Generation of high iron containing wastes such as mill scale, dust and sludge are inevitable in steel making process. It is important to develop and implement processes to recycle and re-use these wastes. An attractive option is to recycle these wastes through BOF steel making process, but is not suitable for handling and efficient operation in available forms. Present work shows the briquetting of steel making wastes using various binders in a pilot scale briquetting machine. In briquetting tests, the effecting parameters have been studied for determining the best combination of binders and operating parameters. A process for briquetting mill scale in optimum combination with CRM dust and BOF dusts using an organic binder has been established. Separate indices were formulated as acceptance criterion for use of mill scale briquettes in BOF service conditions involving dynamic, crushing, abrasive and thermal loads. Subsequently, series of trials were conducted with use of mill scale briquettes as secondary coolant replacing iron ore in 130T LD converter. The present paper compares the effect of mill scale briquettes vis-à-vis iron ore on process parameters in BOF steel making and also highlights its operational advantages.

Converter lining life is an important technical and economic concern of the steelmaking process. An increase in lining life decreases refractory consumption and reduces steelmaking costs. Increased availability of furnaces increases production rates and steel yield. Extended lining life was achieved by utilising the slag as a consumable refractory by splashing it over the lining. Slag splashing is a simple and effective technique followed worldwide to increase the converter life. This paper highlights the online study on various operating parameters and slag characteristics for consistent slag splashing in a 130 t converter. Parameters such as lance height, blow pattern, gas flowrate, bottom purging flowrates, tapping temperature, combination of gunniting with splashing, slag height and slag chemistry, were investigated. An optimised slag has been developed which served effectively to balance the lining erosion during blowing and maintain a uniform thickness throughout the campaign. Some innovative practices and design changes are also discussed. The developed slag regime and optimised parameters have helped in increasing the converter life to an international benchmark. JSW Steel has achieved the converter lining life of 13 771 heats, which is the highest ever recorded in India.

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Steel Melting Shop One (SMS-I) has 03 BOF converters with 135 tons capacity each. The SMS-II has 04 BOF converters with 180 tons capacity each and SMS-III with 1x160 ton EAF Furnace. India's largest integrated complex intend in the near future to build SMS-IV and will reach 16 million tons of steel per year. The other side, common problems during operations of BOF happens like: Jam's formation of blowing lance and converters mouth with dirty skirt. Efforts are made every day to avoid and reduce these effects and increase productivity and reduce costs. This present paper, the focus was enhanced blowing lance operation, reduction of lance jam and converters mouths jam of BOF shops. A new concept of lance tips was introduced for the same to improve more stable conditions during long life lance tips called "Slagless Clean Up cartridge". The target of this work is shown new conditions to reach like: increase cartridges life, reduce jams around lance and mouth contribute for stable operations.