Steel Mill Services
FSNL is pioneer in the field of metal scrap recovery & slag handling in the country. FSNL with their sophisticated and specially designed fixed and mobile equipment's & specialist manpower handles extremely hot metal & slag so that the customers mainly concentrates on their core activity of steel making.
The recovered scrap improves the profitability of the customer steel plants. The slag after recovery of metallics is further processed for recycling in Sinter Plant, Blast Furnace as a substitute of lime stone and in road making and as rail ballast. The technology used by the company converts slag into useful and environmentally beneficial to the customer steel plants apart from revenue to the customers from commercial sale.
FSNL recovery systems improves the profitability of their customer steel plants by maximizing the reclamation of metals as the recovered metallics are used in place of externally purchased scrap which saves their costs substantially.
In addition, it has been established that by using the recovered metallics delivered by FSNL, the customer steel plants achieves considerable savings in energy and natural resources.
Production of one tonne of raw steel from steel scrap when compared to BF / BOF route results in.
Production of one tonne of raw steel from steel scrap when compared to BF / BOF route results in.
- 74% savings in energy;
- 90% saving in virgin materails - one tonne of scrap would lead to savings of 1.5 mt. iron ore, 0.9 mt. of coking coal and 0.5 mt. of lime stone.
- 40% saving in water requirements and 76% reduction in water pollution.
- 85% reduction in air pollution, and
- 97% reduction in mining wastes.
In iron and steel making an estimated metal loss ranging between 4 to 7% of metal produced occurs in each process which is termed as "scrap".
There are mainly two categories of scrap.
Primary scrap : Primary scrap is relatively clean and almost free from slag & its recovery does not require separation from slag. Its processing involves downsizing for remelting in steel making.
Secondary scrap : Secondary scrap is found mixed with impurities like slag, debris, muck, refractories etc. and requires a special and capital intensive mechanised process for recovery.
SCRAP RECOVERY PROCESS.
Manual process :
- Hand - picking of scrap.
- Chiselling and hammering of large pieces manually.
- Hand loading.
Semi - mechanised process :
- Combination of manual operations picking and breaking to size.
- Usage of small capacity handling equipments for loading
Mechanised process (mobile) : Heavy duty capital intensive processing and handling equipments like.
- Crawler electric / diesel crane with magnet.
- Hydraulic Excavator
- Magnetic separator (mobile)
Mechanised process (stationary) : Fixed plant with facilities of
- Conveyors.
- Hoppers
- Feeders
- Magnet drums
- Screens
- Crawler electric / diesel crane with magnet
- Hydraulic excavator
OPERATIONS AT SAIL, RINL, MIDHANI & NMDC STEEL PLANTS
Elements of activities :
- Recovery and processing of iron and steel scrap.
- Hot slag pit management at BF & SMS.
- Handling and processing of iron and steel skulls and jams by lancing/balling.
- Collection, processing of maintenance/mill rejects.
- Handling and processing of rejected rails/ingot/slab/bloom/billet/pig iron etc.
- Scarfing of defective slabs.
- Crushing & Screening of LD Slag for further use at Steel Plants.
- Transportation of worked through Slag after Metallic recovery.
- Handling of sludge & ash, lime dust, mill scales etc.
- Acid Neutralization.
- Value addition to low grade recovered scrap through Fe-enrichment Plant.
- Segregation of refractory bricks
