coke rate reduction in mini blast furnace

To reduce the coke rate you may have to

a) Inject coal

b) Inject oxigen

c)inject steam

d)Use sinter

There are mini sinterplants availble from Chinaand also coal injection units.Incase you are interested, I shall be able to arrange suppliers fron China.

please contact me at

pgpanikkar@rediffmail.com

or

pgpanikkar@engineeringconsultancy.info

00919849457141

Regards,

PGPanikkar

We want like to ask you that we are looking a mini blast furnace plant too fur ca. of 1,2 TPA with reused steel as raw material. Can you tell us how total cost for this project?

Thank you for your reply.

Pintra

I am afraid, l I have not understood your question or you have not made it clear to the reader.

It is well known that iron making is aprocess of reduction and steel making is a process of oxidation.I do not understand why you want to charge the steel in BF and produce pig irion?

I suggest you to go for an induction furnace to melt the steel scraps than to go for a blast Furnace.You can well go for an oxygen blown furnace with hot metal (from a Blast furnece) or arc furnace with sponge iron also used along with steel scraps.

REgards,

PGPanikkar

DEAR SIR,

IRON MAKING IS A MELTING PROCESS/UNIT WHEREAS STEEL MAKING IS A REFINING PROCESS/UNITS.

Iron making is a SMELTING PROCESS and NOT MELTING Process.There is difference between "MELTING" and "SMELTING ". Ion making is a process of reduction- Direct reduction and /or Indirect reduction.

Smelting is the process of separating the metal from impurities by heating the ore/ concentrate/agglomerate with fluxes to a high temperature to cause the metal to melt. It makes use of a chemical reducing agent. like coke in iron making.

Smelting the concentrate /ore produces a metal or a high-grade metallic mixture along with a waste product called slag. one can smelt some ores at a temperature lower than the temperature required to melt the metal.

Now there are Smelting reduction processes (SRProcesses for short) also developed.

Regards,

PGPanikkar

not for pig iron it is for sponge iron ie only reduction prosses means oniy removeing oxygen

Do you want a blast furnace of 128M3 capacity to produce about 1 lakh tons of pig iron /year with sinter plant and a power plant of 2.5MW or 3MW capacity? There are BFs of 158M3 capacity also. Though Chiese designers speak of 3.6T/M3 /day we can take 2.5 to 3T/M3 depending up on the raw materials and technology adopted.If so, please contact me

pgpanikkar@rediffmail.com

we just want information?

As question asked by Mr Tapan of Maheshwary Ispat .The existing furnace need more enriched oxygen blast only hence if you modify the design of shaft of furnace with inceased number of tyures,this modification will permit you to use cheaper type of coal of solid mass from charging door for reduction.THIS WILL WORK DUAL WAY- REDUCE THE RATE OF IMPORTED COKE AS WELL AS ALLOW THE SOLID CARON MASS TO REDUCE THE CIMPORTED COKE RATE HENCE ENRICHED OXYGEN BLAST IS ONLY THE SOLUTION.

You may contact me for the consultancy job in coke consumption reduction.My resume is as below.

you may visit my web site

www.engineeringconsultancy.info also.

Regards,

PGPanikkar

PAZHOOR GOPALA PANIKKAR

Tel: 040- 65443681 ~ Mobile: 09849457141

Email: pgpanikkar@rediffmail.com ~ pgpanikkar2003@yahoo.co.in~pgpanikkar@engineeringconsultancy.info

Seeking consultancy assignments in the areas of Plant Operations / Project Management / Operations & Maintenance with an organization of high repute.

Career Focus

Result driven management executive with multi faceted manufacturing experience of over 4 decades in India & Abroad. Dynamic change agent skilled in repositioning organizations to achieve operational and manufacturing excellence. Extensive experience in Design, Engineering, Commissioning and Operations of Heavy Industrial Units of the integrated Iron and Steel Plants like, Sintering Plants, Material Handling Plants, Propane Storage Systems, 11.81MW D. G. Power Plants, etc. Have successfully constructed and commissioned major units of steel plants like Sinter Plants, Raw Material Handling Systems, etc. in India and abroad. Conducted due diligences for Indian and overseas projects and prepared feasibility studies and due diligence reports of many projects (Azerbaijan, Georgia, etc). Conducted the due diligence work for taking over of a palletizing plant by Ispat in India . Prepared proposals for taking over of various Iron and steel making units in Asian and African nations. Commissioned and operated sinter plants viz., Rourkela, Bokaro, Visakhapatnam Steel Plants in India and Raw Material Preparation Plant of Ajaokuta Steel Plant at the Federal Republic of Nigeria. Possess excellent interpersonal, analytical, troubleshooting and team building skills with proven ability in establishing quality systems / procedures and planning / managing resources.

Core Competencies

- Strategic Planning - Profit Centre Operations - Project Management

- Budgetary Planning - Change Management - Business Development

- Design Engineering - Operations & Maintenance - Cost Optimization & Control

- Production Management - Plant Operations - Erection & Commissioning

- Purchase / Procurement - Quality Management - Commercial Affairs

- Materials Management - Process Engineering - Liaison Work

- Inventory Management - People Management - Training & Development

Employment History

Sept2004-sept 2005 Global Steel Holdings Ltd, Ajaokuta Steel Company Ltd., Nigeria Consultant

Jan2004-sept 2004 Ispat Industries Ltd, CBD, Navi Mumbi Consultant

Feb1995-Jan2004 Ispat Metallics India Ltd., Maharashtra DGM/Consultant

Dec2003-Feb1995 Rashtriyal Ispat Nigam Ltd., Visakhapatnam Steel Plant Superintendent(HOD)

July1972-Dec1982 Bokaro Steel Plant AsstManager

March1963-July 1972 Steel Authority of India Ltd., Rourkela Steel Plant Chargeman

Career Highlights

Ajaokuta Steel Company Ltd., Nigeria - for GSHL Sept2004-sept 2005

As Consultant

q In charge of the Raw Material Preparation Plant of Ajaokutta Steel Plant Ajaokutta, Nigeria.

- The plant consists of two units namely Raw Material Handling Plant and Sintering Plant.

q Responsible for laying of missing control cables of 150 kilometer with out any basic facilities.

q Successfully solved the problem of captive power plant which was not working and power supply from grid was scarce and intermittent.

q Commissioned the Material Handling Units of bulk raw materials like Coals, Coke, Ores and Fluxes. Actively involved in handling the manpower & motivational issues as the Nigerian team was not paid for months and discipline had to be enforced with caution and firmness.

q Distinction of achieving targets against all odds and first time in the history of The Federal Republic of Nigeria, Sinter was produced commercially with Magnetite Ore as basic raw material.

q Recruited expert engineers from Ukraine and India.

q Played a major role in handling various raw materials for the Sintering Plant like Iron Ore Fines, Lime Stone, Coke Breeze, Mill Scale, Dolomite, stored and conveyed them, mixed and used for sintering.

q Modified the facilities available at the river port near the Steel Plant for exporting the bulk Raw materials to the Delta port through the river by barges.

The Ispat Industries Ltd., Navi Mumbai Jan2004-sept 2004

As Consultant

q Responsible for handling business development activities overseas in countries like Azerbaijan & Georgia; performed feasibility studies, due diligence work of various overseas projects including the iron ore concentration plants, Mines, Sintering Plants, Blast Furnace, Coke Oven, Power Plant, etc.

q Actively involved in performing due diligence work of The Rustavi Iron and Steel Works in Georgia (CIS) along with a multi disciplinary team.

q Played a major role in negotiating with the Honorable Minister of Steel of Georgia and submitted the techno economic proposal to the government.

q Prepared the proposal for taking over various Iron and Steel Making Units in many African nations for the Ispat Group.

q Headed the operation and maintenance of Raw Material Handling Systems with bulk storage of Coals, Coke and other Raw Materials.

q Instrumental in undertaking feasibility studies for projects in India and abroad; prepared the due diligence study for the take over of Steel Plants, Mines, Beneficiation Plants, etc. in Azerbaijan, Georgia & Nigeria.

q Prepared proposals for taking over of projects in Liberia and many other African countries.

The Ispat Metallics India Ltd., Dolvi Jan2004- September 2004 Consultant

Feb1995-Jan2004

AsConsultant

q Managed the Engineering of projects and construction activities; commissioned and operated the units like DG Power Plant of 11.MW capacity, Propane Storage Systems, Raw Material Handling Systems for the Blast Furnace and Sponge Iron Plants.

q Acted as Project in Charge of the 11.81DG Power Plant; coordinated the working of civil, structural and mechanical erection contractors, suppliers like Man B&W, Seimens GMBH Germany.

q Supervised the fabrication and erection of Fuel tanks, building structures and equipment structures.

q Coordinated with Government agencies and received clearances from the Airport authority, Pollution control board, Local authorities etc for the project.

q Performed due diligence work for taking over a Palletizing Plant by Ispat along with an expert from Lurgi GMBH Germany.

q Successfully handled operations of bulk Raw Materials for the Steel Plant with handling equipment like Barge Un- Loaders, Stackers, Reclaimers, Belt Conveyors, etc.

q Organized the ware housing job of bulk raw materials and coordinated with Central Ware Housing Corporation, Ferro Scrap Nigam, State Trading Corporation, etc.

q In- charge of Engineering of Sinter Plant & Raw Material Handling Plant at Dolvi (Maharashtra).

q Closely interacted with international agencies like TPE, CMIEC & Lurgi G.M .B .H.

q Played a major role in tracking and ensuring supply chain of equipment's for the re -erection of Blast Furnace especially the dismantled items imported from Duisburg (Germany)

q Instrumental in construction and commissioning of 11.81MWD.G.powerplant.

Rashtriya Ispat Nigam Ltd., Visakhapatnam Steel Plant December 1982-Feb1995

As Superintendent (Raw material Handling, Manager Sinter plant, Dy Manager Design and Engineering/Training)

q Managed the operations of the following departments:

- Design and Engineering Department: Coordinated the working of various design organizations like M. N. Dastur & Co., Gipromez, Makhnobhr, etc. Coordinated working of various units of steel plant like the 5.3 Million tones/annum Sinter Plant crushing, screening & proportioning plants, base mix yard with blenders, reclaimers, wheel on boom reclaimers, weigh feeders, vibrating feeders, mixing drum, stackers, palletizes, etc. Converted Russian design drawings and made them suitable for Indigenous Equipment to be installed at site.

- Works Department: Implemented the base mix technology by weigh proportioning and blending ingredients like Iron ore fines, lime stone, crushed coke breeze, Mill scale, Flue dust, etc. for the production of sinter first time in any public sector steel Plant in India. Commissioned Sinter Plant Complexof 5.26 Million Tons/year capacity operated and maintained the same. Synchronized the working of Indian & International equipment suppliers like Tyazh prom export, MAMC, Davidson (UK), Kurimoto, Marshal, HEC, Mukand, etc.

- Raw Material Handling Department: Handled all Raw Materials (ores, fluxes & coals) needed for integrated steel plant of 3 million tons capacity. Over all charge of raw material handling plant including wagon tipplers, stackers, reclaimers, storage yards, crushing, sizing and screening plants, mixing plant, rotary driers for iron ores, etc.

- Achieved an increase in tippling of wagons by 3 folds. Successfully reduced retention time of wagons and reduced the cost of handling. Achieved an increase of 3 fold related to iron ore production.

Training and Development Department: Organized the training of Graduate Engineer trainees, Charge Men, Technicians, etc. Arranged and facilitated many human resource development programs. Organized training of Engineers, executives, charge men and supervisors.

- Conducted training for artisans of Visakhapatnam Steel Plant.

Bokaro Steel Plant, Bokaro July1972-Dec1982

As AsstManager

q Responsible for handling raw materials like Iron Ore, Lime Stone, Coke Breeze, Mill Scale Flue Dust, etc for the use of sintering process.

q Commissioned 3 x 312 sq. M. Sinter Machines and operated them.

q Controlled the quality & quantity of Sinter production.

q Actively involved in operating the sinter plant with all accessories & ancillary units.

Rourkela Steel Plant March 1963-July1972As chargeman

q Responsible for handling raw materials like iron ore, lime stone, coke breeze, Mill scale Flue dust, etc. for the use of sintering process

q Actively involved in commissioning two Sinter Machines with total capacity of 5000 TPD.

q Operated the Sinter Plant of Koppers GMBH supply with all facilities.

Education

q Accredited Chartered Engineer in Metallurgical Engineering from Institution of Engineers (India)

q AMIE (Equal to a degree in Metallurgical Engineering -BE/Btech) from Institution of Engineers (India)

q BSc from Kerala University with Physics Main and Mathematics Subsidiary

Training / Self Development Programs Attended

q Eighteen month's theoretical & practical training in Rourkela Steel Plant

q Specialized Training in West Siberian Steel Plant (Zap Zip) in Iron Ore Sintering and other Agglomeration practices.

q Executive Development Programs conducted in Bokaro & Visakhapatnam Steel Plants & Ispat Group

q Sidh Samadhy Yoga (SSY) Course.

q The Super Personality Course

q The Art of Living Course, Divya Samaj Nirman courses conducted by The Art of Living Foundation

Kaizen Projects

q Leader of the team of Kaizen Project which implemented the initiative at Ispat Industries Ltd.

- This resulted in the reduction of fines generated while handling the Iron Bearing Materials for the

Blast furnace and the Sponge Iron Plant.

q Suggested and implemented measures with a very nominal cost that increased the production of sized Iron Ore to 3 fold from the existing level in Raw Material Handling Plant of RINL.

Technical Papers Presented

q Improvements implemented in Raw material Handling and sintering practices in Visakhapatnam Steel Plant. (International seminar at RDCIS Ranchi).

q Salient factors in the engineering of sintering plant of Visakhapatnam Steel Plant (Indian Institute of Metals, Visakhapatnam).

q Phased Implementation Road Map for the commissioning and operation of Raw Material Handling Plant & Sintering Plant in Ajaokuta Steel Plant with magnetite ore. (Ajaokuta Engineers Association).

q Methodology adopted for the reduction of fines generation in Raw Material Handling in the integrated iron and steel plant at Dolvi (Institution of Engineers, India, Navi Mumbai).

q Systems adopted for the storage of dismantled items of a blast furnace to ensure regular supply for re –erection (Supply Chain Management) at site.

International Exposure

q Widely traveled for technology selection and business development to Russia, China, Iran, South Korea, Azerbaijan, Nigeria, Dubai and The Republic of Georgia.

Personal Details

Contact Address : 505, S.M.R. Empire , Road No 5, Street NO: 9, West Marredpally,

Nehru Nagar-P.O, Secunderabad -500026, Andhra Pradesh

Date of Birth : 3^rd Mar'1942

Languages Known : English, Hindi, M

dear Mr Panikar ,

I AM PRACTICAL FOUNDRY MAN AND CONSULTING FURNACE ENGINEER AND DESIGNER /ERECTOR UP TO PRODUCTION STAGE SINCE 1974.NOW AT PRESeNT I DEVELOPED A latest "Feore low stake smelting furnace" using cheap type of coal even lignite and brown coal to melt iron ore to produce pig iron of different variety with a control of nitrogen inside the shaft of furnace with developed heat transfer system.for some informatory details you may mail- amarkantakdevired@yahoo.co.in Rest required fees.

Dear Sir,

with high interest I saw your demand to reduce the use of coke for your blast furnace.

My name is Andreas Weber and I'm the Director Sales of company altmayer in Germany. My company is supplying various coal dosing and injection systems for the steel as well as other industries world-wide.

We would be happy to work out a solution for you to inject coal to your blast furnace. Please be so kind to send us the neccessary technical data like number of blast tuyeres, counter-pressure at blast level, amount of coal you like to inject and some drawings showing the location.

Please answer to the following e-mail: weber@altmayer.de

Best regards,

Andreas Weber
Director Sales

Altmayer Anlagentechnik GmbH & Co. KG
Südstraße 14
66780 Rehlingen-Siersburg
Tel: +49 (0) 6835 / 9193 - 27
Fax: +49 (0) 6835 / 9193 - 19
E-Mail: weber@altmayer.de
Internet: www.altmayer.de

Please send me a quotation for a P.C.I plant / oxy coal injection plant to feed 150-200Kg coal /THM to a BF to produce 384THM/day.

Regards,

PGPanikkar

pgpanikkar@rediffmail.com

DEAR MR. PANIKKAR.

THAT IS FLS SMELTING PLANT NOT P.C.I PLANT/OXYGEN COAL INJECTION PLANT.NOW THE PLANTS ASKED FOR QUOTATIONS ARE OUTDATED.PLEASE AVOID ORTHODOX /GIANT BLAST FURNACES AND ADOPT NEW ONE THAT IS FLS SMELTING PLANT WHICH CONSUME LOW GRADE CHEAPER COAL OF SOLID MASS .NO NEED OF HIGH GRADE COSTLY COKE.

PLEASE CONFIRM STILL YOU ARE IN NEED OF YOUR ABOVE SAID PLANT QUOTATION.

1.Kindly send me a quotation addressed to

pgpanikkar@rediffmail.com

and copy to

mahadevmetaliks@yahoo.com

2.What is your opinion about HISMelt process?It gives hotmetal inliquid form and saves energy in steel making if used.

Regards,

PGPanikkar

Please send me a quotation for a P.C.I plant / oxy coal injection plant to feed 150-200Kg coal /THM to a BF to produce 384THM/day.

Regards,

PGPanikkar

pgpanikkar@rediffmail.com

DEAR ANDREAS WEBER,

YOU ARE NEARER TO SOLVE THE PROBLEM BY THREE WAYS BUT NOT CONFIDENT.

I have visited many BFs in Shanxi province of china where coal is injected in to the BFs and coke consumption is much less.If interested , you may contact me at 919849457141.

I have found some simple injection methods there.I may be visiting china again and meet the concerned engineers later in connection with a project I am doing in the Andhra Pradesh(India)

Regards,

PGPanikkar

Sir,

We have nut coke 10 - 25 mm fractions available from Bhushan Power and Steel Ltd Jharsuguda. Do you use nut coke in your blast furnace operation ? because of the small in nature of blast furnace and you may be using the nut coke.

Please contact me

RJKrishnan

GM (Mktg)

094370 85019

rjkrishnan@bpsl.net

Dear Mr Krishnan,

Could you please send a quote for nut coke with quality details, quantity available for sale

mahadevmetaliks @yahoo.com

Attention:Technical director.

Regards,

P.G.Panikkar

9849457141

EVEN COKE BREEZ MAY BE USED IN FEORE LOW STAKE SMELTING FURNACE.

Dear Mr Tapan Kumar Bhadra,

My observations are as below

1.The productivity of 500/265= 1.88 achieved by you is much less than what can be achieved by using better technology and better raw materials. Coke rate of650Kg/T.H.M can easily be reduced by the introduction of PCI, oxygen injection and use of sinter/pellet.You can go for a 40M2 sinter plant to produce about 1150to 1450 Tons of sinter with basicity of 1.6which may be sufficient for your plant.You will be able to make use of the coke screenings and other stock house screenings and metallurgical wastes from your integrated steel plant profitably.

2.I feel you should go for sintering Plant , oxygen injection and coal injection.

3. I think C.R.A of Australia and Midrex corporation have sent up commercial plants for HIS melt. Perhaps, M/s Cobe steel also has that technology.Please contact them also. But your investment costs are going to be higher compared to sinter plants

4.Could you kindly telephone me at 09849457141/040-39184549(office after 12noon to6PM)for further discussions?

I hope I can help you to turn around the unit tp profitability.There are many other suppliers in P.R China who can supply you sinter plants ,P.C.I units in a very low investment.

Regards,

pgpanikkar@rediffmail.com

DEAR MR TAPAN, IN THIS CONNECTION PLEASE USE ENRICHED OXYGEN BLAST TECH.WITH LOW STAKE FURNACE.PLEASE CONTACT FURNACE ENGINEER A.K. SHUKLA EMAIL-amarkantakdevired@yahoo.co.in . In this furnace you can use cheap coal even lignite and brown coal of solid mass for producing iron directly from ore/fines.Furnace engineer can also improve your existing furnace as your company is not using advanced blast cupola of short stake having increased number of tuyers with enriched oxygen blast.FOR FURTHER DETAILS PLEASE CONTACT senior man of the trade Mr ARUN SHUKLA and his Feore small stake smelting furnace for the same.

DrP.K.Roy telephoned me on this subject.Dr P.K. Roy is a well experienced person in Blast Furnace and sinter plant.He is a Guru for all of us.In case you wish to have operational consultancy,or reaserch etc, Dr P.K Roy is the correct man and he is available in Kolkutta also for you. My other friends are also there in Kolkutta whom DrRoy also knows.He can mobilize a team also if he wants so.

If you like to have a sinter plant imported from china on a reasonable rate,or to do project engineering of new technologies which I mentioned earlier,I shall be of help to you.

Regards,

PGPanikkar

+919849457141