High-Quality Hot Strip Production Essar Steel
High-Quality Hot Strip Production Essar Steel
High-Quality Hot Strip Production Essar Steel
Reprint from
Metallurgical Plant and Technology 3/2013,
pages 30-36
In 2010 and 2011, Essar Steel India extended its production capacity at the Hazira steel works by 5 million
t/year of crude steel and another 3.5 million t/year of
hot rolled strip. The pertaining plant technology consists of two 200 t Conarc furnaces, three twin-ladle
furnaces and a CSP plant. Whereas the latter started
operating with two strands, it has meanwhile been
extended to become the worlds first three-strand
CSP plant. This article describes the plant technology and presents the most important operating
results in the commissioning phase.
Autoren:
B. Fernandes, Essar Steel India Ltd., Hazira, India;
C. Klein, H. Rackel, SMS Siemag AG, Dsseldorf, Germany
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HIGH-QUALITY
HOT STRIP PRODUCTION
from thin slabs at Essar Steel in India
Essar Steel India is one of Indias largest producers of
flat steel products intended to be used, for example, in
the automotive, construction and shipbuilding industries. In 2007, the company placed an order with
SMS Siemag for the supply of a steelworks comprising two 200 t Conarc furnaces and three twin-ladle furnaces. With this new steelmaking plant, crude steel
capacity at the Hazira location has been increased to a
total of 10 million t/year.
The new Conarc furnaces are designed for a capacity
of 5 million t/year. The major part of the steel is
intended for the new thin-slab casting and rolling (CSP)
plant, figure 1, which is designed for the production of
3.5 million t/year of hot strip. A further part is processed
in the conventional continuous slab caster.
STEELMAKING PLANT
Whereas the two EAFs represent the heart of the meltshop, three adjacent twin-ladle furnaces are used for
refining. The Conarc EAF process is a combination of
the traditional routes of oxygen and electric arc furnace
steelmaking. The technology consists of a twin-shell
furnace, using a slewable set of electrodes as well as
at least one slewable top lance, which are alternately
used in both shells, figure 2.
This equipment provides for high flexibility in terms of
charge materials. The furnaces can process hot metal,
pig iron, DRI and scrap. The choice of input material can
be dynamically adapted to fluctuating market prices of
energy and raw materials.
SMS SIEMAG
Commissioning
Production capacity
Slab thickness
Strip width
Strip thickness
Product range
Metallurgical length
Liquid core reduction
March 2011
2.5 million t/year (option: 3.5 million t/year)
55 80 mm
850 1,680 mm
1.0 25.0 mm
Carbon steels (low, medium, high-carbon), Si steel, pipe grades, DP steels
8,065 mm (4 segments)
LCR3
SMS SIEMAG
OPERATIONAL RESULTS
The commissioning milestones were as follows:
rolling of the first strip: 31 March 2011
start of hot commissioning: 8 April 2011
start of operation with two casting strands: 12 July
2011
first strip with a thickness of 1 mm: 20 June 2011
first strip with a thickness of 20 mm: 30 August
2011
FAC: 31 October 2011 (first stage with two casting
strands accepted).
Just three months after the start of hot commissioning, rolling with two casting strands was carried out.
After seven months, the first section of the two-strand
caster was accepted by the customer Essar Steel India.
For documentation of the commissioning results, the
following parameters have been considered:
average casting time per ladle and availability of
the caster,
production start-up curve,
cobble rate,
product mix,
performance values attained for thickness, flatness, final rolling and coiling temperatures,
rolling of thin and ultra-thin hot strip.
SMS SIEMAG
After only 250 days following the start of commissioning, the designed daily productivity was for the first
time exceeded, subsequently amounting to 130 %.
(100 % daily capacity corresponds to the nominal
capacity of the plant of 2.5 million t/year with two casting strands.) The Essar CSP plant achieved a cobble
rate of 0.05 % of the total quantity of all coils produced.
Figure 6 shows the development of the minimum (left)
and maximum (middle) final thickness of coils produced
from April 2011 to July 2012. The figure also shows the
quantities of coils in the respective thickness classes.
The lowest final thickness of 1 mm was rolled 57 days
after the start of hot commissioning. The thickness of
20 mm was rolled 120 days after the start of hot commissioning. Approx. 20% of the production was rolled
down to final rolling thicknesses of less than 2 mm.
0.32% of the production ranges between 15 mm and
Since the final rolling and coiling temperatures are decisive parameters for the internal strip quality, these temperatures are within a very narrow range. As shown in
figure 9, more than 96% of all measured values are
within a tolerance range of 15 K.
SMS SIEMAG
Thin and ultra-thin gauges. The results of several successive thin-strip rolling campaigns are presented in figure 10. The aim was to roll thin strips of
thicknesses of 1.5 mm down to 1 mm. The final rolling
width was 1,000 mm. Coils ranging from 2 to 3 mm at
the beginning of the sequence are typical of the structure of the rolling campaigns. Only five to seven strips
at the beginning of the campaign are needed to achieve
a final rolling thickness of 1.5 mm. In these particular
campaigns, the final rolling thickness of 1 mm is maintained for around 30 strips before a roll change is performed and the next sequence starts. Using flying
gauge change, Essar Steel India has also already produced ultra-thin hot strip of 0.8 mm thickness.
10
SUMMARY
Thanks to the perfect interaction between the proven
process models and the control circuits tailored to the
mechanical equipment and to the optimum preparation
in the plug & work test, production results to the customers full satisfaction were achieved after an
extremely short time. The successful commissioning
of the steelworks and the CSP plant at Essar Steel
India once again demonstrated the advantage of having
the mechanical equipment and the electrical and
automation systems supplied from a single source.
SMS SIEMAG AG
SMS SIEMAG AG
Wiesenstrasse 30
57271 Hilchenbach Germany
Eduard-Schloemann-Strasse 4
40237 Dsseldorf Germany
E-mail: [email protected]
Internet: www.sms-siemag.com
E-mail: [email protected]
Internet: www.sms-siemag.com
S1+W4/216E
750/07/13 . ky . Printed in Germany
The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these
characteristics as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will
not have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.