OLD DILUTION PROCESS STAINLESS AISI 304 MAKING FAST TRACK & USUAL PROCESS STAINLESS STEEL, AISI 304 MAKING IN DILUTION METHOD

An Experience to Share with (Event having taken place in Dec. 1975): Performer- Mr. S.N. Singh
Location: - Alloy Steel Plant, Durgapur (SAIL)

 

Event:- Melting & refining of 54 tons Stainless Steel (AISI-304) in Record time of 2hrs 18min (tap to tap) against standard time of 6hrs!

Process followed:- Oxidation-Reduction, Alloying, Dilution and Refining.

Inputs: Stainless Steel Scrap, Plain Carbon Steel Scrap, High Carbon Ferro Chrome, High Carbon Ferro Manganese, Ferro Chrome Silicon, Ferro Silicon, Nickel, Electrical Power, Electrodes, Oxygen.

Comparison in Various Process Elements /Factors

Process Elements

Fast track Process
In Minutes

Normal Process
In Minutes

Time Management Start

00

00

Fettling & Charging

10

30

On Power

70 (Run at Highest Tap)

120 ( Run at Multiple Taps)

O2  Lancing

Same as above

30’ extra of melting.

Coolant & Charging

10

20

Reduction

20

60

Alloy Test, Adjustment of Composition

28

90

TOTAL TIME

138

350

Chrome Recovery

87.2%

88.5%

Nickel Recovery

99%

99%

Silicon Consumption

30Kg/ton

25Kg/ton

Silicon-Chrome - Manganese

40 Kg/Ton

40 Kg/Ton

Oxygen

50M3 /ton

40M3/ton

Power Consumption

270 Kwh/Ton

400Kwh/Ton

Other Gains, including Electrodes, Refractory

Minimum 20% Lesser than Usual

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Lamination in Rolled Products

1.5%

2.2%

Remark: The event was broadcast on air.  It also got reward from Indian Institute of Metals. Fabulous performance for the year 1975!