are two sintering machines namely SP1 and SP2 of identical shape and design having sintering area of 204 m 2. The green mix coming from base mix plant is mixed into a single rotary drum termed as Mixing and Nodulizing Drum (MND). Raw materials are supplied to sinter machines after ball formations of green mix. Each sinter machine has its own MND. Belt conveyor assembly supplies the raw materials directly to the MND. Operation of one of the MND having internal diameter 4.0 m and overall length 15.0 m was studied in detail. [2] Balling efficiency of the drum had been calculated and a modified system for water addition was suggested which was fruitful. 2.0 EXPERIMENTAL

2.1 Description of the Mixing and Nodulizing Drum (MND) MND is a rotary drum system for agglomerating fines into spherical bodies in the form of pellets and larger balls from finely divided material such as iron ore and flux. Objective of this drum is recycling of fines to nodulize it without a binder other than water into pellets or balls which give green mix high gas permeability suitable for sintering into a coherent agglomerated cake mass. In sintering of the fines in continuous endless conveyor type sintering machines, it is necessary to nodulize or pelletize the fines before laying them onto the sintered strand in order to provide a layer or mass which is permeable to the through flow of the gas or flame. Most materials can be nodulized with water as the sole binder since they contain inherentproperties such that when wetted the balls produced become of such great density that they retain their shape and the desired bed permeability even after the moisture has been driven off in later stage. Beds so formed give a sintering layer of high permeability which permits high rates of sintering. With such very high rate of sintering speed, the nodules must be prepared and supplied to the sinter strand as they are freshly formed and at a rate sufficiently fast to maintain the continuity of a sintering layer at all times over the sintering strand.The drum is operable in horizontal axis and has a feed end and the other is discharge end. The entry of base mix in MND is through a conveyor belt and the balls formed due to this discharged over another conveyor.One of the most important factors which influence bed permeability is the sizing of feed to the sinter strand. Naturally, the larger and more uniform the sizing of the feed, the more open and permeable will be the bed. It is evident that the mixing and preparation of the feed for a sintering machine is of vital importance to the whole sintering operation. In most movable grate sintering operations, the raw materials are mixed with the proper amount of water in either a balling drumor a disc pelletizer. In all cases, the principal object is to produce pellets or balls of the raw material which are as uniform in size as is possible, in order to have uniform air flow for uniform sinter.

2.2 Proposed schematics for addition of water in MND

In the existing system, base mix are coming to the sinter plant SP 1&2 via RMHS (Raw Material Handling System), conveyor at JHA (Junction House A) and distributing the base mix to the two plants through a reversible belt feeder and series of conveyors. Limestone and solid fuel are coming to the sinter plant SP 1 & 2 via RMHS, conveyors at JHB (Junction House B) and distributing the limestone and the solid fuel to the two plants through a diverter gate and conveyors. Process water is added to the mixing and nodulizing drum. The belt conveyors downstream of the drum have been designed for conveying the output of MND.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

In its first third, the drum is fitted with lifter blades and the water addition system. The various materials are homogenized in this first third and about 70% of optimum amount of process water is added. In the remaining part, the drum has flat bars. There the mix is rerolled for granulation (converted into micro spheres) and the remaining 30% process water is supplied. The total retention time in drum is about 5 minutes. The finished sinter mix with optimum moisture content is transported by belt conveyors to the feed hopper for charging over the sinter machine. The water addition system in MND was designed by Outotec based on the granulometry of iron ore fines, where ISP was supposed to get blue dust/micro fines to the context of 50%. Thus to overcome the dusts water addition system was installed just after the entry of material in the drum. Figure 1 showed the installed existing water addition system. But, ISP is receiving the much coarser materials, Iron ore fines, coke breeze etc. (0 to 10 mm). Even after grinding, coke breeze contains coarser fraction, which makes its distribution among the components uneven. In view of the high moisture content, the concentrate formed large nodules, which makes mixing of other components difficult. [3] Thus, the fed amount of water in initial part of the MND was disturbing the mixing and often landed to segregated coke breeze. Based on study, an improved design for water addition had been provided which was used for trial purpose. The schematics are given in Fig. 2 .

Fig.1 :Schematics of water addition before modification

Figure 1 showed that the installed existing water addition system has water spraying system started from 1.9 m from the entry side of the drum which did not allow the sinter mix to be mixed in a dry condition. This landed to segregated coke breeze and the mixing of carbon in sinter mix was not homogeneous. Due to this, heat patches in the sinter bed could be clearly seen. Flame front also does not move downward uniformly.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Fig. 2: Modified water arrangement system in MND

2.3 Sampling of materials inside the MND Sampling of material inside the drum was a major job. The samples were collected inside the drum in such a fashion that the sampling would cover a whole cross–section at entry as well as discharge side. The samples were collected from right to left 3 nos. from the surface of the layer after stopping the MND and termed as position 1, 2 and 3 and two from in between of the sample collected position of 1-2 and 2-3 after removing the surface layer carefully and termed as position 4 and 5 respectively. This is presented in Fig. 3 .

Fig.3: Sample collection points inside cross-section of MND

Before Nozzle plugging 10 samples were collected: 5 from entry side of MND and 5 from the discharge side of MND. Similarly, 10 samples were collected: 5 from entry side of MND and 5 from the discharge side of MND after modifying the water addition system at MND. 2.4 Preparation of material for testing and analysis

The collected samples were taken to Research and Control laboratory, SAIL ISP in a sealed bag for chemical analysis. A part of these samples were also sent to RDCIS Ranchi in a sealed bag. Each sample was weighted. The samples were dried above 100 0C to remove the moisture and then these were again weighted and the loss of amount of water/moisture was recorded. The samples were crushed into fine particles with a binder. The crushed samples were taken in a testing pot for chemical analysis. The result of the test is given in Table 4 .

3.0 Results and Discussions

Option described in Fig.2 was the best suited for increasing the mixing zone. Three numbers of nozzles from entry side were plugged at SP1. Samples from MND of SP1 were collected before nozzle plugging for Mixing and Balling analysis. Samples were again collected after nozzle plugging. The various machine parameters were collected during sampling for before and after innovation and given in Table 1 . The granulometric analysis for samples collected before and after MND before plugging the nozzle; i.e; before innovation is given in Table 2 . Additionally, two more samples were collected and balling index of those 2 samples was calculated which was coming around 1.6. Similarly, Table 3 gives the granulometric analysis of one sample collected before and after MND for calculation of balling index after plugging the nozzle; i.e; after innovation. Balling index was calculated and it was improved from 1.6 to 1.9.

Table 1: Machine parameters Sl No. Parameters (unit) Before Innovation After Innovation 1 Feed Rate (t/h) 288 306 2 Coke Trimming (%) 2.10 2.60 3 Return Sinter (%) 28 23 4 Machine Speed (m/min) 1.70 1.60 5 Bed Height (mm) 680 690

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

6 Hearth Layer (mm) 60 60 7 BTP ( oC) 380 376 8 Wind main Temp. ( 0C) 160 168 Water addition: Tonnage Primary (t) 7.00 7.80 Tonnage Secondary (t) 1.99 1.29 9 Pressure in Primary (bar) 5.77 6.00 Pressure in Secondary (bar) 5.20 5.78 Valve opening in Primary (%) 48 51.72 Valve opening in Secondary (%) 66 49.54

Table 2: Granulometric analysis of samples collected before and after MND before innovation Sample-1 Sample-2 Size Before MND After MND Before MND After MND (+)3mm% 32.2 52.3 33.1 52.1 (-)3mm% 67.8 47.7 66.9 47.9 Balling Index 1.62 1.57

Table 3 : Granulometric analysis of samples collected before and after MND after innovation Before MND: After MND: Size Size Weight (kg) (%) Weight (kg) (%) (mm) (mm) + 3 2.20 30.77 + 3 5.05 59.41 - 3 3.45 40.59 - 3 4.95 69.23 Total 8.50 100.00 Total 7.15 100.00 Balling Index 1.93

In Table 4 , A represents the entry side of the MND and D represents the discharge side of MND. The Numbers 1,2,3,4 and 5 represents the position inside the MND as described above in Fig. 3 . Before innovation shows that the samples collected before plugging the nozzles and after innovation shows that the samples collected afterplugging the nozzles.

Table 4 : Mixing analysis report of ISP base mix collected from MND

Sample No. FeT% SiO 2% Al 2O3% CaO% MgO% LoI% C% A1 49.57 4.49 2.77 8.76 4.17 8.31 3.66 A2 49.54 3.88 2.83 9.1 4.04 8.64 3.87 Before Innovation A3 48.64 3.89 2.83 8.78 4.25 10.07 4.21 A4 50.62 4.17 2.75 8.87 4.04 7.18 2.93 A5 49.87 4.04 3.2 9.04 3.99 7.78 3.16 Standard 0.71 0.25 0.18 0.15 0.11 1.09 0.52 Deviation D1 47.38 3.65 3.14 9.62 3.63 11.57 5.02 D2 48.27 4.01 2.73 9.29 3.32 11 4.86 Before Innovation D3 48.17 4.15 2.78 9.15 3.08 10.98 4.67 D4 49.92 3.59 2.79 8.42 2.97 10.2 3.99 D5 49.52 4.13 2.87 8.46 3.01 10.86 4.27

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Standard 1.04 0.27 0.16 0.53 0.28 0.49 0.43 Deviation A1 47.61 4.91 3.47 7.76 3.78 11.36 5.56 A2 49.48 4.49 3.58 7.4 3.2 9.92 4.74 After Innovation A3 48.45 5.14 3.31 7.81 3.86 9.97 4.91 A4 47.5 4.16 4.1 8.09 3.6 11.46 5.21 A5 48.07 4.43 3.59 7.88 3.78 10.89 5.61 Standard 0.80 0.39 0.30 0.25 0.27 0.74 0.39 Deviation D1 47.72 4.75 3.54 8.25 3.83 10.74 5.26 D2 47.69 4.43 3.4 8.24 3.69 11.43 5.67 After D3 48.9 4.64 3.96 7.54 3.17 10.12 5.12 Innovation D4 47.94 4.85 3.71 7.84 3.58 10.86 5.25 D5 48.68 5.26 3.22 7.46 3.06 10.74 5.54 Standard 0.57 0.31 0.28 0.37 0.33 0.47 0.23 Deviation

The results revealed that the after shifting the positions of nozzle, the base mix got enough time for dry mixing in the entry side of MND. After dry mixing, water was mixed and this helped in homogenization of base mix. From Table 4, it is evident thatthe variation in the chemical composition of samples at different points along and across the stream also indicated that the individual components were localized in different regions of the stream of the moving drum.Thus, more concentrate were located in central part of the stream. This can be seen from the higher content of ferrous oxide and the low lime content of discharge side of mixing and nodulizing drum. Flux moved preferentially along the periphery of the stream.

4.0 Conclusion

i) The mixing analysis from MND showed that the distribution of carbon (% C) and other minerals after plugging the nozzle was proper as seen from the reduction in standard deviation. ii) The standard deviation for carbon (% C) was reduced from 0.52 to 0.23. It is also confirmed that, sinter mix during the passage through a drum, the fines concentrate was localized at the centre of drum, whereas, the flux moves mainly along the edge. iii) After plugging of 3 nos. of initial nozzles, it was observed that there was an improvement in the balling index of MND. Thus, the recommendation regarding addition of water in the mixing and nodulizing drum after 3 m from the entry side of Sinter mix was helpful. iv) The homogenous mixing of carbon in base mix helped it in proper burning at the sinter machine. The balling efficiency had also improved.

5.0 References

1. Operating Manual, Sinter Plants 1 and 2, IISCO Steel Plant. 2. Instrumentation Manual for Sinter Plant, IISCO Steel Plant, pp. 22-43. 3. Spektor, AN et.al., Investigating the operation of Mixing Drums, Metallurgia, July1971, pp. 588-593. 42

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Global Steel industry scenario in the face of new challenges

Mr.Lohitendu Badu, General Manager, DSP/SAIL

ABSTRACT

Global steel industry currently is at the end of a rare cycle as China completes its rapid economic growth phase. Share of EAFs in the total global steel production and the share of ferrous scrap in total metallic demand recently declining. However, global scrap availability is expected to grow strongly, suggesting that steel industry can increase its use of ferrous scrap considerably in the medium and long-term. Steel industry has shown considerable improvement in productivity and environmental footprint. Steel has superior environmental characteristics as it is 100 percent recyclable. Steel has superior recyclability, when compared with competing materials. Innovative use of steel saves six times as much CO 2 as is caused by the production of the steel. Life cycle thinking reveals the advantages of steel.

Key words- Carbon footprint, life-cycle thinking

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Butt friction stir welding of aluminium to steel - a review

AbhijitDatta , SitanshuShekharChakraborty

CSIR-Central Mechanical Engineering Research Institute, Durgapur 713209, India.

Abstract

This article aims to provide a critical review of literature onbutt friction stir welding (FSW) of aluminium to steel. As per the standard ISO 25239-2011, FSW is a "joining process producing a weld by the friction heating and mixing of material in the plastic state caused by a rotating tool that traverses along the weld". This process overcomes the difficulties associated with the poor joint efficiency in fusion welding of these two materials because of almost insolubility in each other and generation of brittle intermetallics. The joining mechanism, as well as the effect of process parameters on the weld quality responses have been discussed.

Key words:-Dissimilar joining, butt joining, FSW

1. Introduction

Specific strength (ultimate tensile strength/ density) of aluminium alloys is typically more than double the specific strength of steel. For example specific strength of low carbon steel (AISI 1010) and stainless steel (AISI 304) are 46.4 kN.m/kg and 63.1 kN.m/kg, respectively. On the other hand, specific strength of AA 6061-T6 and AA 7075-T6 aluminium alloys are 115 kN.m/kg and 204 kN.m/kg, respectively (Specific Strength, Wikipedia.org). Therefore, for lightweight structure which can provide fuel economy of automobiles and aircrafts, use of aluminium is preferred. However, apart from the typical higher cost of aluminium sheet compared to steel sheet (Hadly et al., 1999), the processing, like forming and especially, welding of aluminium is a big challenge (Barat et al., 2019). Typically, the joint strength of fusion- welded aluminium sheet is less than the base material. This limitations can be overcome using solid state welding process like friction stir welding (FSW) (Misra and Ma, 2005). In case, aluminium is to be joined with steel, the limited solubility of aluminium into steel and especially, the chances for formation of brittle intermetallics, are significant barriers against choosing fusion welding as the joining process. During joining of these two metals mainly three points are taken into considerations, firstly Galvanic corrosion, secondly different melting point and finally formation of brittle inter-metallic phase at high temperature (Osikowicz , 2018). The limitation of long set-up time, limited plate thickness etc. of the solid state welding process like diffusion

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

welding are also not very encouraging. In this case also, friction stir welding is a viable alternative process for joining steel to aluminium. Such dissimilar joints has many applications. In the context of replacing a part of the structural steel with aluminium alloys to reduce weight for the advantages like enhanced fuel economy etc., this dissimilar FSW of aluminium to steel has gained more importance recently. For example, Fig. 1 shows the structure of a typical car in which portions of aluminium and steel are indicated with different colours. Hence, significant research attention has been attracted towards this research problem. This article aims to provide a critical review of literature onbutt FSW of aluminium to steel.

Fig. 1. Mixed Material body structure (New Techniques for Joining Steel and Aluminum, 2017) 2. Overview of butt friction stir welding process

The Process Friction Stir Welding (FSW) is a solid state joining process in which a rotating cylindrical tool with a shoulder and a pin is plunged between the adjoining plates to be joined and traversed along the line of the joint. The plates are tightly clamped on to the bed of the FSW equipment to prevent them from coming apart during welding. A cylindrical tool rotating at high speed is slowly plunged into the plate material, until the shoulder of the tool touches the upper surface of the material. A downward thrust force is applied. Frictional heat generated between the tool and the material, causes the plasticized material to get heated and softened, without reaching the melting point. The tool is then traversed along the joint line, until it reaches the end of the weld. As the tool is moved in the direction of welding, the leading edge of the tool forces the plasticized material, on either side of the butt line, to the back of the tool. 45

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

In effect, thetransferred material is forged by the intimate contact of the shoulder and the pin profile. It should be noted that, in order to achieve complete through-thickness welding, the length of the pin should be slightly less than the plate thickness, since only limited amount of deformation occurs below the pin. The tool is generally tilted by max. 5°, to facilitate better consolidation of the material in the weld. Upon reaching the end of the weld, the tool is withdrawn, while it is still being rotated (Said et al., 2016). Fig. 3 shows the butt FSW process schematically. Table 1 enlists the process parameters (inputs) and variables (responses).

Fig. 2: Friction stir welding process (Said et al., 2016)

Table 1: Process parameters and variables in FSW aluminium to steel PROCESS PARAMETERS VARIABLES Rotation speed UTS & % elongation Welding speed Microstructure Axial load or Thrust force Weld zone / HAZ Tool tilt angle Fatigue Insertion depth of the tool pin Residual stress Shoulder plunge depth

Tool shoulder diameter

Tool geometry (cylindrical or conical)

3. Aluminium to steel butt joining by friction stir welding - Current Status Kimapongand Watanabe (2004) explained the joining process in dissimilar FSW of aluminium to steel using different amount of tool offset, i.e. distance of tool pin axis and the faying surface, as shown in Fig. 3.a and 3.b. 46

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Fig. 3. Effect of tool offset in butt FSW of aluminium to steel on (a) tensile strength and (b) microstructure of the joint (Kimapong and Watanabe, 2004). They explained the mechanism of joining is the following. The tool has to rub the faying surface of the steel plate which should be on the advancing side, to remove oxide from the surface. The other portion of the rotating tool should then carry with its rotation the aluminium on the retreating side and paste the same onto the faying surface of the steel. That is why only slight penetration into the steel plate (0.2 mm) provided the highest joint strength. Yazdipour&Heidarzadeh(2016) studied the effect of tool rotational speed and welding speed or the traverse speed in butt FSW of Al 5083-H321 and 316L stainless steel plates using H13 steel tool. They found maximum tensile strength of 238 MPa of the weld joint for rotational speed of 280 rpm and traverse speed of 160 mm/min.

Effect of different process parameters on to the weld quality parameters like, tensile strength (transverse), percentage elongation and microhardness as found in different investigations are listed in Table 2 in comparison to the aluminium alloy which is the weaker base material. These three parameters shall indicate the joint strength relative to the base material (similar to joint efficiency in similar butt welding), formability of the welded joint and the abrasion wear resistance of the butt FSW joint.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Table 2: Effect of process parameters in butt friction stir welding of steel to aluminium

Sl. Mater ial Tool material, RPM Feed Shoulder Offset of Quality responses Reference no. (Thickness in Tool geometry, rate plunge pin centre mm) (AS-RS) Tilt angle (mm/ depth from the 1. UTS weld (MPa) min) (mm)/ faying /UTS Al (MPa) Thrust surface 2. % force (N) towards Elongation weld / the Al %Elongation Al plate (mm) max 3. VHN weld / max VHN Al 8 SS400 mild steel (2 Material: High 250 25 0.8 (optm) 240 / 275 (86%) Kimapong, and mm) - A5083 Speed Tool Steel (optm) Watanabe, 2004 aluminium (2 mm) (SKH57), Pin shape: Straight Cylinder Shoulder diameter: 15 mm, Pin diameter: 2 mm, Pin length:1.9 mm 2 SS 316L (5 mm) - Material: H13 steel 280 160 0.4 238 / 240 (99%) Yazdipour, and AA5083-H321 (5 Pin shape: Straight (optm) (optm) Heidarzadeh, mm), Butt joint Cylinder 2016 Shoulder diameter: 20 mm, Pin diameter: 5 mm, Pin length: 4.7 mm Tilt angle: 2.5° 3 304 SS (3 mm) - Material: WC 500 80 Shoulder 1.5 mm 1. 175/210 (without Habibnia et al. 5050 Al alloy, Butt Pin shape: Tapered plunge (optm) annealing); (2016) joint cylinder depth: 0.2 198/210 Shoulder diameter: mm (optm) (annealing at 350 20 mm °C for 90 min) Pin diameter: 4mm 2. 9/25 (without (lower end) to 6 annealing); 20/25 mm (shoulder end) (annealing at 350 Pin length: 2.75 mm °C for 90 min) Tilt angle: 2° 4 IF steel (3 mm) - Material: High 600 100 Thrust 0.75 mm 1. 123/132.1 Kundu et al. CP Al (3 mm), Butt Speed Steel Force: 5 kN 2. 4.5/9.8 (2013) joint Shape: Tapered 3. 470±10/49±4 Cylinder Shoulder diameter: 25 mm Pin diameter: 2.5 mm (bottom) to 5 mm (top) Pin length: 2.7 mm Tilt angle: 2° 5 A7075-T6 Material: not 500 100 1.6 - 1.7 1. 333/460 Tanaka et al. aluminium alloy (3 mentioned (2009) mm) - mild steel (3 Shape: cylinder mm), Butt joint with standard thread Shoulder diameter: 12 mm Pin diameter: 4 mm Length: 2.9 mm optm: optimum

4. Conclusion

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

This article briefly outlined the process of butt friction welding process (FSW) and presented a review of mechanism and effect of process parameters in butt FSW of aluminium to steel reported in the recent literature.

References Specific strength - Wikipedia.org: https://en.wikipedia.org/wiki/Specific_strength, 16/12/2019

Hadly, S.W., Das, S., Miller J.W., 1999, Aluminum R&D for Automotive Uses And the Department of Energy’s Role, Report no. ORNL/TM-1999/157, U.S. DEPARTMENT OF ENERGY;https://www.researchgate.net/publication/237426784_Aluminum_RD_for_Automotive_Uses_and_the_D epartment_of_Energy's_Role/link/004635256a16503650000000/download

Barat, K. and Venkateswarlu, K., 2019. Laser material interaction parameter: New tool for developing property diagrams for welds. Journal of Laser Applications , 31 (3), p.032012. Mishra, R.S. and Ma, Z.Y., 2005. Friction stir welding and processing. Materials science and engineering: R: reports , 50 (1-2), pp.1-78. OsikowiczWojciech, July 2018, What to consider when joining dissimilar metals, (viewed 20/11/19). New Techniques for Joining Steel and Aluminum, Light weighting is forcing automotive engineers to explore cutting-edge technology, April 11 2017, (viewed 23/11/19). < https://www.assemblymag.com/articles/93777-new- techniques-for-joining-steel-and-aluminum > Said et al., 2016, Experimental Study on Effect of Welding Parameters of Friction Stir Welding (FSW) on Aluminium AA5083 T-joint, Volume 15 (4): 99-107. (viewed 15/11/19).

Kimapong, K. and Watanabe, T., 2004. Friction stir welding of aluminum alloy to steel. Welding journal, 83(10), p.277. Yazdipour, A. and Heidarzadeh, A., 2016. Dissimilar butt friction stir welding of Al 5083-H321 and 316L stainless steel alloys. The International Journal of Advanced Manufacturing Technology, 87(9-12), pp.3105-3112. Habibnia, M., Shakeri, M., Nourouzi, S. and Givi, M.B., 2015. Microstructural and mechanical properties of friction stir welded 5050 Al alloy and 304 stainless steel plates. The International Journal of Advanced Manufacturing Technology, 76(5-8), pp.819-829. Kundu, S., Roy, D., Bhola, R., Bhattacharjee, D., Mishra, B. and Chatterjee, S., 2013. Microstructure and tensile strength of friction stir welded joints between interstitial free steel and commercially pure aluminium. Materials & Design, 50, pp.370-375. Tanaka, T., Morishige, T. and Hirata, T., 2009. Comprehensive analysis of joint strength for dissimilar friction stir welds of mild steel to aluminum alloys. ScriptaMaterialia, 61(7), pp.756-759.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Effect of Molasses and Lime on Strengthening Property of Chromite Briquettes

Soumya Mukherjee 1) , Siddhartha Mukherjee 2)

1) Department of Metallurgical Engineering, KaziNazrul University, Asansol-713340 2) Dr. M. N. Dastur School of Materials Science and Engineering, IIEST Shibpur, Botanical Garden Area, Howrah, West Bengal 711103

Corresponding author: [email protected] , [email protected]

Abstract: Large amount of chromite fines are generated due to fragile nature of ores and mechanized mining. The need of agglomeration technique is to be adopted for use as electric furnace charge. The optimizations of lime and molasses amount are to be controlled to achieve good mechanical properties of agglomerates. Extensive studies have been carried out to strengthen chromite agglomerate by varying various properties. Molasses an industrial binder can be used with lime to generate good binding properties with an improvement in shatter index and abrasion index of the briquettes. Briquetting process is more convenient for its simple plant design and economical process. Poor quality briquette leads to poor productivity, high dust loss and high power consumption. These make quality briquette production an essential one for high performance of smelting furnace for the production of charge chrome. The scope of present investigation includes a) size determination of chromite and its grading b) Choice of binders and its characterization c) Reducibility of briquettes. Finally an attempt has been made to compare smelting of lumpy chromite with briquette charge. Keywords: Chromites, briquettes, agglomerates

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Improvement in steel ladle life at ISP: A case study

Abdur Rouf 1, Dr. S K Dhua 1, Kumar Abhishek 1 and B K Sinhamahapatra 2 1Research & Development Centre for Iron and Steel, ISP Burnpur Centre, Burnpur 2Refractories Engineering Department, IISCO Steel Plant, Burnpur

1.0 Abstract In the present scenario, process optimization and cost control in steel making are the key objectives in any steel plant. Refractory consumption is one of the major areas for cost reduction in steel industry.Ladle refractory performance depends on the refractory quality as well as on the ladle operating parameters. Ladle operating parameters and conditions has been changed slowly without changing the quality of refractory. Ladle operating conditions include slag chemistry, arcing duration at ladle furnace, ladle empty time after casting end and total metal holding time etc. Ladle lining performance has been improved with the change of ladle operating conditions. The ladle operating parameters and ladle performance has been discussed in this paper. Key Words: Magnesia Carbon (MgO-C), Refractory, Slag Basicity, Ladle Furnace (LF), Erosion, Thermal shock. 2.0 Introduction A steel ladle is a metallurgical vessel lined with refractory material. Metal holding capacity of steel ladle at IISCO steel plant is 150 T. Steel making process route is basic oxygen furnace (BOF), ladle furnace (LF) and caster. After BOF operation, steel is poured into steel ladle for further metallurgical operations at ladle furnace. Steel temperature varies from 1650 °C to 1700 °C at the time of tapping from converter to preheated ladle. During tapping, addition of lime, dolomite and bauxite were done as per requirement. These basically act as fluxing agent for slag formation. Then the ladle goes to ladle furnace for reheating and final alloying during secondary steel making. Vigorous chemical reactions and heat treatment take place at ladle furnace.

Ladle lining is comprises of two main layers: working lining and safety lining. Working lining refractory is magnesia carbon (MgO-C) with thickness of 178 mm at metal zone and 203 mm at slag zone. Alumina - magnesia - carbon (AMC) bricks are used at the impact area of ladle bottom. Safety lining compose of insulating ceramic paper on the metallic shell and castable lining on the insulating paper for safety purpose. Functional refractories are two numbers purging blocks, one slide gate system and sealing materials.

The performance of MgO-C bricks in any metallurgical vessel depends on resistance to corrosion, erosion and thermal shock properties. Degradation of lining material results from the interactions with chemical, thermal and mechanical phenomenon. The factors influencing the performance are (i) working time of ladle with liquid steel, (ii) ladle empty time i,e the time between end of casting and start of tapping, (iii) tapping temperature from the convertor, (iv) arcing duration and (v)metallurgical processing in the secondary steel making at ladle furnace [1] . The lining material mainly suffers from chemical corrosion in the contact area with slag. Steel making slag is a complex mixture of many oxides like FeO, CaO, SiO 2, Al 2O3 and MgO[2]. The wear mechanism of MgO-C bricks has been documented [4] . At the interface of MgO-C bricks and slag, slag penetrates into inter granular silicate bond of the sintered and fused MgO grains. This interaction promotes low temperature phase formation and facilitates the MgO grain loosening [4] . The carbon part as flaky graphite is mainly introduced into the MgO-C bricks due to its non wetting property with liquid slag. The graphite forms a protection layer against slag penetration into the refractory brick. The wear mechanism of MgO-C liningof ladle is cyclic. First oxidation of carbon on the surface of the lining takes place with oxygen from surrounding 51

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

gasses, dissolved oxygen in the steel and oxidized slag containing Fe and Mn oxides. Then formation of porous layer of the lining material occurs adjacent to the surface due to the reaction. Subsequently, infiltration of liquid slag into the decarbonized and porous layer takes place. Dissolution of the MgO grains and accompanying phases in ladle slag also occurs. This wear mechanism depends on the slag chemistry, system temperature and duration of the reaction. Data has been collected for the period of February, 2018 to December, 2018 for all the campaigns for all operated ladles. Data collected for slag chemistry i,e slag basicity, arcing duration in ladle furnace, total metal holding time, ladle turned around time for selected ladles and average ladle life for normal wearing campaigns. Correlation graph has been made with ladle life and analysis has been done.

3.0 Change in operational condition Capturing of ladle life data has been started from middle of 2015 after commissioning of SMS shop. Ladle life was very less during stabilization period. Ladle lining life slowly started improving and reached above 40 heats by middle of 2017. From middle of 2017 up to February, 2018, ladle life become almost stagnant. At this time, it was felt that there is a need to change the operating conditions. There were 4-5 refractory suppliers for the entire set of ladle lining material. Each supplier provided the entire working lining refractory except functional refractories for a campaign. It was found that irrespective of the supplier, ladle life was more or less in the same range. At this situation, operational conditions have been changed to observe their effect on ladle lining performance. At first slag modification has been done; lime and bauxite additions have been increased into ladle during tapping from converter. Coke addition started in case of mild steel grades in the ladle bottom during tapping from converter. Arcing time has been reduced to the extent possible.

4.0 Data Collection During the period of study, 22 numbers steel ladles were available with the shop, out of which one ladle was damaged. Any point of time, 10-11 ladles were in operation. A few ladles were in emergency stock and rest of the ladles was either in relining or in preparation stages. Each ladle with liquid steel went through various process parameters starting from tapping of steel from converter, LF operation and finally casting of the steel. Data was collected from February, 2018 to December, 2018 except September, 2018 as plant was under shut down. Data was collected for the parameters of slag chemistry i,e slag basicity, arcing duration in ladle furnace, total metal holding time, ladle turned around time for selected ladles and average ladle life of normal wearing of working lining. Left out thickness measurement has been performed for a few ladles.

5.0 Result and Discussion Monthly averaging was done for the slag basicity, metal holding time, arcing time and ladle life data. Correlation of lining life has been done with each of these parameters.These parameters are being discussed below correlating with ladle working lining performance.

5.1 Slag Composition Monthly average data of LF out slag has been given in Table1. It was seen that slag basicity i,eCaO: SiO2 ratio was 1.26 in the month of February,2018. Slag basicity had improved slowly to more than 1.5 after modification of slag. It was seen that MgO% in the slag composition was inversely proportional to the slag basicity. MgO % was highest of 15.18% in the slag in the month of February, 2018 where slag basicity is lowest of 1.26. MgO% was lowest of 9.50% in the month of December, 2018 where slag basicity is highest of 1.56. 52

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Table 1: Chemical composition of LF slag Slag basicity CaO SiO 2 Al 2O3 MgO FeO MnO (CaO/SiO2) Feb,18 42.98 34.06 3.22 15.18 1.51 0.09 1.26 Mar,18 46.03 31.70 7.12 11.58 0.56 0.76 1.45 Apr,18 46.72 31.39 7.28 10.92 0.58 0.71 1.47 May,18 46.21 31.32 7.33 10.46 0.89 0.79 1.47 Jun, 18 46.89 30.89 7.33 10.61 1.05 0.88 1.52 Jul, 18 46.21 31.16 7.71 10.93 0.95 0.81 1.48 Aug,18 47.02 30.12 9.31 9.79 0.92 0.72 1.56 Oct,18 45.66 30.57 7.54 10.48 1.03 0.86 1.50 Nov,18 46.39 30.50 7.49 10.07 1.03 0.92 1.53 Dec,18 46.88 30.15 7.84 9.50 1.22 1.0 1.56

Higher SiO 2 level in slag makes the slag corrosive in nature and hence high corrosion in the slag zone area was observed as shown in Fig.1. Figure2 indicates left out thickness of slag zone of working lining after 28 heats, measured in February, 2018. Blue area is left out thickness of slag zone after 28 heats and red area is erosion of slag zone. Maximum erosion measured between rings 6 to 8 and then erosion slowly reduced up to 12th ring. According to the wear mechanisms of magnesia bricks, slag rich in CaO, SiO 2 and Al 2O3 penetrates between the grains of MgO by capillary and chemical reaction [2]. The liquid silicates inside MgO grains lead to detachment from the mass of refractory lining. Carbon presence in the grain boundary prevents the penetration of slag in to the matrix because carbon does not melt and wet by slag. Oxidation of graphite increases the brick porosity which allows slag penetration into the matrix of brick resulting dispersion of magnesia grains in the liquid slag [4] . The slag movement can also be reason for washing out a small part of the lining material.

Fig.1: Slag zone high corrosion Fig.2: Left out thickness of slag zone after 28 heats

Ladle slag modification was done by redesigning of flux addition during taping of steel into ladle to form soft and fluid slag. Calcined lime addition was increased and accordingly bauxite addition was also increased to maintain the slag fluidity respectively. Figure3 indicates the trend of monthly average slag basicity and monthly average ladle lining performance in terms of number of heats per campaign. It is visible from the graph that ladle life was 42 heats in February, 2018 and corresponding slag basicity was 1.26. Then both slag basicity and ladle life are almost proportionally increased. Ladle life was reached to 56 heats when slag basicity was 1.56.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Fig.3: LF slag basicity (monthly average) vs monthly average ladle life

5.2 Arcing duration A ladle furnace is used for reheating of liquid steel through electric power by graphite electrodes and homogenization of steel temperature and chemistry through inert gas stirring with the help of porous plug. Secondary functions of LF treatment are alloy additions to achieve final chemistry of the desired grade steel and act as a buffer for downstream steelmaking. During arcing, stirring of liquid steel is a necessary process to get effective increase of steel temperature. There is a chance of localize heating while arcing without stirring. Argon gas is purged into the ladle bottom through purging block. The argon gas in the form of bubbles rise up through the steel melt and stirred the steel. High temperature due to localized heating increases the reaction rate between slag and refractory. Arcing duration for all heats made in a month has been collected and monthly average duration has been plotted against monthly average ladle life as shown in Fig.4. Arcing time was monitored and reduced to 19.57 minutes per heat in December, 2018 from 23.95 minutes per heat in January, 2018. It was seen that ladle refractory performance was increased with the reduction of arcing time. Higher arcing duration and longer treatment time in ladle furnace adversely affects the ladle lining performance.

Fig.4: Arcing duration at LF and monthly average ladle life

5.3 Metal holding time Metal holding in a ladle starts from the beginning of taping of the converter. The ladle is no more a vessel, it is a metallurgical furnace wherein different metallurgical reactions take place starting from taping, transportation to ladle furnace and during operation at ladle furnace. After LF

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

operations, the ladle carries the steel to caster and finally teaming of the steel during casting process. This entire duration till end of casting is called metal holding time. The liquid steel stays in the ladle for a long time which includes LF operation time as well as casting duration. Strong scour of molten steel, slag and airflow causes the lining brick to be subjected to corrosion attack and severe thermal shock. Figure5 shows the monthly average metal holding time and ladle lining performance. Average metal holding time ranged from 171 minutes to 184 minutes with mean value was around 180 minutes. Standard deviation of monthly average metal holding time for all 12 months was 5.66. With this variation of metal holding time, variation of ladle life was not significant. Whatever small variation was seen in Fig.5 might be because of some other predominant reasons like slag corrosion and arcing duration. However, ladle lining performance can vary with abrupt variation of metal holding time.

Fig.5: Metal holding time vs monthly average ladle life

5.4 Turned around time Casting end to next tap start time for a ladle is called as turned around time. After casting, ladle goes for slag dumping and after slag dumping, ladle comes to ladle preparation stand. In ladle preparation stand, ladle is cleaned and checked for any abnormality in the lining. If required, functional refractories, i.e, slide gate plates, inner and outer nozzles and purging blocks are changed. After preparation the ladle goes for tapping. If turned around time is more means the ladle is losing temperature and become cold. The cold ladle is more susceptible to more thermal shock during holding metal just after tapping from converter. It was observed that the resistance to mechanical and thermal stresses is one of the most important characteristics for refractory lining [3] . Turned around time for ten ladles for a full campaign was captured and normalized with respect to 100% in different segment as shown in Table2.

Table2: Percentage of occurrences of turned around time Percentage of occurrences of turned around time (minutes) Sl No Ladle Life <120 120-180 180-240 240-300 >300 >180 1 3 14 59 16 8 83 47 2 36 47 17 0 0 17 55 3 32 49 17 3 0 20 54 4 44 38 12 6 0 18 55 5 39 41 18 2 0 20 56 6 41 50 9 0 0 13 54 7 39 50 9 0 2 13 54 8 37 45 14 4 0 18 61 9 40 51 8 0 3 11 54 10 33 21 11 9 0 20 52

Ladle life was 47 in serial number 1. 83% cases of the turned around time for the campaign were more than 180 minutes. Lining material comparatively exposed to more thermal shock during the 55

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

campaign as a result the campaign was matured at low life. In serial number 8, 18% cases of the turned around time for the campaign were more than 180 minutes and campaign life was comparatively more. Turned around time for rest of the campaigns were similar with the campaign in serial number 8. More turned around time means either ladle was kept idle or preparation time was more.However ladle was releasing heat energy continuously and getting colder gradually. This colder ladle was observed severe thermal shock in contact with liquid steel of temperature up to 1700°C during tapping.

6.0 Conclusion 1. Slag basicity plays a major role in the performance of ladle lining refractory. Slag zone refractory corroded and eroded faster because of low slag basicity. MgO percentages in the slag compositions increased when slag basicity was less.

2. Stirring of liquid steel during arcing is a necessary process to get effective increase and homogenization of steel temperature. There is a chance of localize heating while arcing without stirring. High temperature due to localized heating increases reaction rate between slag and refractory lining.

3. Ladle refractory performance was increased with the reduction of arcing time. Higher arcing duration and longer treatment time in ladle furnace adversely affected the ladle lining performance.

4. Performance of ladle refractory cannot be assessed with small variation of metal holding time. However, it is well known that ladle life deteriorates with abrupt increase of metal holding time because of more corrosion and thermal shock.

5. Higher turned around time leads to cooling of refractory lining slowly. As a result, lining materials observed higher thermal shock during next tapping of liquid steel. Ladle life was less for those ladles passed through more turned around time.

7.0 References 1. W Zelik, R Lech, Key factors influencing the lifetime of a steel ladle in respect of the wear of refractories , MaterialyCeramiczne/Ceramic materials, 69,1, (2017), pp.10-17 2. E Benavidez, E Brandaleze, L Musante, P Galliano, Corrosion study of MgO-C bricks in contact with a steel making slag , International Congress of Science and Technology of metallurgy and Materials, SAM-CONAMET 2013, ProcediaMaterails Science 8 (2015), pp.228-235. 3. M AQuintela, F D Santos, C A Pessoa, J D A Rodrigues and V C Pandolfelli, MgO-C Refractories for steel ladles slag line , Refractories Application and News, Vol.11, Number 5, Sep/Oct 2006. 4. S Camelli, M Labadie, Analysis of the wear mechanism of MgO-C slag line bricks for steel ladles , 49. InternationalesFeuerfest-Kolloquium, 2006.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Non Destructive testing( NDT) a useful tool for damage assessment of industrial Component S Ray Sr. Technical Officer ,ISR group, CMERI, Durgapur-713209,

The field of Nondestructive Testing (NDT) is a very broad, interdisciplinary field that plays a critical role in assuring that structural components and systems perform their function in a reliable and cost effective fashion. NDT technicians and engineers define and implement tests that locate and characterize material conditions and flaws that might otherwise cause component in-service failure. These tests are performed in a manner that does not affect the future usefulness of the object or material. In other words, NDT allows parts and materials to be inspected and measured without damaging them. Because it allows inspection without interfering with a product's final use, NDT provides an excellent balance between quality control and cost- effectiveness.

The main goal of NDT is to predict or assess the performance and service life of a component or a system at various stages of manufacturing and service cycles. NDT is used for quality control of the facilities and products, and for fitness of purpose assessment (so-called plant life assessment) to evaluate remaining operation life of plant components (processing lines, pipes and vessels). NDT inspection of industrial equipment and engineering structures is important in power generation plants, petroleum and chemical processing industries, and transportation sector. State- of the art methodology is applied to assess the current condition, fitness-for-service, and remaining life of equipment. NDT inspection provides basic data to develop strategic plans for extending plant life.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Role of in-situ Metallography for damage assessment of critical high temperature thermal power plant components

A.Mondal, H Roy and D Ghosh Industrial Service and Research Group , Central Mechanical Engineering Research Institute, Durgapur

Abstract

Periodic in service inspection of power plant components by means of non-destructive testing (NDT) to obtain information on damage assessment is carried out as a routine and mandatory procedure. Continuous and indefatigable research and development have evolved effective methods for predicting residual life of thermal power plant components, apart from developing methods for repair, replacement and enhancement of life of such components. Thick walled components like superheater, reheater and attemperator headers, main steam & hot reheat pipelines are most vital components as they are exposed to the conditions of high temperature and pressure. Since conventional sampling and metallography is not feasible, non destructive in- situ metallographic technique are adopted to assess the extent of deterioration in thick walled components. Under the influence of temperature and stresses, these components react by creeping leads to microstructural degradations. In-situ metallography by surface replication technique is the only NDE method for the assessment of microstructural degradation of engineering components. This paper highlights the importance of on-site metallographic technique in connection with damage assessment and Residual Life Assessment (RLA) of high temperature components of thermal power plant.

Key words: NDT, In-situ metallography; surface replication; creep damage.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Cleaner Steel Making Technology for Green House Gas Emission Reduction – a review

D Ghosh 1* and U Bhattacharyya 2 1 Senior Principal Scientist, , CMERI, Durgapur-713209, 2 DGM, Durgapur Steel Plant (DSP), Durgapur-713203

Abstract:

The modern world is built on steel. In developing and developed nations, steel has become an indispensable part of life. Global steel production has been growing for the last 50 years. In the 1950s, world steel production was about 200 mmt. In the last five years, the pace of growth has accelerated and in 2006, the figure stood at 1,239.5 million metric tons (mmt).The future growth in demand for steel will be driven mainly by the needs of the developing world. The steel industry must continue to grow by 3-5% worldwide and by 8-10% in China, India and Russia to satisfy their needs. According to the Intergovernmental Panel on Climate Change (IPCC), the steel industry accounts for between 3-4% of total world greenhouse gas emissions. On average, 1.9 tonnes of carbon dioxide are emitted for every tonne of steel produced. The CO 2emissions are responsible for creating pollution hazards and also global warming , which is a newer threat to the world. So there is an absolutely need to for making cleaner steel making technology to reduce the green house gas ( mainly CO 2) emissions reduction for the steel industry. Research on Cleaner steel making technology was going on for last 10 years in Europe, north America and Asia. But no feasible technology is yet to come out. Most of the technology describes are in research stage ( as a pilot plant model , which may be commercialized after 10- 20 years. some of the technology like ULCOS are being popular in European union for effective reduction of CO 2 gas emission.

This paper is a review on the different technologies adopted in pilot plant and also demonstration scale mode in European union ( EU), Asia and North America. The paper also briefly describes the different processes adopted to SAIL, India for reducing green house gas emissions.

Keywords: Steel, Iron, Green house gas, CO 2, Blast furnace, ULCOS

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Development of new generation high speed wheels: A make in India drive at WAP,DSP-SAIL

Er. S.K.Behera DGM(OP),WAP DSP-SAIL Email.skbehera@ saildsp.co.in

Wheel and Axle Plant is a pride of Durgapur Steel Plant as it is the only quality wheel manufacturer in the country through forging process. The product is very quality sensitive as the life of innumerable commuters depends on it. For achieving this type of total quality products Durgapur Steel Plant has constantly upgrading its processes, keeping a strict vigilance on the wheel manufacturing starting from steelmaking to final dispatches to Railways. The plant has been supplying wheels comparable to International standards to the Indian Railways and quality of the wheels has been tested at TTCI, USA twice for validation. The wheels supplied are catering to the needs of both Locomotives' and 'Coaches' fleets.

The new generation wheel manufacturing is a challenge as the profile varies from wheel to wheel and their utilizations demand different service condition requirements. Starting from steel making, forging ,rolling, heat treatment to machining operations have been standardized by us .We have successfully developed and standardized a number of new generation wheels like LHB,METRO,EMU,WAP-5.WAG-9,NTPC MGR etc as a part of the “make in India” campaign .The steps taken by WAP-DSP,SAIL are towards Nation building .This has facilitated saving of foreign exchange also. It also builds up capability within the country for manufacturing of much high tricky wheels and thus India is becoming self reliant. The manufacturing of above wheels here at Wheel X Axle plant has already opened up new vistas for DSP/SAIL.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Li ion batteries (LIBs): Technology of the Green World

Dr.Indu Elizabeth Scientist in CSIR-National Physical Laboratory, New Delhi in the Force and Hardness Metrology Division Abstract There has been an enormous increase in the global demand for energy in recent years as a result of industrial development and population growth. The demand for energy, especially from liquid fuels, and limits on the rate of fuel production has created a bottleneck leading to the current energy crisis. Currently nearly 80% of the global energy consumption is met by non-renewable fossil fuels which causes grave environmental, climate and health issues and thus is non- sustainable. The utilization of green energy like solar, wind etc. is believed to be the most promising way to circumvent this problem and have a sustainable development. However, the usage of solar and wind powers for advanced applications as well as electric vehicles requires highly efficient energy storage devices. Among the available energy storage systems the better option to save electricity is battery because of its portability and non-polluting nature. Batteries have moderate cost and high conversion efficiency. In this regard, lithium-ion batteries (LIBs) can play an important role because of their high energy density, long cycle life and low self-discharge rates. LIBs are being widely used in portable electronic devices such as laptops, mobile phones, and medical microelectronic devices. Among all rechargeable electrochemical systems, Li-ion technology is the first-choice candidate as a power source for electric vehicles. For the broad and practical application of LIBs in stationary energy storage and electric vehicles there has to be further improvement in their energy, power densities, safety and reduction in the cost. With the present LIB technology consisting of a graphite anode and Li metal oxide cathode it is very difficult to achieve higher energy densities mainly because of the limited specific capacities of the electrode materials. Hence, it becomes important to develop high performing electrode materials with excellent cycle life and capacities. Also, the demand for flexible or bendable energy storage systems based on LIBs have increased with the recent advancements in technology of portable electronic devices like roll-up displays, in-vivo medical implants, IC smart cards, radio-frequency identification tags etc. Development of such batteries requires the fabrication of flexible electrodes with excellent electrochemical performance.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

MOLECULAR DYNAMICS BASED DESIGN AND DEVELOPMENT OF SURFACE NANOSTRUCTURED Ti-Al ALLOY FOR ADVANCED STRUCTURAL APPLICATIONS D. Banerjee* and M.M. Ghosh Department of Metallurgical and Material Engineering, National Institute of Technology, Durgapur-713209, West Bengal, India *Corresponding Author Email: [email protected]

ABSTRACT We present here the procedure and results of molecular dynamics (MD) simulations for designing surface nanostructured Ti-Al alloy using nanoindentation modelling, for deep space applications. With the aim of enhancing mechanical properties viz. hardness, modulus of elasticity, creep resistance, etc. for use in deep space environments, surface nanostructured Ti-Al alloy with tuned alloy composition, crystallite size and thickness of nanostructured surface film has been designed first by means of a series of MD simulations followed by optimum analysis. Nanostructured polycrystalline film of Ti-Al alloy on a coarse grained substrate of same alloy have been generated and equilibrated at 298 K. Then the material is subjected to nanoindentation in a displaced controlled mode by a spherical shaped rigid indenter. Full indentation cycle which includes loading, holding and unloading stages has been performed and based on load- displacement curves the hardness and Young’s modulus of the materials have been calculated using Oliver-Pharr method. The nanoindentation modelling has been done under NVE ensemble. The embedded atom method (EAM) potential, which is proved to be reliable for metallic systems, has been used here for all interatomic interactions, both during nanoindentation and prior thermal equilibration stages. Numerical integration involved here in all MD simulations has been done using Velocity Verlet algorithm taking time step size of 1 fs. During the process of nanoindentation, the resultant load in the nanoparticle has been calculated by summing up the fz component of force of each atom at each step. The corresponding displacement of the indenter has been calculated taking the centre of mass position of the indenter after it touches the top surface of the nanoparticle, as the reference. The results extracted so far have indicated the dominant role of surface effect of nano-polycrstalline material is enhancing the hardness and other mechanical properties. Hence, use of this type of material in nanostructured form can be thought as an effective reinforcement for making promising composite materials for such type of critical applications. Keywords: Molecular dynamics; Nanoindentation; Polycrystalline material; Mechanical properties; Young’s modulus; Hardness.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Crack propagation and fracture characteristics of copper-nickel single crystal alloy nano-particles: A molecular dynamics study Ajay Kumar Mishra *, Krishnan Bandyopadhyay and M.M. Ghosh Department of Metallurgical and Materials Engineering, National Institute Technology, Durgapur-713209, West Bengal, India

*Corresponding author. E-mail: [email protected]

Abstract: Fracture mechanics is a useful tool for the design of mechanical and materials properties of mechanical components. We have developed an atomistic model of tensile deformation of a pre- notched sample highlighting the propagation and growth characteristics of crack during failure stage under mode I loading of a single crystal copper-nickel alloy nanoparticle. Similar type of simulations were carried out with the same crosshead velocity and identical geometry but with different alloy compositions. The simulation procedure is analogous to real experiments, but in order to manage the computation time, the movable crosshead velocity was set several orders of magnitude greater than that used in experiments for bulk materials. A cubical simulation box has been created first with a V-shaped notch tip and equilibrated at 298 K by Nose Hoover thermostat. The many body Embedded Atom Method (EAM) potential was used in each LAMMPS run with non-periodic shrink wrapped boundary condition. The tensile deformations have been done for different wt% of nickel content (viz. 10%, 20% 30%, 40%, 50%, 60%, 70%, 80%, 90%) at 298 K under 50 m/s crosshead velocity and the results have been compared. The effect of adding varying nickel% in copper based nanoparticles were investigated in terms of stress-strain curve generated by a set of MD simulations. The stress-strain plots thus obtained have been correlated with configuration and internal dislocation structure at different stages of loading. The visualization of the particles and dislocation analysis has been done by 'Ovito', the MD data visualization software. The yield stress, Young’s modulus and percent elongations of copper-nickel alloy nanoparticles have been calculated from the engineering stress-strain curve. It was found that with increase in wt% of nickel in copper-nickel alloy nanoparticles, the Young’s modulus and yield stress both increase.

Keywords: Copper-nickel alloy nanoparticle, Molecular dynamics, Crack propagation, Fracture

Acknowledgment:The financial support of NIT Durgapur for carrying out this research work is thankfully acknowledged.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Design of tungsten nanoparticles with enhanced nano-mechanical properties for advanced structural applications using MD based modelling approaches

Krishnan Bandyopadhyay *, S. Banerjee, H. Kumar, A.K. Mishra, K.S. Ghosh and M.M. Ghosh

Department of Metallurgical and Materials Engineering, National Institute of Technology, Durgapur – 713209, West Bengal, India

*Corresponding Author. E-mail: [email protected] (Mobile no.9875528305) Abstract In the present work molecular dynamics (MD) has been used to model bulk deformation behaviour under tensile loading and localized surface deformation behaviour during nanoindentation of single crystal tungsten nanoparticles. From the tensile model, engineering stress - strain curve and the corresponding configuration of the particles at different stages of tensile loading have been obtained. Analysis of these data has given important idea about the bulk deformation behaviour of tungsten nanoparticles and also the bulk mechanical properties of the particles, viz., yield strength, Young's modulus and percent elongation have been extracted there from. On the other hand, a displacement controlled nanoindentation modelling of the nanoparticles has provided fundamental knowledge about the surface deformation under localized loading conditions. From the nanoindentation modelling the surface property, viz. hardness has been estimated. The results of present simulations have indicated severely enhanced strengthening (yield strength and hardness) of tungsten nanoparticles arising due to dominant surface effect. Both the models can be useful in the design and development of nanostructured materials for advanced structural applications where high strength and toughness are required.

Keywords:Molecular dynamics; Tensile deformation; Nanoindentation; Mechanical properties.

References 1. W.C. Oliver and G.M. Pharr, J. Mater. Res. 19 (2004) 3-20.

Acknowledgment:The financial support of Centre of Excellence under TEQIP-III is thankfully acknowledged.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Development of Welding Procedure for High Strength C-Mn-Si (SA299 Gr.B) Steel through Optimization of Normalizing and PWHT Cycles

Suvam Chatterjee, Pawan Agrawal GE Power

ABSTRACT

SA299 Gr.B - Manganese Silicon Carbon steel (C:0.21%, Mn:1.47%, Si:0.37%) is one of the candid steel for Steam Drum and Mud Drum Application at Sub Critical Power Plant station. Drum plates are first hot rolled at above upper critical temperature for bending & forming operation. But, this thermal operation distorts the metallurgical and mechanical property of the base metal. A subsequently normalizing (around 910°C, Soaking time: 2hrs 30 mints) operations is carried out to restore the microstructural and mechanical property before start of welding. The drum plates are then welded after proper fit up with backing strip by Shielded Metal Arc Welding (SMAW) process and followed by Submerged Arc Welding (SAW) process. But, the Drum gets distorted due to high residual stress induced by welding process. Re- hot rolling of the Drum plate above upper critical temperature again performed to restore proper shape. Then the base metal and weldment experienced a normalizing cycle (around 910°C, Soaking time: 2hrs 30 mints) which is followed by a post weld heat treatment cycle (around 610°C, Soaking time: 3hrs) to restore the microstructural and mechanical property and to reduce the residual stress. So, the base metal is experiencing two normalizing and one tempering cycle. And the weldment is experiencing one normalizing and one post weld heat treatment cycle. Unavailability of commercial data on this particular steel and effect of subsequent thermal cycle on mechanical and metallurgical property act as a prime mover to initiate this scientific study.

In the first part of this research, a Simulation Study of base metal was carried out where the same thermal cycles (two normalizing and one tempering) were induced to study the mechanical and metallurgical property through mechanical test and microstructural characterization. From this investigation, it is found that force cooling after soaking of normalizing cycle is produce a more uniform microstructure which is validated through higher tensile strength and impact toughness property of base metal. In the second part of this research, the welding procedure was developed. The weldment was first normalized (around 910°C, Soaking time: 2hrs 30 mints) and then post weld heat treated (around 610°C, Soaking time: 3hrs) .Selection of consumable for procedure development was a major tusk in this study. The welding procedure was validated through tensile test, bend test, hardness test, macro analysis, microstructural characterization and Scanning Electron Micrograph (SEM) analysis.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Use of Fly Ash and Flue Dust in Agglomeration: A Sustainable Technology for Waste Recycling Ritwik Das 1, Manas Kumar Mondal 2, Susanta Pramanik 2 1PhD Scholar, 2Associate Professor, Metallurgical and Materials Engineering Department, National Institute of Technology Durgapur

Abstract: Agglomeration in the form of pellet, briquette, sinter and nuggets etc. is one of the useful techniques to use the iron ore fines generated by mechanised mining. The main advantage of agglomeration technique is almost zero dust emission to the environment. Metallic values of the ore can be increased through agglomeration and subsequent extraction process. Agglomeration is such a technique through which various waste materials also can be used for extraction of useful metal. Integrated iron and steel plant generated waste such as flue dust is agglomerated along with iron oxide fines. The power plant generated wastes such as fly ash possesses self cementing property to prepare the composite agglomerate for iron extraction. The present work aims to investigate the properties of agglomeration of pure iron oxide fines, fly ash, flu dust and graphite fines. Subsequently, the agglomerated briquette was reduced and mechanical properties of dried and reduced briquettes were evaluated. Briquette preparation achieves minimum handling loss of raw materials fines.

Iron ore fines and graphite are mixed stoichiometrically. Reduction of the briquette was carried out at 900°C, 1000°C and 1100°C. Maximum 91% reducibility was achieved. Effect of temperature on the compressive strength of reduced composite briquette was examined at same temperature. The compressive strength of hot reduced composite briquette increases from 197 MPa to 413 MPa as the reduction temperature increases from 900°C to 1100°C. XRD analysis confirms the presence of metallic

Fe along with FeO, Fe 3O4, C, SiO 2 and Fe 2SiO 4. The products coexist within the reduced composite briquette after reduction at 1100°C. Existence of Fe 2SiO 4 and SiO 2 endorse the development of thermally stable iron-slag network which impart strength for further mechanical working of hot reduced briquette. The metallic iron and slag phases are observed through FESEM-EDS analysis. Presence of metallic Fe is confirmed by EDS spectroscopy. This work entirely emphasis on the reuse of industrial wastes fly ash and flue dust up to the mark so that better reducibility and good strength can be coupled together and detrimental effect of these wastes on the environment can be diminished.

Keywords: Flue Dust, Fly Ash, Reduction, Compressive Strength, Composite Briquette, Environment.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Mechanical, Degradation, Biocompatibility study of Mg-Ca-Zn alloys prepared by Melt spinning route

Sudeep Paul a,b,* , Ramasamy Parthiban c, Mitun Das b, Durbadal Mandal a, Mariana Calin d, Jürgen.Eckert c,e , Supriya Bera a aDepartment of Metallurgical and Materials Engineering, National Institute of Technology, Durgapur - 713209, India bBioceramics and Coating Division, CSIR-Central Glass & Ceramic Research Institute, 196 Raja S C Mullick Road, Kolkata-700032, India cErich Schmid Institute of Materials Science, Austrian Academy of Sciences, Jahnstraße 12, A-8700 Leoben, Austria dIFW Dresden, Institute for Complex Materials, P.O. Box 27 01 16, D-01069 Dresden, Germany eDepartment Materials Physics, Montanuniversität Leoben, Jahnstraße 12, A-8700 Leoben, Austria

*[email protected] (Presenting Author)

ABSTRACT

Keyword: Mg-based alloy, elastic modulus, degradation, non- toxicity

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

Extraction of Metals from Industrial Wastes by Using Transferred Arc Plasma

Ramesh Kumar Mittal a, Arup Kumar Mandal a* , Om Prakash Sinha b

aDepartment of Metallurgical and Materials Engineering, NIT Durgapur bDepartment of Metallurgical Engineering, IIT(BHU), Varanasi *Corresponding author: [email protected]

Abstract:

Bulk utilization of industrial solid waste material towards making constructional product does not give much value addition as well as not possible to recover valuable metals. Coal CombustionResidues (Fly ash and bottom ash) are the by products from thermal power plant. Silica and alumina present in bottom ash as combined form of Mullite which is difficult to separate out through hydrometallurgy route, hence prefer high temperature route. Plasma arc gives enormous heat especially in transferred arc plasma.Hydrogen gas provides heat even at non arcing condition. Earlier investigation shows the possibility of Silicon and iron recovery from fly ash by argon plasma in an Extended Arc Flash Reactor (EAFR) but fails to recover aluminium due to vaporization at high temperature, whereas production of aluminium alloy was successfully done in electric arc furnace in order to produce a high aluminium alloy at 2300–2500 °C from bauxite flotation tailings.

Present investigation aimed to establish a new concept of multi-metallic components recovery through carbothermic reduction of bottom ash and iron ore slime in presence of metal solvent bath (iron) under plasma environment.

The feeding material either pellet or powder form was charged with iron slime and carbon in the plasma zone above the liquid iron bath. The reduced metals from the waste materials were absorbed immediately by iron bath even low vaporization temperature metal like aluminium. The studies were carried out by using different charge mix, plasma (H 2/N 2) and exposure time. The samples were analysed to know the metal recovery.

The result shows that the extraction of metals like silicon, manganese, aluminium could be possible from industrial wastes (i.e. bottom ash and slime) under plasma environment.Huge heat generated from plasma, could reduce more stable oxides like alumina silica etc in presence of carbon or only by reactive plasma gas. Plasma creates inert environment inside the furnace hence oxidation loss of metals became minimize. Recovery of metals like silicon upto 72%, Manganese upto83% and aluminiumupto 9% could be achieved. Recovery of metals in case of H 2 plasma is more than N 2 plasma. H 2 plasma itself reduces metal oxides instead of carbon. Sound level (dB) decreases after plasma run. H 2 Plasma generates more sound than N 2 plasma .Variation of sound is more at starting and gradually decreased during progress of melting. Powdered charge submerged arc totally therefore creates less sound than pellet charging. Super-heated furnace gives more steady state plasma resulting less sound and uniform sound.The maximum metals recovery was found in the case of nitrogen plasma of charge containing powder form of bottom ash and iron ore slime mixture. From the experiment it could be predicted that the metal recoveries are possible from the waste using transferred arc plasma in presence of metal solvent bath.

33rd National Convention and National Conference on ‘Climate Responsive Technologies vis-a-vis Iron and Steel Production Scenario’ January 17-18, 2020

The Institution of Engineers (India)

100 years of Relentless Journey towards Engineering Advancement for Nation Building

Durgapur Local Centre was established in the year 1961 at the National Institute of Technology Durgapur formerlyknown as Regional Engineering College. Durgapur Local Centre was shifted from R E College Durgapur to its present building on Nehru Avenue, B-Zone, Durgapur-5 in the year 1984. Local Centre is trying to give the best effort to build this Institution to the highest pick of success. For the benefit of the students local centre regularly conducts Guidance classes as well as Lecture Meeting, Seminar, Workshop, Technical Visits etc for the benefit of Technicians & Sr. Technicians’ members on regular basis. IEI, Durgapur Local Centre organizes conference/seminars/workshop

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