Good News For Induction Furnace Owners !

Vaibh Metallurgical Solutions Pvt. Limited (Previously Vaibhav Furnaces) have developed a
proven process for reducing PHOSPHOROUS(P) & SULPHUR(S)
NORMAL ISSUES IN IF STEEL : From Steel tapped from Induction Furnaces(IF). The P & S
contents are appreciably high , in case high phosphorous bearing DRI is used.
It is found that in IF :
P (Min - Max) = 0.08 0.1 %
S (Min - Max) = 0.06 0.8 %
DIFFICULTIES IN REDUCING P & S from IF : For reducing P from steel we need to introduce
Oxygen & Lime into steel which react with P become part of the slag . This slag has to be taken out
at approx. 1550 deg.c else it will revert back to steel.
It is not possible to introduce Oxygen & Lime into IF as the crucible lining is of Silicon &
lining will also erode appreciably. This is very easy in EAF (Electric Arc Furnace)
For S reduction also , we need to introduce Lime , yet again (after P slag removal).
E I ,5TH FLOOR,STREET NO.360,RISHITECH PARK, RAJERHAT,NEWTOWN, KOLKATA 700156 (WB) INDIA
Vaibh Metallurgical Solutions Pvt. Limited (Previously Vaibhav Furnaces) have developed a
proven process for reducing PHOSPHOROUS(P) & SULPHUR(S)
NORMAL ISSUES IN IF STEEL : From Steel tapped from Induction Furnaces(IF). The P & S
contents are appreciably high , in case high phosphorous bearing DRI is used.
It is found that in IF :
P (Min - Max) = 0.08 0.1 %
S (Min - Max) = 0.06 0.8 %
DIFFICULTIES IN REDUCING P & S from IF : For reducing P from steel we need to introduce
Oxygen & Lime into steel which react with P become part of the slag . This slag has to be taken out
at approx. 1550 deg.c else it will revert back to steel.
It is not possible to introduce Oxygen & Lime into IF as the crucible lining is of Silicon &
lining will also erode appreciably. This is very easy in EAF (Electric Arc Furnace)
For S reduction also , we need to introduce Lime , yet again (after P slag removal).
Solution From VMSPL : For Reducing P & S !
VMSPLhave developed a proven process for reducing PHOSPHOROUS(P) & SULPHUR(S)
STEPS IN REDUCING PHOSPOROUS : In our process P & S are reduced in the Ladle (Lined like
tapping Ladle for Ladle Furnace)
Pre-heat the Ladle
Put the Oxygen bearing agents & Catalysts into the Ladle
Start intensive purging , while tapping the Liquid Steel at approx. 1620deg.C , From Induction
Furnace
Transfer the Ladle onto a Ladle Car with Tilting Arrangement
The temperature is brought to approx. 1550deg. C
Tilt the Ladle into a Slag Pot & Phosphorous bearing slag is poured/skimmed off.
Phosphorous is reduced by 50% (from tapped content) in approx. 15-20 minutes.
Once The Phosphorous is reduced & Slag off is done , the liquid steel is heated further for
30-40 minutes for temperature raising.
STEPS IN REDUCING SULPHUR : For reducing S from steel we need to transfer the same Ladle
Car to the Ladle Heating Furnace (LHF). LHF is a must as we have to raise to temperature to
1650deg.c. In the LHF we introduce Lime into steel which react with S & become part of the slag .
This slag is normally not removed & is cleaned after Casting is over.
E I ,5TH FLOOR,STREET NO.360,RISHITECH PARK, RAJERHAT,NEWTOWN, KOLKATA 700156 (WB) INDIA
VMSPLhave developed a proven process for reducing PHOSPHOROUS(P) & SULPHUR(S)
STEPS IN REDUCING PHOSPOROUS : In our process P & S are reduced in the Ladle (Lined like
tapping Ladle for Ladle Furnace)
Pre-heat the Ladle
Put the Oxygen bearing agents & Catalysts into the Ladle
Start intensive purging , while tapping the Liquid Steel at approx. 1620deg.C , From Induction
Furnace
Transfer the Ladle onto a Ladle Car with Tilting Arrangement
The temperature is brought to approx. 1550deg. C
Tilt the Ladle into a Slag Pot & Phosphorous bearing slag is poured/skimmed off.
Phosphorous is reduced by 50% (from tapped content) in approx. 15-20 minutes.
Once The Phosphorous is reduced & Slag off is done , the liquid steel is heated further for
30-40 minutes for temperature raising.
STEPS IN REDUCING SULPHUR : For reducing S from steel we need to transfer the same Ladle
Car to the Ladle Heating Furnace (LHF). LHF is a must as we have to raise to temperature to
1650deg.c. In the LHF we introduce Lime into steel which react with S & become part of the slag .
This slag is normally not removed & is cleaned after Casting is over.
Advantages for Phosphorous & Sulphur Reduction From IF :
INDUCTION FURNACES have got distinct advantages over EAF on
following counts :
Very simple Installation
If we can reduce P & S from IF , they can compete with Steel from
EAF
E I ,5TH FLOOR,STREET NO.360,RISHITECH PARK, RAJERHAT,NEWTOWN, KOLKATA 700156 (WB) INDIA
INDUCTION FURNACES have got distinct advantages over EAF on
following counts :
Very simple Installation
If we can reduce P & S from IF , they can compete with Steel from
EAF
Extra Cost Of Phosphorous & Sulphur Reduction From IF
Operation cost for P & S reduction from IF :
The estimated extra running cost will be approx. Rs.1500-1700/T(US$
28/T) of LM, in total.
E I ,5TH FLOOR,STREET NO.360,RISHITECH PARK, RAJERHAT,NEWTOWN, KOLKATA 700156 (WB) INDIA
Is Addition Of LHF/LRF Disadvantageous Over EAF ?
Really Not ! The reason is illustrated below :
In all modern EAFs routes , liquid metal is further treated into the LHF
By Introducing LHF after EAF/ IF the productivity increases almost
double
While EAF/IF are used for melting LHF is used for refining of the
liquid steel & increase the production
LHF is also used as a buffer for Sequence Casting (into Caster) ,
which means that liquid metal can be held in LHF
Really Not ! The reason is illustrated below :
In all modern EAFs routes , liquid metal is further treated into the LHF
By Introducing LHF after EAF/ IF the productivity increases almost
double
While EAF/IF are used for melting LHF is used for refining of the
liquid steel & increase the production
LHF is also used as a buffer for Sequence Casting (into Caster) ,
which means that liquid metal can be held in LHF
Additional Expenses On LRF/LHF
Installation Cost of one 10T LHF would be approx. Rs. Two Crore OR
US$ 0.45 Million
Power Consumption : ~0.5 kwh /t of Liquid Steel /deg.c ~ 70kwh/t
Electrode Consumption : ~11 gms/kwh ~ 0.77kg/t
E I ,5TH FLOOR,STREET NO.360,RISHITECH PARK, RAJERHAT,NEWTOWN, KOLKATA 700156 (WB) INDIA
Is Ladle Car With Tilting Arrangement A MUST ?
Theoretically Not ! However, EOT Crane will be a bottleneck for
handling Ladle for additional operations. Also , Ladle Tilting operation
can not be precise from an EOT Crane.
Unique Advantage of Our Process (of P & S reduction)
With the LHF , if infrastructure permits , two heats of Induction
Furnace can be mixed . This allows , more sequence casting in the
Caster .
More Heats can be taken from the Induction Furnaces as tapping
temperature is reduced to 1600-1620 Deg. C
As Installation of LHF costs an investment , it is advisable to
treat 8-10T of Liquid Steel in the LHF. However , it is also a very
good idea to combine two heats of smaller furnaces ( say 5+5T
=10T) & treat them for reduction of P & S.
They can produce Alloy Steel from LHF , which can fetch more
returns on Ingots .
E I ,5TH FLOOR,STREET NO.360,RISHITECH PARK, RAJERHAT,NEWTOWN, KOLKATA 700156 (WB) INDIA
With the LHF , if infrastructure permits , two heats of Induction
Furnace can be mixed . This allows , more sequence casting in the
Caster .
More Heats can be taken from the Induction Furnaces as tapping
temperature is reduced to 1600-1620 Deg. C
As Installation of LHF costs an investment , it is advisable to
treat 8-10T of Liquid Steel in the LHF. However , it is also a very
good idea to combine two heats of smaller furnaces ( say 5+5T
=10T) & treat them for reduction of P & S.
They can produce Alloy Steel from LHF , which can fetch more
returns on Ingots .
Unique Advantage of Our Process (of P & S reduction)
Induction Furnace owners can use their existing IF & compete
with EAF owners.
E I ,5TH FLOOR,STREET NO.360,RISHITECH PARK, RAJERHAT,NEWTOWN, KOLKATA 700156 (WB) INDIA
Induction Furnace owners can use their existing IF & compete
with EAF owners.
Ladle Car With Tilting Facility At LHF Station
Kolkata
E I ,5TH FLOOR,STREET NO.360,RISHITECH PARK, RAJERHAT,NEWTOWN, KOLKATA 700156 (WB) INDIA
THANKS FOR THANKS FOR
Taking Interest In Taking Interest In
Vaibh Vaibh Metallurgical Metallurgical
THANKS FOR THANKS FOR
Taking Interest In Taking Interest In
Vaibh Vaibh Metallurgical Metallurgical
Kolkata