Record life of Steel Ladle achieved at Rourkela Steel Plant
Rourkela: The Steel Melting Shop-I (SMS-I) of Rourkela
Steel Plant (RSP) has achieved a record Steel ladle life of 100 heats on 15th December 2012, which is a
major milestone in the history of SMS-I. This has been possible with the
combined effort of the employees of Refractory Engineering Services, SMS-I and
other associated departments.
It is worth mentioning here that till the year 2007-08,
the ladle life used to be around 40 heats. After the innovative introduction of
full Mag-Carbon lining, the ladle life improved upto 50 heats in 2008-09. Since
then, many improvements have been implemented in the areas of Operation and
Refractory Practice, which has resulted in achieving an average life of 80
heats and a record life of 100 heats at present.
The new practices include the study of wear
out profile and modifying brick composition and lining pattern accordingly,
systematic joint inspection of ladles starting from early life and taking
corrective action, introduction of hot maintenance practices like gunning and
hot patching, scheduling the mid campaign repairs in line with erosion profile
and operational improvements in terms of Ladle rotation, addition of
ferro-alloys and optimum turndown temperature.
The improvement in Ladle life from 50 heats
to 100 heats has resulted in bringing down the specific consumption of
Refractories in SMS-I Ladles from 12.99 Kg per Tonne of Crude Steel in 2007-08
to the present level of 8.56 Kg per Tonne of Crude Steel. Accordingly
specific cost has come down from Rs. 263.73 per Tonne of Crude Steel to
Rs. 243.90 per Tonne of Crude Steel in spite of substantial increase in the
price of refractories in recent time. On an average, as a
result of this improvement, RSP will be saving around Rs. 7.2 lakhs
per month.
The enhanced lining life has also contributed
in better availability of ladles for production with zero delay on the account
of ladles. The improved ladle life will also help in synchronized functioning
of the plant after commissioning of on-going expansion projects. The Collective
has worked dedicatedly and in an innovative manner to achieve such a
spectacular feat.
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