Trans Indian Inst Met
DOI 10.1007/s12666-013-0295-1
TECHNICAL PAPER
R&D Interventions at SAIL to Meet Challenges of Expanded Steel
Industry in India
S. S. Mohanty • Atul Saxena
Received: 14 January 2013 / Accepted: 5 May 2013
 Indian Institute of Metals 2013
Abstract Indian steel industry has grown at a fast pace in
last one decade and expected to grow faster in near future.
Growth of steel industry necessitates expansion of existing
steel plants and construction of new ones. Capacity
enhancement of Indian steel sector will be accompanied by
challenges and opportunities particularly issues related
with raw material, energy, environment and product
development. R&D is one of the major enabler to deal with
emerging challenges and opportunities. Due to the capacity
enhancement in the past, SAIL has been subjected to a
variety of challenges which are expected to aggravate in
near future and. R&D interventions have always been
strong facilitators in SAIL to meet the challenges and to
exploit the opportunities. Also, R&D resources in SAIL
have been equipped to meet the challenges of future. This
paper highlights some of the high-quality R&D work which
has been done recently in SAIL in the areas of raw mate-
rial, coke making, iron making, steel making, rolling
environment, energy and product development. The paper
also enumerates some of the R&D work SAIL is planning
to take up in near future to deal with various challenges and
opportunities arising out of ongoing and upcoming
expansion of SAIL steel plants.
Keywords Coking coal  Ladle lining life 
Slime beneficiation  Microstructural modeling 
Formability  Grain refinement
S. S. Mohanty
Steel Authority of India Limited, New Delhi 110003, India
A. Saxena (&)
Research and Development Centre for Iron and Steel,
Steel Authority of India Limited, Ranchi 834002, India
e-mail: gmprodsect@sail-rdcis.com
TP 2728
1 Introduction
In commensuration with the growth of Indian economy,
steel industry in India has also grown rapidly from a crude
steel production of less than 22 million tonnes in 2000 to
about 72 million tons in 2011–2012 with a CAGR of
11.4 %. Moreover, Indian steel industry is expected to take
giant leap in near future as the Working Group on Steel
industry for 12th Five Year Plan has envisaged the steel
production capacity to reach a level of 150 million tons per
year by the end of 2016–2017. Such phenomenal rise in
steel production capacity will predominantly be due to rise
in steel consumption particularly in rural sector.
Such bright scenario of steel industry in India is full of
challenges and opportunities. The enhancement of produc-
tion capacity requires construction of new steel plants and
expansion of existing plants. Also, capacity enhancement
will cause fierce competition among the steel producers to
produce quality steel through cost-effective technology.
Both construction & expansion of plants as well as fierce
completion will engender challenges and opportunities. The
major issues associated with challenges and opportunities
include raw material quality, environmental issues and
introduction of new state of the art technologies. Though a
multi-pronged approach is required to deal with the emerg-
ing opportunities and challenges, R&D input is one of the
major enablers to address these issues. In India, most of the
major steel producers like SAIL, TATA, RINL, JSW,
ESSAR etc. have their own R&D units. Additionally, many
of the research and academic institutes like IMMT, NML,
IITs etc., are also involved in R&D activities related with
iron and steel making technologies. Therefore, steel sector in
India is fairly equipped with R&D resources to meet the
challenges and opportunities in the future. However, R&D
investment by steel companies in India is presently around
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0.25 % of the sales turnover which is quite low in compari-
son to R&D investment in major companies abroad where it
is more than 1.0 % of sales turn over. Concerted efforts are,
therefore, required to enhance the R&D investment in Indian
steel sector to meet the international standards.
SAIL, being one of the largest steel producers in India,
is a major player in ensuring capacity enhancement in
Indian Steel industry. The steel production capacity of
SAIL is presently around 14 million tonnes which is
expected to increase to 23 million tons after completion of
its on-going modernization and expansion programme. In
view of its expansion programme, SAIL is likely to be
affected with the problems associated with raw material
quality, environmental issues and introduction of new state
of the art technologies. In view of this, R&D interventions
are also essential for SAIL to meet the challenges and to
exploit the opportunities.
2 R&D Interventions in SAIL
RDCIS, the corporate R&D of SAIL, has for last many
decades has worked incessantly for last many decades to
address the needs of various production units for
improvement in existing process, reduction in production
cost, product development, energy efficiency etc. Particu-
larly in recent years, when quality requirements of steel has
increased manifold due to fierce competition in India,
RDCIS has come out with a number of innovative solutions
in various technological areas related with iron and steel
making technologies to produce quality steel in cost-
effective and environment friendly manner. Some of the
good quality work carried out recently by RDCIS in areas
like coke making, iron making, steel making, steel rolling,
environment, energy and product development are high-
lighted in this paper. Also, included in the paper are the
futuristic schemes which RDCIS is planning to take up in
coming years to meet various challenges accompanying the
expansion and modernization of SAIL steel plants.
2.1 Coke Making
The major concern for growing Indian Steel industry is low
availability and poor quality of indigenous coking coal.
India has meagre reserves of proved coking coal which
accounts for 13 % of total coal reserves. Also, Indian coking
coal has high ash content (20–25 %), low vitrinite content
and poor coking/caking properties. Low availability of good
indigenous coking coal has resulted in import of good
quality coking coal from countries like Australia, New
Zealand, Indonesia and USA. The Indian steel industry is
expected to import 26.8 million tonnes of coking coal which
will increase to 43 million tonnes in 2013.
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SAIL, like other steel producers in India, is also facing
acute shortage of good quality coking coal. To minimize
the coking coal related constraints of SAIL, RDCIS has
taken a number of initiatives for improvement in the
availability and quality of indigenous coking coal. Some of
the initiatives are briefly described here.
Demonstration of usability of low volatile medium
coking (LVMC) coals, which were mainly used as thermal
coal, in BF coke making after their beneficiation (ash
content of 17 % max) through pilot oven carbonization
tests. The pilot oven carbonization tests carried out at
RDCIS with SAIL blends showed that it’s blending of
LVMC coal, Ghanoodih IV to VII combined seam of Jharia
coalfield, with SAIL coal blends up to 30 % produces
improvement in both M10 and CRI/CSR values (Fig. 1).
Use of high volatile low rank liptinite Indian coal in BF
coke making after their beneficiation (Ash content
*10–15 %) was also found to be possible.
Characterization of raw feed coals linked to different
BCCL and CCL washeries of Coal India to suggest mea-
sures for improving properties indigenous washed coking
coals was also carried out [1].
The poor coke quality in SAIL is mainly attributed to
inferior raw material base, non-availability of technologies
such as stamp charging and CDQ and deviations in oper-
ations. The 7 m tall ovens are in place in Bhilai Steel Plant
(BSP) and the same are now available at Rourkela Steel
Plant (RSP) and IISCO Steel Plant (ISP). The coke dry
quenching plants are now in operation at RSP & ISP. These
resulted in significant improvement in coke properties at
RSP & ISP. In addition, R&D Centre of SAIL has taken
some other initiatives for improvements in coke properties.
2.1.1 Development of ‘‘Differential Crushing’’ to Improve
Coke Quality
RDCIS has developed ‘‘Differential crushing scheme to
improve coke quality’’. At Bokaro Steel Plant (BSL),
70
63.5
M10 CSR CRI
60
52.3 51.1
50 44.5
Values, %
40
32.8
27.8 29.3
30
20 16.3
9.6 8.3 7.8 8.6
10
0
0 10 15 100
Ghanoodih Coal (Ash: 13.6%), %
Fig. 1 Effect of use of washed NLW coal in SAIL coal blends on BF
coke properties
Trans Indian Inst Met
crushing index (-3.2 mm fraction) of coal blend was
82–83 % with a high micro-fines content (-0.5 mm) of
47 %. Introduction of differential crushing scheme has
helped in improving M10 index of BF coke from 9.5 to 9.3
during trial period even with lower imported coal usage. Its
implementation has resulted in an annual saving of Rs. 4.58
crores at BSL.
2.1.2 Improvement in Overall Coke Quality of COB # 10
w.r.t Coke Strength and Moisture at ISP
Based on pilot coke oven study at RDCIS, measures were
taken to improve coal blend crushing. In addition to the above,
improvements were made in selection/blending of coals,
heating control, coke quenching and testing of coke samples.
With the above investigations and recommendations,
average M10 value has been improved from 13.6 (average
during November, 2010 to February, 2011) to 11.5 at present.
2.1.3 Development of an Index Based on Cross-Leakage
Measurements for Assessment of Battery Health
As a coke oven battery ages, cracks and fissures develop on
the refractory wall separating the ovens from the heating
walls through which leakage of raw gas takes place from
the ovens to the heating walls leading to chimney emis-
sions [2]. This cross-leakage is an early indication of bat-
tery health and refractory condition. Conventionally, cross-
leakage has been visually estimated in terms of chimney
smoking or vertical flue inspection. However, these meth-
ods are qualitative and subjective in nature.
To quantify cross-leakage, two methods have been
developed, one for oven wise cross-leakage determination
and second for determining cross-leakage of the whole
battery.
2.1.4 Performance Improvement of Coal Crushing System
at DSP
One of the reasons for inconsistency in the crushing index
is the poor life of hammers (40,000–50,000 tons of coal)
and improper working of crusher adjustment mechanism.
Modifications in the hammer materials were made to
improve consistency in the crushing index [3, 4]. Hammers
fabricated from 50CrMo4 plates of Alloy Steel Plant (ASP)
and heat-treated at Durgapur Steel Plant (DSP) have
resulted in twofold (90,000–1,00,000 tons of coal) increase
in life of the hammers at DSP. Modifications in the crusher
adjustment mechanism have also helped the operators in
maintaining crushing parameters more effectively.
In the coming years, RDCIS will take following work in
the area of coal and coke:
2.1.5 Development of Technology for Production Low Ash
(*10 %) Clean Coal for Metallurgical Purpose
R&D project for development of technology for production
of low ash coal for metallurgical purpose has been
approved by Ministry of Steel and being carried out by
IMMT, Bhubaneswar, CIMFR, Dhanbad, NML, Jamshed-
pur, NEIST, Jorhat, RDCIS, SAIL, Ranchi and CMPDI,
Ranchi. This will help in better usability of indigenous
coking coals and provide opportunity for production of PCI
coal.
2.1.6 Use of Magnetic Water for Moisture Addition
in Coal Blend
Moisture is added in coal blend to reduce the dust emission
during charging and roof carbon deposition. At present,
about 8 % moisture level is maintained for smooth opera-
tion of the battery. As per literature, bulk density of the
coal blend is minimum at 8 % moisture. Reduction in
moisture results in higher bulk density but the same time
dust emission increases while higher moisture addition
leads to an increase in specific heat consumption and
charging hopper jamming.
Magnetised water has lower surface tension and thus its
spreadability becomes better. Using magnetised water, dust
emission can be controlled with lower moisture level. It
will improve bulk density of coal charge and reduce heat
consumption in coke ovens.
2.2 Iron Making
2.2.1 Raw Material
Research activities are being carried out in the area of iron
ore processing at SAIL mines for production of quality
product. In recent past, RDCIS team along with mines
personnel have worked very extensively to recover fine
concentrate particles from the slime/process rejects.
A massive slime beneficiation unit has been installed
and commissioned at Dalli mines, where the slime with
49 % Fe is being enriched to 63 % Fe through various
innovative techniques. While 50 % of slime is treated
through fluidized bed classifier (FBC) unit, the remaining is
being treated through a cluster of hydro-cyclone followed
by medium intensity magnetic separator (MIMS) and
modified slow speed spiral classifier (SSSC) [5, 6]. FBC
unit is designed in-house, which is basically a combined
system of commercially available hydro-cyclone & flotex
density separator (FDS). The entire system is shown in
Fig. 2 as line diagram. Both the lines have been dovetailed
with the existing system and an extra generation of fines
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Fig. 2 Line diagram of slime beneficiation system, installed at Dalli
mines, SAIL
concentrate at a rate of 40 t/h is being recovered from the
slime.
Another slime beneficiation unit has been designed and
installed at Meghahatuburu mines very recently, where the
overflow of existing conventional hydro-cyclones has been
treated in a 2600 cluster hydro-cyclone through a slurry
pump as a second stage of beneficiation. With this system
working very efficiently, not only high grade (63 % Fe)
fines concentrate is recovered but also solved the jamming
problems completely in the downstream equipment like
thickener and slurry pumps. The slime loss has been
drastically reduced to *10 from *20 % with the recovery
of quality fines concentrate. The concentrate product from
SSSC unit is to the tune of 50 tph, which is added to the
sinter fines product.
At Kiriburu mines also, a compact slime beneficiation
system consisting of slurry pump, hydro-cyclones followed
by drum magnetic separator and de-watering screen has
been installed after the bench & pilot scale test work at
RDCIS. The schematic flow diagram is shown in Fig. 3.
The entire slime beneficiation system is mounted on one
platform, where separation process is taking place from
topmost equipment as hydro-cyclone and bottommost
equipment as dewatering screen.
In near future, SAIL will be incorporating slime bene-
ficiation system in rest of the mines, viz, Barsua & Bolani
mines. With installation of slime beneficiation system, the
processing of ore will be mostly by wet mode and thereby,
improve the quality of ore, fines product in particular. The
ore of Barsua mines consists of two minerals namely
Gibbsite and Goethite, which are difficult to handle. At
present, RDCIS is pursuing the slime beneficiation project
at Barsua mines with the help of leading CSIR laboratories
(NML, Jamshedpur & IMMT, Bhubaneswar) to get rid of
gibbsite mineral and recover concentrate with 64 % Fe and
total gangue \4 %.
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Fig. 3 Flow sheet for proposed slime beneficiation system at
Kiriburu mines
2.2.2 Sintering and Agglomeration
Prepared burden in the blast furnace plays a vital role for
improving the hot metal production and reduction in coke
rate. Sinter assumed significance due to its improved
properties as compared to lump iron ore. The sintering
plants in SAIL are old in design and are not able to meet
the increased demand of sinter for blast furnace. RDCIS
has developed few innovations for increasing the sinter
production. Some of the major R&D innovations in SAIL
are described below:
2.2.2.1 Performance Improvement of Sinter Machine
Through Reducing Air Leakages into the Suction Track at
BSL, Bokaro Rate of sintering depends on the rate of flow
of gases through the mix which, in turn, depends on the
vacuum created in the wind boxes by the exhauster. Opti-
misation of gas dynamic parameters of the sinter machine,
enables one to achieve higher under grate suction and leads to
substantial improvements in the techno-economic parame-
ters. Increase in suction by 100 mmwc will increase 10 %
productivity of machine. Speed of sinter machine depends on
vertical sintering speed, which in turn depends on air filtra-
tion velocity and difference of pressure in sinter bed. RDCIS
took projects in different sinter plants to improve suction by
determining the leakages through aerodynamic studies so
that repairs can be planned for rectifying the leakage points
during shut down/capital repairs.
2.2.2.2 Development of Magnetic Plate Charging Sys-
tem For the improvement of productivity and yield in the
sintering process, the control of void fraction in the sinter
bed and increase of the sinter yield in the upper layer are
important. A magnetic charging system was developed and
installed in sintering plants of DSP and BSLs. The mag-
netic segregation plate assembly consists of individual
magnetic elements/pieces, fixed in appropriate rows and
columns and are enclosed all around by SS 304 enclosure.
Trans Indian Inst Met
Fig. 4 Magnetic plate feeder charging system at DSP and BSL
The schematic diagram of magnetic plate charging system
is given in Fig. 4. Magnetic plate attracts paramagnetic
materials i.e. return sinter and mill scale to the top of the
bed which helps in retaining the heat for longer duration,
thus improving the overall yield [7].
2.2.2.3 Waste Heat Recovery System from Sinter Cooler at
SP-3, BSP As sintering plants in SAIL were commis-
sioned in early sixties, no heat recovery system was pro-
vided in the original design. RDCIS initiated project for
waste heat recovery from cooler to raise the water tem-
perature to 90 C for addition in mixing and nodulising
drum in SP-3, BSP. Addition of hot water in sinter mix
helps in increasing the balling characteristics of mix which
in turn increase the machine speed thus specific produc-
tivity also increases. The system description is given in
Fig. 5. It is estimated that 150,000 kcal/h heat will be
recovered from cooler which is presently discharged to
atmosphere [8].
Future work in the agglomeration area includes devel-
opment of structure property relation model, development
of mathematical model for sintering process and produc-
tion of highly reducible sinter.
2.2.3 Blast Furnace
Distribution of burden inside the blast furnace is important
to optimize the gas flow. RDCIS is having the facilities of
two bell system & bell less model blast furnace. These two
cold models help to optimize the burden distribution.
The shape, size & position of cohesive zone (softening–
melting zone) determine the permeability at lower zone of
furnace. By the help of Meltdown Determination Appara-
tus (Fig. 6), softening–melting temperature [9] can be
measured and it can be optimised with varying ferrous
burden combination & chemistry.
Study of viscosity of BF slag using viscometer and
theoretical calculations will help in deciding the optimum
slag chemistry having fluidity & sulphide capacity. By
optimising MgO input through sinter, the adverse effect of
Al2O3 in slag can be decreased.
Alkali has adverse effect such as scaffold formation,
degradation of coke etc. in blast furnace. So flushing of
alkali is required for smooth blast furnace operation.
Optimization of blowing parameter helps in maintaining
constant thermal regime inside the furnace. The furnace
irregularities such as hanging, slipping, scaffold formation
or hearth erosion etc. should be minimum for better
operation.
Optimization of casting practice improves better wind
acceptance. Coke rate can be decreased by chemical energy
substitute such as coal dust injection in BF tuyere. The rate
of coal injection through tuyeres of Blast Furnaces can
enhanced through optimisation of burden distribution,
blowing parameters and by adjustment of position of
injection lance.
Productivity can be increased either by increasing wind
volume or decreasing coke rate. Production increases 2 %,
for every 1 % increase in oxygen enrichment.
Injection of Ilemenite sand through tuyeres in BF’ces or
charging of titaniferrous ore in BF’s prevents further ero-
sion of the hearth lining of Blast Furnace [10].
2.3 Steel Making and Refractories
2.3.1 Process Technology for Aluminium Killed Steel
at DSP
Durgapur Steel Plant (DSP), was facing a chronic problem
of ladle nozzle and SEN clogging during continuous cast-
ing of Al-killed steels. Selection of improper flux and de-
oxidation practice, viscous ladle top slag in Ladle Furnace
(LF), poor de-sulphurisation and absence of calcium &
inclusion flotation treatment at the end of refining in Al-
killed steel leads to ladle and tundish nozzle choking dur-
ing casting. The study of existing flux and de-oxidation
practice for production of Al-killed blooms through LF
route revealed that optimisation of flux, de-oxidation and
suitable steel refining practice was necessary to avoid
clogging during casting.
Based on theoretical calculation and slag analysis, the flux
& de-oxidation practice has been modified to achieve a low
melting fluid top slag. Steel refining practice was re-designed
to achieve low (FeO ? MnO) level for better de-sulphuri-
sation, conversion of solid alumina inclusions to liquid cal-
cium aluminates and its removal from liquid steel to slag
phase in DSP condition. Plant trial with modified flux, de-
oxidation and refining practice resulted in better slag-metal
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Fig. 5 Scheme for waste heat
recovery system at BSP
Fig. 6 Softening–melting determination equipment
mixing, higher de-sulphurisation, better inclusion flotation
and smooth casting without any ladle and SEN clogging.
2.3.2 Control of Rhomboidity in Bloom Caster at DSP
Bloom caster at DSP was facing severe problem of
rhomboidity (difference in diagonal of bloom [15 mm)
during continuous casting. This led to rejection of bloom
at section mill and subsequent down-gradation/re-classi-
fication of bloom. In addition to this, DSP was also
facing severe customer complaint due to rhomboidity. In
view of this, a scientific study was undertaken to identify
suitable continuous casting parameters influencing the
generation of rhomboidity in bloom during continuous
casting and control these parameters to reduce
rhomboidity.
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The study indicated that problem of rhomboidity is
mainly due to non-symmetric cooling of solidifying strand
in mould, non-symmetric cooling in upper zone of sec-
ondary cooling. The non-symmetric cooling of solidifying
strand in mould was mainly due to absence of water
channel gap adjustment in mould during tube changing.
Frequent chocking of secondary cooling nozzles particu-
larly in foot-roll led to asymmetric cooling of solidifying
strand. The quality of water was poor in terms of presence
of iron bearing scales, which was responsible for frequent
choking of secondary cooling nozzle. In view of this, fol-
lowing technological measures has been implemented to
control rhomboidity:
• Periodic water channel gap adjustment in mould
• Adjustment of foot-roll alignment with mould
• Introduction of billet nozzles of full cone JATO 5065 in
LOOP1 from Lechler 460.644 to avoid nozzle clogging
and have high cooling water spray
• Revamping of sand filter to reduce nozzle clogging
• Periodic checking, cleaning and replacement of strainer
in duplex filter
The above technological measures have led to reduction
of rhomboidity by *55 %.
2.3.3 Enhancement of Lining Life of Steel Ladles at RSP
and BSL
In 150T steel ladles of RSP, both in-house and purchased
bricks are used and average lining life was 101 heats during
2009–2010. In 1st phase, seven trials were conducted with
96 % MgO sintered natural magnesia (QMAG) as an
alternative to 97 % MgO sea water magnesia (SWM) to
reduce cost. Average lining life with QMAG based lining
Trans Indian Inst Met
Fig. 7 Existing and modified lining design of 300T steel ladle of
BSL
was similar (*107 heats) but it was cheaper by Rs. 7,138/
T compared to SWM. Action taken to use QMAG in RSP
and other SAIL plants.
In the 2nd phase 6 trials were conducted with modified
zonal lining using spinel added SWM based MgO-C in
metal zone, tabular/brown fused alumina based Al2O3–
MgO-C (AMC) in bottom impact area and special antiox-
idant [11] added high carbon MgO-C bricks in porous plug
side of slag zone and high carbon MgO-C in remaining slag
zone. Average lining life with brown fused alumina based
AMC was 125.5 heats with maximum of 138 heats.
In 300T steel ladles of BSL MgO-C bricks are used as
working lining material and average lining life with SRU
bricks during 2010–2011 was 70 heats. Based on the wear
profile of earlier campaigns, zonal lining w.r.t quality and
thickness have been designed. Brick quality was improved
by optimization of granulometry, magnesia and graphite
quality, addition of spinel in metal zone bricks [12] etc.
Figure 7 shows zonal lining pattern of existing and modi-
fied design. Lining life was increased to 100 and 101 heats
which is the highest with SRU bricks achieved in 300T
steel ladles of BSL.
2.3.4 Introduction of Composite Lining with New
Generation Monolithic in Soaking Pit
for Improvement of Lining Life and Energy Saving
at BSP
At BSP, soaking pits walls are lined with 38 % Al2O3 bricks
and lining life was 2–2‘ years with 6–8 repairs, In order to
improve the performance of soaking pit, brick lining design
was changed to composite lining consisting of ceramic fibre,
light weight fire bricks and new generation monolithic low
moisture castable (LMC). For stability of monolithic wall
lining a novel anchor design was developed and patented.
The anchors were flexible in design to take care of mismatch
of thermal expansion between SS anchors and refractory
[13]. Drying and heating of the lining was done following
special heating schedule to avoid cracking/bursting. Two
pits with new design are in operation without any repair for
more than 1.5 years since January 2011. This has increased
pit availability by 15 % and reduced energy consumption by
12 %.
In the future, RDCIS will be working in the following
areas related with refractories:
• Refractories for working lining and bottom
• Functional refractories e.g. well block and housing
block
• Ladle heating system
• Development of model based ladle tracking system and
thermal status monitoring system
• Trial with spinel bricks at RSP for benchmarking
• Introduction of nano sized carbon and additives in
magnesia carbon system.
2.4 Rolling Mills
2.4.1 Flat Rolling
In the area of flat rolling, RDCIS has done high quality
work leading to quality improvement of flat products like
plates, hot rolled coils etc. Some of the recent works car-
ried out by RDCIS are as follows:
2.4.1.1 Modelling of Microstructure Evolution During Hot
Strip Rolling Accurate prediction of mechanical proper-
ties after hot rolling using mathematical modelling tech-
nique has been an important subject of research for the last
three decades [14, 15]. The mechanical properties are
predicted by modelling of thermal regimes, deformation
behaviour, recrystallization kinetics and phase transfor-
mation observed during rolling.
An on-line microstructural model has been developed by
RDCIS at hot strip mill, BSL to predict mechanical prop-
erties of hot rolled coils. This model calculates grain size of
steel in reheating furnace, roughing stands, finishing stands
and run out table on the basis of empirical equations. The
structure–property correlation equations have been subse-
quently used to predict mechanical properties. This model
has been integrated with mill automation system and an on-
line predictive model has been developed. This model
takes input data from mill process computers and predicts
the mechanical properties of hot rolled coils along coil
length. This model now generates a Virtual Test Certificate
(VTC) based on predicted mechanical properties. This
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model has been validated with measured data of 3,000 coil
samples and its accuracy level was [95 %.
On-line microstructure prediction of mechanical prop-
erties and generation of VTC will be an integral part of the
hot strip mills at SAIL in the coming years.
2.4.1.2 Development of Roll Bite Lubrication (RBL)
Technology Introduction of lubrication at roll bite in hot
rolling mills helps in reducing interfacial friction and wear
of work rolls [16–18]. This technology was introduced by
RDCIS at HSM, BSL. Operation of RBL system resulted in
increase of campaign size of rolling by 10–20 %, reduction
in grinding off-take of rolls by 30–50 % and reduction in
roll force and power by 5–10 %.
Based on the experience, RDCIS has now developed an
experimental RBL system (Fig. 8) which has been installed
and commissioned at the first finishing stand (F1) of HSM,
RSP. Semi-synthetic type hot rolling oil developed by
Indian Oil Corporation was used as lubricant. In this sys-
tem, dispersion of oil-in-water is prepared by mixing them
at high pressure in a mixer close to the mill stand and is
sprayed over the work or backup rolls. Level of lubrication
at the roll bite can be varied by varying concentration and
pressure of dispersion.
Introduction of RBL system has led to reduction in roll
force and power consumption by *10 % in Stand F1. Also
there has been an appreciable improvement in the surface
quality of the used work rolls leading to reduction of mill
wear and decrease of grinding off-take of the rolls.
The RBL system is now being installed in all finishing
stands of HSM both at BSL and RSP.
2.4.1.3 New Rolling Mills in SAIL for Flat Products The
technology packages of flat rolling mills coming up in
SAIL modernization programme have been aimed at
Fig. 8 Experimental roll bite lubrication system
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Trans Indian Inst Met
production of cost effective special steels. Also the tech-
nologies have been selected with a view to bridge the gap
faced in the area of yield, mill utilization and specific
energy consumption. Some of the important mills coming
up in the SAIL modernization programme have been dis-
cussed below.
4.3M Wide Plate Mill at RSP: In order to satisfy cus-
tomer requirements for dimensional accuracy, heavier
gauges, higher strength and improved weldability, a new
4.3M wide Plate Mill is being set up at RSP.
Following are some of the important features of the new
plate mill at RSP:
• Reheating furnace of 225 t/h capacity with level II
automation
• PVR technology, roll bending and shifting facility
• Accelerated cooling technology
Other features include primary and secondary descaling
units of 220 kg/cm2 pressure, hot leveler with a minimum
hot leveling force of 33,000 KW for improved flatness of
plates and double side-trimming shear capable of on-line
side shearing of plates.
Cold rolling Mill, BSL: A cold rolling mill complex of
capacity 1.2 Mt/year has been set up at BSL under SAIL
modernization programme. The technology selection for
cold rolling mill has been done with a view to produce cold
rolled and coated products for automobile and white good
sectors. Some of the important features for the new CRM
are given below:
• Coupled pickling and tandem mill
• Hydrogen batch annealing
• Single stand 6-high skin pass mill
• Hot dip galvanizing.
2.4.2 Shape Rolling
SAIL specialises in producing special sections like Z-bar,
Z-piling (Fig. 9), colliary arch, rails, and railway wheels
etc. SAIL is the major supplier of rails and wheels to Indian
Railways and has continuously endeavoured to develop
different grades of rails and wheel for laying in specific
routes and environmental conditions such as high load
freight routes, corrosion prone routes.
Niobium alloyed rails, vanadium alloyed rails and
110 UTS rails have been developed for higher axle load
and increased traffic density [19, 20]. Apart from that
RDCIS is working on futuristic demand for developing
high toughness corrosion resistance rails and carbide free
bainitic rails [21].
With the commissioning of long rail complex and flush
butt welding machines at BSP has the capacity to produce
260 m long rails. Soon BSP will have new Universal Rail
Trans Indian Inst Met

Fig. 10 Floor tiles prepared using BOF slag

related programmes recently pursued by RDCIS are given

Fig. 9 Z-Piling section here.

2.5.1 Studies on Technical Feasibility Improving

Mill to produce rails and structurals. The new mill will
Utilization/Recyclability of BSP BOF Slag
possess online head hardening of rails with a capability to
produce symmetrical flat bottom rails, asymmetrical rails
Due to inherent limits of certain components like ‘Phos-
and grooved rails. It will be equipped with world‘s latest
phorus’ in steel, total BOF slag recycling inside steel plant
state of the art technologies for universal rolling, finishing
is not feasible. Through detailed experimentation it was
& testing. It will be able to supply world’s longest welded
established that BOF slag can be used as cement substitute.
panels of 520 m. Setting up of these state of the art mills
The maximum amount of BF slag should be 10 % in
will provide opportunities to RDCIS to produce new
concrete blocks and 15 % in floor tiles for retaining basic
quality rails to meet the requirements of Indian Railways.
physical properties required for intended application.
Other new long product mills under installation in SAIL
Under the project a process and apparatus was developed in
are medium structural mill at DSP and a heavy universal
laboratory scale for upgradation of BOF slag for stabil-
section mill at ISP. In the new structural mills of DSP &
ization of free lime through steam ageing. It was also
ISP all the existing products will be rolled and additionally
established that BOF slag can be used as neutralization and
parallel flange beam of all sizes (100–750 mm), wide
conditioning agent. Figure 10 shows floor tiles prepared
flange beam (100–260 mm) will be rolled. Besides, mill
using BOF slag.
will be capable to produce special section like bulb bar,
Z-bar. As the mills will be equipped with walking beam
2.5.2 Development of Electro Sonic Process
type furnace and more rigid stands with controlled cooling
for Pre-treatment of Coke Oven Effluent
facilities, different grades like carbon structural, low alloy
structural, SAILMA, high tensile, corrosion resistant, DMR
High level of toxicity in coke oven effluent is responsible
grade of steel will be produced.
for its recalcitrance (low degradability) towards biological
treatment. In order to render biological treatment effective,
2.5 Environment
reduction of toxicity and breaking up of complex com-
pounds into smaller ones is a prerequisite. A novel process
The challenge for steel industry in the new millennium is
has been developed in laboratory scale, based on principle
no longer to prove its capacity to create growth, but to
of high frequency sonication [22], where more than 50 %
show that it is a material that is ecologically sustainable. In
reduction in cyanide level (the key marker of toxicity) has
view of this, efforts of RDCIS in last few years have been
been achieved (Fig. 11).
oriented towards developing processes for utilization of
Following are the ongoing projects in the area of
wastes, increasing efficiency of wastewater treatment and
environment:
introduction of monitoring systems for improving effec-
tiveness of water and wastewater treatment aimed towards 1. Development of integrated process for coke oven
reduction in water consumption. Some of the environment effluent: Under this SDF funded project an integrated

123

Fig. 11 Removal of dissolved cyanide through sonication
state of the art process for treatment of coke Oven
effluent is under development.
2. Studies on generic attenuation of water quality impact
[23, 24]: Under this project, an off-line simulator has
been designed and is being fabricated to study
utilization prospects of generic chemicals as replace-
ment of proprietary chemicals for cooling water
treatment.
3. Studies on utilization prospects of BF flue dust: In-
plant recyclability and external utilization potential of
BF flue dust is being explored under the project.
2.5.3 Future Plan
RDCIS has also identified focus areas of working in next
few years, in line with emerging requirements arising out
of SAIL’s plan of doubling its capacity by 2020 with
minimal environmental footprint. Few of these areas are:
1. Increasing internal and external recycling of BOF slag
2. Reduction in water consumption
3. Development of sustainable water and wastewater
treatment processes
4. Introduction of automation in water and wastewater
system utilities
5. Introduction of state of the art monitoring systems.
2.6 Automation
In steel industry, automation is the very fabric that syner-
gistically weaves the other technological disciplines, apart
from its stand-alone accomplishments. It has been found
that automation has a positive correlation with market
share, profitability and thus is one of the key force multi-
pliers for a healthy balance sheet in the manufacturing
sector.
123
Trans Indian Inst Met
In this quest of automation & IT, SAIL has also
developed some key technologies and implemented them
in the integrated steel plants. The coking control technol-
ogy propped up by a veritable oven identification system;
on-line controls the flow, draft and the poise time for an
optimum thermal regime resulting in better coke quality
and energy conservation. The surface inspection system
provides instantaneous information to the user with respect
to different surface defects, if any, in the hot rolled coil. In
the field of industrial wireless, applications have been
developed in SMS and coke oven to reduce cable costs.
Level-2 models have been developed for hot rolling for
better shape control.
2.7 Energy
The iron and steel industry is constantly striving to reduce
its energy consumption and thereby minimize its overall
costs. RDCIS has made immense contribution towards
reduction in energy consumption & GHG emission and
improvement in furnace productivity and product quality in
SAIL plants by implementing innovative ideas, introducing
in-house developed energy efficient combustion system
and optimisation of thermal regimes. Some of the major
efforts made by RDCIS towards reduction in energy con-
sumption in SAIL Plants are briefly highlighted here.
2.7.1 Design, Development and Introduction of High
Capacity Blast Furnace Gas Burner for Boiler # 6
of Power Plant #1 at BSP [25, 26]
This unique burner design for firing blast furnace gas
(BFG) at high rate (10,000 Nm3/h) was developed for
boiler no. 6 of Power Plant-I of BSP to use surplus BFG
and replace purchased coal. BFG being a lean gas (calorific
value *800 kcal/Nm3) has low flame temperature and
poor in-flammability etc. for which pure BFG is used
mainly in blast furnace stoves and boilers. BFG burners
used in boilers are normally fired along with other rich
fuels like furnace oil, coke oven gas (COG) or pulverized
coal. To generate desired bushy type stable flame within
the width of the firing chamber of the boiler, high rate of
mixing of the out-coming BFG and air streams has been
achieved by increasing interfacial surface area between gas
and air streams (Fig. 12).
Six such burners (3 nos. on each of the two side walls)
have been installed in boiler no. 6 (Fig. 13) and they are
working quite well since commissioning. Properly
anchored and bushy flames are being generated in all the
six burners. BF gas is being consumed at a rate of
40,000–60,000 Nm3/h.
The balance heat load is being supplied by COG through
original composite burners. Steam is being generated in the
Trans Indian Inst Met
Fig. 12 Burner nozzle
Fig. 13 Modified water-tubes near burner port
range of 100–120 t/h at 40 atm pressure and 450 C tem-
perature using by-product gases (COG and BFG). Major
benefit of this endeavour include reduction in particulate
(fly ash) chimney emissions and green house gas emissions
by 15,000 and 100,000 ton/year respectively due to utili-
zation of surplus by-product gases generated in the steel
plant. Also, substantial monitory benefit is accrued due to
elimination of purchased coal.
2.7.2 Design, Development & Introduction of Curtain
Flame Ignition System in Sinter Plants [27, 28]
Curtain type flame based ignition system was developed to
improve the ignition of top layer of sinter mix and to
reduce the specific gas consumption. The concept involved
mounting several small capacity burners close to one
another on the roof across the sinter bed to generate curtain
shaped continuous flame across the sinter bed, which
ignites the top layer of the sinter bed. All the burners are
mounted in a single row perpendicular to the direction of
strand movement. In the conventional system, side burners
Fig. 14 A sketch of curtain flame burner block
Fig. 15 Curtain flame ignition hood
are used on both the side walls of sinter hood and this has
an inherent problem of slow and uneven heat distribution
across the sinter bed. To avoid this, several side burners are
used, which requires large furnace (ignition hood) length
and consumes higher quantity of heat.
In the curtain flame burner, primary air is sent through
swirls for better mixing of gas and air and secondary air
slots are provided in the burner module to obtain curtain
flame configuration (Figs. 14, 15).
In this system higher quantity of heat transfer (to start
ignition) to the top layer of sinter bed takes place by
convection instead of radiation as in the case with con-
ventional side burner. Initially several experiments were
123

Fig. 16 High velocity ladle heating burner
conducted with different designs in Combustion Research
Unit at RSP to evaluate sinter quality. Only after getting
encouraging results, the curtain flame ignition system were
installed in sinter machines of RSP, BSL, BSP and DSP. It
has resulted in reduction in specific fuel consumption by
30–40% and also furnace volume by about 80 %, thereby
reducing the cost towards fuel and refractory consumption
and increase in productivity by extra furnace length
available for sintering process.
Major benefits of this work are (1) reduction in specific
fuel consumption by 30–40 % (from 0.042 to 0.027 Gcal/t),
(2) reduction in GHG emission by 1,87,000 t/year.
2.7.3 Design and Development of High Velocity Burner
for Ladle Heating Stand in SAIL Plants
RDCIS conceptualised the design and developed high
velocity burner suitable for ladle heating system for the
first time in SAIL. In the new system, combustion air is
supplied either from a conventional air blower or from a
compressed air ejector to inject atmospheric air into the
burner, for combustion of COG. The combustion system
developed for ladle heating mainly comprises of a high
velocity burner with COG to generate long flame
(2.5–4.0 m) to reach up to the bottom of the ladle (Fig. 16)
and a ceramic fibre insulated ladle cover to minimize heat
losses to the surrounding atmosphere.
High velocity ladle heating combustion system has been
introduced in almost all ladle heating stands of Steel
Melting Shop & Ladle Repair Shop of SAIL plants. This
has resulted in improvement in ladle temperature to
1,050–1,150 C, reduction in skull formation and
improvement in ladle refractory lining life, reduction in
tapping temperature etc. Benefits of this new system are (1)
123
Trans Indian Inst Met
Fig. 17 Rockbolt and its use in tunnels
reduction in heating duration of green ladles from 16 to
10 h, (2) saving in CO gas by 40 % due to reduction in
heating duration.
2.7.4 Future Plan
Presently, SAIL is working on waste heat recovery from
sinter coolers of SP#2 & SP#3 at BSP to generate hot water
for utilisation in mixing drum.
Potential exists for further reduction of specific energy
consumption in SAIL by maintaining technological disci-
pline, regular energy audits, beneficiation of raw material
to improve its quality, 100 % by-product fuel recovery and
utilisation, phasing out obsolete technologies like twin
hearth, ingot route etc. and adopting newer technologies
like CDQ, TRT, alternate fuel injection in BF, 100 %
continuous casting, thin slab casting and rolling facility etc.
2.8 Product Development
During recent times a number of special steel products in
key segment area were developed jointly by RDCIS, and
various SAIL steel plants. Special mentioned may be made
of SAIL HITEN 690 AR plates for manufacture of ATM
chest [29], high tensile plates with through thickness duc-
tility for Defence & railways, ASTM 387 A Gr. 12 plates
for high temperature applications in boilers and pressure
vessels, high strength fine grained steel for PEBM & Auto-
chassis [30], Ti-bearing LPG steel for gas cylinders, low
carbon steel for auto applications, API X-70 grade HR coils
for oil and gas transportation [31] in the flat product area.
In the long products category, EQR TMT rebar [32], roof/
rock Bolt TMT rebars for mines and tunnels (Fig. 17) [33],
corrosion resistant TMT rebars for construction, Al-killed
low carbon CC blooms for cold reducers, Al-killed medium
carbon CC blooms for forging have been developed
recently.
Trans Indian Inst Met
Development of high strength formable grade steels for
automobile segment is an important area where all the
major steel producers in India are focusing. With installa-
tion of secondary steel making facilities like RH-OB &
state of the art cold rolling mill, a number of special steel
grades such as supper EDD (C \ 0.03 %), Dual Phase/
Multi Phase Steel, IF/High Strength IF, Bake hardenable,
HSCR and CR products with special surface finish for auto
segment are expected to be developed in near future.
In order to construct pipelines to sustain very high
operating pressure during transmission of oil & gas, efforts
has started in SAIL to produce API X-80 grade HR coils
through high temperature processing (HTP) technology.
Demand for high strength (YS: 1,200 MPa min) auto
components made from HR & CR coils is going to increase
manifold for auto segment from year 2013 onwards when
new crash worthiness norms will come into force. Hot
stamping of C–Mn steel is the most effective process for
fabricating various components for autos. In view of the
future prospect of such steel, efforts are already underway
for production of this steel in SAIL.
During the last 2–3 decades, R&D efforts in the galva-
nizing technology have brought about various improve-
ments in the galvanizing process leading to numerous
advanced galvanized products (AGP) worldwide. Some of
the important AGPs are one side/differential Galvanized
sheet, Spangle free/Zero spangle products, Advanced High
strength Galvanized Sheets, colour coated products etc.
Though some of these coated products are under devel-
opment in India, more thrust is required for development of
products like Zn–Mg, Zn–Ni coated sheets and advanced
high strength (TRIP & Dual phase) galvanized sheets for
auto segment.
CRGO steel is used mainly for fabrication of large sized
transformers. This steel is characterized by presence of
GOSS texture [(110) \001[] along the rolling direction
which in turn ensures low core loss values. Presently,
demand for CRGO steel in India is *2.0 lakh tones per
year which is met through import. This is one of the major
futuristic product which require attention of SAIL for its
development.
3 Conclusion
In recent years, RDCIS has executed a number of chal-
lenging tasks successfully in all the technological areas i.e.
coke making, steel making, iron making, steel rolling,
environment, energy, product development associated with
iron and steel production in various SAIL steel plants. The
highlighted R&D work further indicates that SAIL has the
requisite expertise and resources to meet the challenges
which it may face in future due to its ambitious expansion
and modernisation plan. As shown in this paper, RDCIS
has already chalked out its future plan and started working
upon them through various plant based, basic research,
centre of excellence projects. However, RDCIS will have
to focus on areas like beneficiation of low grade/difficult to
benefitiate iron ore like BHI, BHQ etc., development of
relevant technologies for beneficiation of high ash, difficult
to wash Indian coking/non coking coal, development/
adaptation of direct smelting technologies for iron making
using iron ore fines and non-coking coals. For energy
efficiency and conservation, concerted efforts are required
by RDCIS to work upon technologies like coke drying
quenching, coal moisture control, hot stove waste recovery,
blast furnace top pressure recovery turbine (TRT), increase
use of automation at all levels, compact strip casting (CSP),
strip casting etc. For environment protection, development
of technology for ultra low CO2 steel making, development
of technology for 100 % recycling/utilization of LD/EAF
slag, CO2 sequestration in the plant environment are some
of the research programmes which require immediate
attention from RDCIS. In the product development area,
RDCIS will have to concentrate on indigenous develop-
ment of products like CRGO, steel for power sector, ultra
high strength steel with good formability for automobile,
construction and infrastructure sectors.
Acknowledgments The authors express their gratitude to all GMs
of RDCIS for giving valuable advice which came handy in prepara-
tion of this paper. Authors also like to thank all engineers from
RDCIS for their immense contribution in carrying out above-men-
tioned R&D work and for providing input for preparation of this
paper. The authors are also thankful to their colleagues in various
SAIL steel plants for their untiring efforts which resulted in suc-
cessful execution of R&D projects.
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