Primetals Technologies Expands Jindal Stainless Capacity with High-Tech Production Line
Primetals Technologies has completed the installation of a new stainless steel production line at Jindal Stainless Ltd. (JSL) in Jajpur, Odisha. The project, which includes a 150-ton Argon-Oxygen Decarburization (AOD) converter, a 150-ton ladle furnace, a single-strand continuous caster, and advanced automation systems, has received the Final Acceptance Certificate (FAC) from JSL. This upgrade will increase Jindal Stainless’s production capacity by 1 million metric tons annually, marking a significant milestone in the company’s growth.
Innovative Features of the New Production Line
The new stainless steel production line at Jindal Stainless is packed with state-of-the-art technology designed to optimize the steelmaking process, improve product quality, and reduce energy consumption.
1. AOD Converter: High Efficiency and Faster Cycle Times The AOD converter is the cornerstone of the new production line. This 150-ton vessel features a top-blowing lance, an exchangeable converter, and a process gas mixing station, which optimizes the decarburization process. The converter's design reduces cycle times, processing the entire cycle from charging to tapping in just about one hour, thus increasing overall throughput. Additionally, its efficient use of process and reduction gases significantly reduces operational costs and environmental impact.
2. Ladle Furnace: Optimized Metallurgical Control The 150-ton ladle furnace installed alongside the AOD converter plays a crucial role in fine-tuning the steel’s chemistry. It is integrated with the LF Optimizer, a sophisticated system that uses advanced metallurgical models to enhance process control. This ensures the final product maintains consistent quality while minimizing energy use and consumption of raw materials like AOD process gases. By optimizing power consumption during the steel refining process, the ladle furnace helps Jindal Stainless achieve better control over product quality and operational costs.
3. Continuous Caster: Precision and Automation The single-strand continuous caster is designed to process stainless steel in the 200, 300, and 400 series. It features the LevCon Mold-Level Control System, which ensures dynamic bulging compensation, and the Level 2 CC Optimizer System, which aids in production planning, data recording, and real-time monitoring of the casting process. These systems enhance process stability, allowing for optimal control over the casting conditions and improving production efficiency.
The caster’s integration of the Mold Expert System allows it to detect and prevent caster-mold breakouts, a common issue in the casting process, while the Yield Expert System optimizes cut lengths and strand adjustments to maximize production yield. This ensures that Jindal Stainless can produce high-quality slabs, ranging from 850 to 1,680 millimeters in width and 160 to 220 millimeters in thickness, efficiently and consistently.
4. Advanced Automation for Smarter Production Primetals Technologies’ automation solutions, including advanced process control systems like the AOD Optimizer and LF Optimizer, integrate directly with the new equipment to optimize steelmaking. These systems enable real-time adjustments to the process, ensuring stable product quality while minimizing waste and energy consumption. The automation systems also ensure the equipment’s operational efficiency by providing predictive maintenance capabilities, helping avoid unplanned downtimes and extending the lifecycle of critical equipment.
Additionally, the Mold Expert and Yield Expert systems further enhance the casting process by minimizing defects, improving quality, and ensuring the slabs meet Jindal Stainless’s strict specifications.
Impact on Jindal Stainless’s Operations
The new equipment and automation solutions are poised to have a significant impact on Jindal Stainless’s operational capabilities:
• Increased Production Capacity: By adding 1 million metric tons to its annual capacity, Jindal Stainless will be able to meet the increasing global demand for high-quality stainless steel, further solidifying its position as India’s largest stainless steel producer.
• Higher Product Quality: The advanced metallurgical and automation systems ensure that Jindal Stainless’s products consistently meet high-quality standards. The precise control over the decarburization process and metallurgical optimization during refining helps Jindal Stainless produce premium-grade stainless steel with minimal waste and defects.
• Energy and Cost Efficiency: The advanced systems reduce both energy consumption and raw material usage. For example, the integration of AOD and ladle furnace optimizers ensures energy-efficient steelmaking, reducing operating costs and helping Jindal Stainless improve its environmental footprint.
• Operational Excellence: The faster cycle times and reduced maintenance needs thanks to advanced automation lead to an increase in throughput and operational efficiency. The new production line supports continuous production without sacrificing quality, ensuring Jindal Stainless can deliver on-demand orders with minimal delays.
Jindal Stainless: India’s Leading Stainless Steel Producer
Founded in 1970 by Om Prakash Jindal, Jindal Stainless Ltd. has become India’s largest stainless steel producer. The company operates multiple manufacturing and processing facilities across India and internationally, with a production capacity exceeding 3 million metric tons annually. Jindal Stainless’s product range includes stainless steel slabs, coils, plates, sheets, wire rods, precision strips, rebar, and coin blanks. The company has consistently invested in innovation and technology, ensuring it remains at the forefront of the stainless steel industry in India and worldwide.
Jindal Stainless has also made significant strides in sustainability, working towards reducing the environmental impact of its production processes. This new production line, featuring energy-efficient and environmentally friendly technologies, will help further the company’s commitment to sustainable manufacturing practices.
Primetals Technologies: A Global Leader in Steelmaking Solutions
Primetals Technologies, headquartered in London, United Kingdom, is one of the world’s leading providers of plant engineering, equipment, and lifecycle services for the metals industry. The company specializes in providing integrated solutions for steelmakers, offering a complete portfolio that includes automation, digitalization, and environmental solutions. Primetals Technologies is part of Mitsubishi Heavy Industries and has around 7,000 employees worldwide.
The company’s expertise in steelmaking processes and its innovative solutions have made it a trusted partner for leading steel producers, such as Jindal Stainless. With its advanced technologies and automation solutions, Primetals Technologies continues to lead the way in enhancing the efficiency, quality, and sustainability of steel production globally.
Key Takeaways:
• Final Acceptance Certificate (FAC): Primetals Technologies received the FAC for its installation of a new production line at Jindal Stainless in Jajpur, Odisha.
• 1 Million Metric Tons Increase: The new production line will increase Jindal Stainless’s annual production capacity by 1 million metric tons.
• Advanced Equipment: The new line features a 150-ton AOD converter, 150-ton ladle furnace, and a single-strand continuous caster, all equipped with cutting-edge automation systems.
• Automation Systems: Integration of AOD Optimizer, LF Optimizer, LevCon Mold-Level Control, Mold Expert, and Yield Expert systems ensures enhanced process control, better product quality, and optimized production.
• Energy Efficiency: The new equipment minimizes energy consumption, improves sustainability, and reduces operational costs.
• Faster Cycle Times: The AOD converter reduces cycle times to approximately one hour from charging to tapping, enhancing throughput.
• Global Leader in Stainless Steel: Jindal Stainless is India’s largest producer of stainless steel, with a focus on high-quality, sustainable products.
• Partnership with Primetals Technologies: This collaboration emphasizes technological innovation and operational excellence in the steel industry.
The successful completion of this project not only boosts Jindal Stainless’s production capabilities but also demonstrates how advanced technologies can transform steelmaking processes, ensuring higher efficiency, quality, and sustainability in the industry.
