The Refractory Engineering Services [RE(S)] Department of Rourkela Steel Plant (RSP) has set new records in every area of operation in the last one year. The department has made significant contributions not only in increasing the lining life of steel converters and ladles as well as hot metal ladles but also has created records in the field of specific refractory consumption.
The Refractory Engineering Services Department along with the Steel Melting Shop-II collective had notched up an exemplary performance in the field of techno-economics with Converter ‘B’ of the Shop registering a record lining life of 6842 heats in the month of February 2013. With this RSP broke its previous record of 6543 heats achieved in September 2011 in Converter ‘A’. Due care was taken that all equipment are kept in proper shape to sustain such a long campaign life.
The Steel ladle No 8 of SMS-II achieved a record life of 150 heats which is the best among SAIl Plants. This was due to a combined effort of lime Dolomite and Brick Plant (lDBP), RE(S) and SMS-II (Operation). The Research and Development wing of SAIl ie the RDCIS was associated with the in-house brick manufacturing unit lDBP to develop tailor made bricks for these ladles. Refractory Engineering Services carried out all the relining and repair activities with utmost care. Zonal lining was done to take care of the areas of highest erosion. Quality of workmanship was the top priority and hence regular inspection was done from the beginning and each and every heat was closely monitored. The Department also contributed to the achievement of a record Steel ladle life of 100 heats at the Steel Melting Shop-I which is again the best performance in SAIl for small ladles. After the innovative introduction of full Magnesia-Carbon lining, the ladle life improved up to 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. Achieving best ever ladle life of 1705 casts in the 140 Tonne Hot Metal ladle was another feather in the cap of the department. This along with the average lining life of the Hot Metal ladle is the best performance in SAIl. All these efforts and achievements have led to the registering of the lowest ever specific Refractory consumption of 9.41 kg per tonne of crude steel. Team RSP, not one to rest on its laurels, is now planning to use new Refractories for steel ladles on a regular basis and march towards achieving the best steel ladle life and best converter lining life in India.
