A journey: Achieving 11KT of daily hot metal production milestone at blast furnace 1, Tata Steel Kalinganagar

Blast Furnace 1 at TATA Steel Limited, Kalinganagar has consistently produced 10,000 ton of hot metal daily. Through a shift in operational philosophy and relentless efforts to sustain the driving rate, the aspiration to reach 11,000 ton of hot metal production was successfully realized. This paper delves into the identification of the key enablers, their impact on crucial process parameters, and the invaluable insights gained during this transformative journey. The study rigorously explores the influence of various process variables on furnace productivity, encompassing top gas pressure, burden distribution, optimized slag regime, raceway adiabatic flame temperature, PCI injection rate, and casting practices. Additionally, it analyses the trial of incorporating colemanite powder with the objective of enhancing furnace permeability. A controlled approach to colemanite injection, optimized through an in-house developed injection route, facilitated increased wind volume at the same differential pressure across the furnace. This paper also presents comprehensive results and observations stemming from the combined injection of colemanite and PCI.