PROCESS OF INDUCTION FURNACE

Raw materials for the process are scrap, fluxes and Ferro alloys. Sponge iron can substitute scrap up to 50%. The Steel Scrap received from various suppliers will be placed in the steel scrap storage yard based upon the Grade and Size at different locations.

The scrap from the storage yard is handled either manually or by a small dosing device to the Bundling Machine and will be stored in the steel Scrap Yard as per the Grade if any. The 16”x16” size Scrap bundles will be Lifted and Transported by Over head cranes and fed to Induction Furnace.

Scrap/ sponge iron, fluxes, Ferro alloys are melted in an Induction furnace, wherein electric current is passed through it. In the Induction Melting Furnace the scrap melts at temperature of about 16500C. When the total charge is melted into hot liquid metal then the metallurgy of steel in terms of carbon, phosphorus content, alloy elements etc, is controlled at this stage. Based upon the Composition of the molten steel, additives will be added to get the requisite composition and grade of Steel .The molten material is poured into mould to produce ingots.

The ladle is placed over the Continuous Casting machine to cast the molten steel into required size of billets. The Cut Billets are transported by a Billet handling crane and stored in the Storage yard as per the Grade and Quality for dispatch.

STEEL MAKING PROCESS IN THE INDUCTION FURNACE

LIST OF MACHINERY/ EQUIPMENTS FOR INDUCTION FURNACE UNIT

S. Quantit Description No y Induction furnace with Transformer, 33 KV VCB, H.T L.T. Cables, Complete with 2 1 crucibles, one year spares& instrumentation. One crucible in operation and another in 1Nos Stand by. 2 Casting Crane 70/10 T approx. 22 M span 1 No 3 Charging crane for feeding scrap through magnet 2 Nos Electro magnet 1800 mm dia Copper wound with 20 minutes battery backup with all 4 2 Nos electric accessories & batteries 5 Vibro feeder for sponge iron 1 No 6 Wet lab equipment for chemical Analysis 1 Set 7 Water pumps for Furnace and Concast water Cooling. 3 Sets 8 Emergency water circulation system for Induction furnace Coil D.G. Pump. 1 Set 9 Cooling Tower for Furnace and CCM Circulating water. 3 Sets 10 Air Compressor 120 CFM at 8 Kg/Cm2 1 No 1 Set 11 Pipe and pipe fittings 1 Lot 12 Shed 22 X 100 m with rail height at 17 m 1 No 13 Induction furnace Building pump house with CT& Lab 1 No

DESIGN PHILOSOPHY OF POLLUTION CONTROL SYSTEMS

The design philosophy of pollution control system is given as following: Quantum of Emissions: Considering the temperature of charge the volume of pot and continuous charging of input materials from the beginning up to few minutes before tapping it has been found that total volume of gaseous of emissions including inspiration of air from surrounding atmosphere may reach a maximum 50,000 M³/Hr. From test results it has been found

that hydrocarbon are near above 50 mg/lit/hour and CO+ CO2 are less than 1 ppm. The suspended particulate matter ranges from 125 to 450 mg/cum. If the charge consists of oily and highly rusted scrap the SPM may go to 1000 mg/cu. m.

Size of SPM: Considering the mixed steel scrap charge used in melting it is found out that the particulate size varies from 0.7 to 8.0 microns. The SPM range in terms of weight will be 0.7 to 1.0 Kg/ton of steel or approx 0.15% of steel scrap melted. SPM may go up to 600-1000 mg/M3.

POLLUTION CONTROL EQUIPMENT FOR INDUCTION FURNACE