STEEL & METALLURGY :: Abstract for July 2014 Issue

View of July 2014 Issue
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An Integrated Approach towards Achieving Lower Energy Intensity at Rourkela Steel Plant
By V.T. Selvan, T.S. Reddy and N. Behera; R&D Centre for Iron & Steel,
Rourkela Steel Plant Steel Authority of India Limited, India.

ABSTRACT
Rourkela Steel Plant (RSP) has witnessed energy cost increase from 81 to 271 per GJ in the last decade. This led to progressive increase in the cost component of energy, from 21 to 28% of the crude steel cost, over the same period. RSP handled this added cost pressure, through concerted efforts, by achieving increased productivity and efficiency of operation. This has resulted in steady decrease in the energy intensity, from 36.4 to 27.9 GJ per tonne of crude steel, an impressive 23% reduction from the base value. As part of the expansion programme, RSP has recently commissioned Sinter Plant#3 of capacity 3.7 MT/annum, Coke Oven Battery#6 (COB#6) of 1800 t/day and Blast Furnace #5 of 2.2 MT/annum. This will lead to an increase in hot metal production capacity from the present 2.54MT to 4.5MT/annum. These new units have energy saving features like Coke Dry Cooling Plant in COB#6, Pulverised Coal Injection (PCI), Top Pressure Recovery Turbine (TRT) and waste heat recovery system using heat pipes to preheat combustion air and BF gas in BF#5. These state of the art new units will bring in further reduction in energy consumption per tonne of crude steel. Through the operation of the new units to their full potential, RSP is slated to achieve the energy intensity figure of 24.28 GJ/tcs from the present 27.90 GJ/tcs. Additional 2 MT produced through the new units will have energy intensity 19.52 GJ/ tcs. This compares well with the world average of 19.60 GJ/tcs.

Implementation of Human Resource Management System at RDCIS, SAIL
By S Selvi, Manas Rath, N N J Hemrom, A K Biswal, A Bhattacharya,
D S Nigam RDCIS, Steel Authority of India Limited, Ranchi, India

ABSTRACT
Every organization is information driven and its the employee who drives and carries out day to day activities. The P&A department train the people, organizes them, so that employees can effectively perform these activities. This requires viewing people as human assets, not costs to the organization. Looking at people as assets is part of human resource management and human capital management. For managing and automating the HR Process to maximize the productivity of the organization, the organization has to implement HRMS, a Human Resource Management System. HRMS system will help in reducing costs, saving time, integrating and aligning HR efforts with the rest of the organization. Employees will be empowered and engage with more input and control over their work life. Through HRMS one can quickly build the workflows and processes. The powerful flexibility features keep employees current and compliant, even as rules and regulations change.

We are thankful to Oerlikon Leybold Vacuum system which is giving us required process optimisation and pump out time
By Our News Bureau

ABSTRACT
Oerlilon Leybold Vacuum is a renowned name in the vacuum technology with its highly innovative solutions. Mr. Pankaj Agrawal, Director, Jailaxmi Casting & Alloys Pvt. Ltd. as a customer shares his experience about Oerlilon Leybold Vacuum with Steel & Metallurgy.

Clean Technology for Green Iron and Steel Making Through DRI Process and Cleanliness with Refining of Steel for Exclusive Application with Zero Discharge
By Dr. Ranajit Chowdhury, PhD. Engg., FIE

ABSTRACT
The article reviews energy efficient environment friendly eco sustainable process for iron and steel making through DRI technology with zero waste with super and ultra cleaning of steel with refining practice for exclusive application the quality of which meets ISO 9000.

Optimize your Operating Profit through Rotary Machine Healthcare
By Our News Bureau

ABSTRACT
A Rolling Bearing is the heart of a rotary machine. So long as the bearing remains healthy, the rotary machine remains in productive mode. But as soon as the bearing fails, the machine comes to a stand still resulting in downtime and the associated loss of production. If it happens regularly, the result will be evident in the reduced Operating Profit. The core concept of maintenance of a rotary machine, therefore, should be focused on the maintenance of bearings. Today, several generalized maintenance philosophies are practiced in the engineering industry. However, the machine maintenance philosophy that is found to be the most effective is Bearing Centred Maintenance (BCM). A Rolling bearing is designed to withstand fatigue caused by continuous application of a periodic load over a long period of time. Keeping in mind the arduous and demanding operating conditions that it has to withstand during operation, the bearing will be handled and stored properly, used with components having commensurate quality , fitted without damaging it, lubricated correctly and maintained carefully, so as to eliminate possibilities of other modes of premature failures such as Wear, Plastic Deformation, Corrosion or Fracture.

Small & Light The Readychain Rack Light Fits Into Even the Smallest Corner if the Machine
By Our News Bureau

ABSTRACT
The igus assembly transport racks readychain rack and readychain rack light reduce process costs by up to 80 percent. The light and slim assembly transport rack readychain rack light from igus now allows a perfect-fit, plug and play pre-assembled energy chain system to be used even for small applications. When combined with the already popular large readychain rack, the igus energy chain system readychain is finely tuned to customer requirements. Machine and plant engineers can reduce their process costs by up to 80 percent with the help of the readychain racks.