Furnace preparation
lining for heat start
& safety practices.
SHYAM STEEL INDUSTRIES LTD.
Contents
BASICS OF INDUCTION FURNACE & ITS WORKING PRINCIPLE
FURNACE LINING PREPARATION FOR STARTING HEAT
SAFTY PARAMETER OF FURNACE PANEL & PHYSICAL INSPECTION OF F/C LINING
RAW MATERIAL
PROCESS
CCM
PRODUCTION
SAFETY
CONCLUSION
induction furnace
WORKING PRINCIPLE
ELECTROMAGNETISIM
(BOTH ELECTRIC AND MAGNETIC)
EDDY CURRENT
(SECONDARY CURRENT)
MAINLY HEAT IS GENERATED BY
MAGNETIC FLUX CUT WITH
CHARGE MATERIAL.
TYPES OF INDUCTION FURNACE
CORE TYPE
CORE LESS OR CHANNEL TYPE
PARTS OF INDUCTION FURNACE
FURNACE CASE BODY
COPPER COIL
YOKE
SPOUT
FORMERS
FURNACE REFRACTORY BLOCK
FURNACE LINING PREPARATION FOR HEAT START
MATERIALS USED:-
➢ SILLICA RAMMING MASS (SIO2)
➢ BORIC ACID (H3BO3)
➢ FORMER
RAMMING BORIC
FORMER
MASS ACID
PREPARATION OF RAMMING MASS
[Link] OF RAMMING MASS
➢ Drying for removal of traces of moisture.
➢ Mixing boric acid 1.2% of ramming mass properly.
[Link] OF CRUCIBLE
➢ First bottom is rammed.
➢ Then former is entered and packing is done using holder uniformly
from all sides ramming mass mixture is poured rammed using
pneumatic rammer/electric vibrator.
➢ Dilute sodium silicate solution is added to the topping silica ramming
mass. The spout & top of the f/c is formed by the same topping mix.
[Link] OF FURNACE CRUCIBLE
➢ Sintering is done by running f/c on low power for sometime after fill
the crucible with charge material.
DETAILS OF FORMER USED & LINING
THICKNESS
It is made by using HR coil.
TOP- 45’’ TAPPER-10’’
[Link]-42’’ BOTTOM THICKNESS-13’’
LENGTH-82’’ SIDE LINING THICKNESS-
4.5-5”
44’’
METALLIC FORMER
SAFTY PARAMETER OF F/C PANEL
F/C VOLTAGE:-
➢ Voltage during heat start – 3500 V
➢ Voltage during last heat end should be – 2800 V
F/C FEREQUENCY :-
➢ Frequency during heat start – 580hz
➢ Frequency during last heat end should be – 620hz
GLD PARAMETER:-
GLD full Sensitivity at -100 %
During sintering heat sensitivity set at - 65 -70 %
After that GLD sensitivity should be set on – 90 %
PHYSICAL INSPECTION :-
➢ It is done by sprinkling water by using spoon on the top of the f/c & viewing side
lining, Bottom & tapper carefully.
Raw materials
➢ SPONGE IRON LUMPS
➢ SPONGE IRON PELLETS
➢ PIG IRON
➢ FERROSHOTS
➢ POOLED IRON
➢ CAST IRON
➢ CPC, A COAL
➢ SCRAP
➢ SILICO MANGANESE
➢ DE OXIDISER (FeAl,Al ingot,Al shorts,ALMIX etc.)
RAW MATERIALS
SPONGE IRON LUMPS SPNGE IRON PELLETS
SIZE- +4 MM SIZE- 10 MM-18 MM
C%- 0.10 -0.13 C%- 0.10 -0.17
S%- 0.30 S%- 0.30
P%- 0.70 P%- 0.85
Fe(M)-80 Fe(M)- 78
Raw material
PIG IRON SCRAP
RAW MATERIAL IS PROPERLY CHECKED IN LAB IN TERMS OF QUALITY AND COMPOSITION AND
ALLOW FOR FUTHER PROCESSING ELSE REJECTED BY SMS .
Process
FLOW DIAGRAM
◦◦◦
RAW MATERIAL SPONGE AFTER 2/3 RD FILL WITH
SCRAP, PIG IRON TO (IRON & PELLETS) METAL TAKE THE SAMPLE
CREATE MOLTEN POOL WITH CPC/A. COAL FOR ENSURING C %
TAPPED METAL IN ADDED AL AND SIMN
CASTING THE LIQUID PREAHEATED LADDLE AT FOR DEOXIDATION &
METAL IN CCM TO MAKE 1670◦C IN LADDLE & ALLOYING AT TEMP
BILLET. THEN PURGING. AROUND 1635◦C.
Process
REACTION OCCURRED INSIDE THE FURNACE
FeO + C Fe (M) + CO
C + 1/2O2 CO (g)
Si + O2 SiO2
2P +5/2 O2 P2O5
S + O2 SO2
Mn +1/2O2 MnO
CCM (continuous casting machine)
ONE CASTING MACHINE
OPEN BILLET CASTER
➢ 6/11 CASTER(SMS group)
PRODUCT (MILD STEEL,CRS)
BILLET OF DIFFERENT SQUARE CROSS SECTION OF 100MM,125MMOF DIFFERENT LENGTH.
COMPOSITION:
MILD STEEL (MS) CRS
CARBON%- 0.10 – 0.15
CARBON % - 0.20 SULPHUR% - 0.25 – 0.30
SULPHUR%- 0.30 SILLICON% - 0.25
SILLICON%- 0.10-0.20 PHOSPHORUS% - 0.065
PHOSPHORUS%- 0.80 MANGANESE% - 0.65
MANGANESE%- 0.60 CHROMIUM% - 0.25
ALUMINIUM%- 0.007
COPPER% - 0.25
Cycle prospective of SMS
Production
WITH 6 FURNACE (12TON CAPACITY) SMS CAN ACHIEVE THE TARGET OF 24,000 MT
MONTHLY .
WE ARE MAKING 100 mm&125 mm CROSS SECTION BILLET MILD STEEL ,CRS WITH
DESIRED CHEMICAL COMPOSTION.
ROLLING MILL GET BENIFITTED FROM SMS TO MAKE TMT BAR OF DIFFERNENT
DIMENSIONS.
Conclusion
WHILE WORKING IN SMS, EVERYONE CAN LEARN WIDE FIELD OF KNOWLEDGE
AND THAT CAN BE HELPFUL FOR ACHIEVING GOALS.
TEAM WORK
IS DREAM
WORK…