NEW GENERATION ENERGY EFFICIENT REFRACTORY APPLICATION IN SOAKING PITS OF BHILAI STEEL PLANT, SAIL

Abstract

In Bhilai Steel Plant (BSP), soaking pits are used for heating ingots for successive rolling into blooms. Pits are operated at a temperature of around 1350°C. Mixed gas (Mixture of Blast Furnace gas & Coke Oven gas) of calorific value around 2040 kcal/Nm3 is used as fuel. The walls of soaking pits were lined with traditional 38% Al 2 O 3 firebricks and top 500mm was cast with 70% Al 2 O 3 low cement castable (LCC). This type of lining results in frequent damages due to hitting by ingots while being lifted from pit by overhead cranes thus affecting the availability of pit. Life of pits was 2 to 2.5 years in BSP with 3-4 cold repairs and 3-4 hot repairs. Energy loss through the wall is also quite high in this type of lining. To triumph over the limitations of the conventional lining, a lining design was developed for the walls which consist of special 70% Al 2 O 3 LCC having high hot strength (HMOR) in combination with specially design flexible SS-304 anchors. Ceramic fiber blanket and insulation bricks were provided between castable and the metallic shell of the pit to minimize the heat loss. A heating schedule was developed and introduced based on available infrastructure at BSP for proper curing of modified LCC based lining. After introduction of modified lining, pit no. 14/2 is running for more than 2.5 years without any repair. To capitalize the success, two more pits i.e. 12/1 and 9/2 were converted to modified lining. These pits are also running satisfactorily for more than 1.5 years. The modification has resulted in higher availability with substantial increase in production. Shell temperature of the modified pits reduced to 90° – 140°C from 120° – 200°C of conventional pits. This shows reduction in heat loss through walls, resulting less fuel consumption and energy saving of about 18%.