Essar Steel

Innovations and improvements
• 1996- Turbo expander, a second hand plant was commissioned to take care of rich gas supply.
• 1997- For process monitoring, process software package ,called FIXDMACS started for better
Process evaluation with the help of historical data.
• 1997- Thin wall refractory liner installed in the furnace increasing the furnace ID from 5.0 meters to
5.15 meters – Midrex design.- Mod-1
• 1999- Reformer expanded from 288 tubes to 336 tubes providing 16% additional reforming capacity
(In-house design)- Mod-1
• 1999- Oval Top Gas duct replaced standard off-take providing an additional 0.3 meters of reduction
zone height – Midrex design- Mod-1,2.
• 1999- Reformed Gas cooler was replaced by modified temperature control system – Midrex concept
and (In-house design)- Mod-1,2,3.
• 1999- Oxygen injection equipment installed to allow operation at elevated reduction temperatures to
maximize production – Midrex concept and (In-house design). Mod-1,2,3.
• 1999- Naphtha injection to the furnace cone trails were carried out. The concept was a success and
the other modules have been similarly equipped. At this time naphtha can be utilized as a natural gas
substitute in all three modules.
• 1999- An additional set of heat recovery bundles were designed in house and placed in service to .
improve energy efficiency (In-house design). Mod-2
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