DESMET REAGENT PVT LTD.

HOT METAL
DESULPHURAZION
SYSTEM
S.O.P.
 STANDARD OPERATING PROCEDURE (S.O.P.)

SL Focus area SOP Description

no
LOADING & Truck unloading
1. UNLOADING
AREA
1. Prior to loading and unloading
 Prior to loading/unloading visually check all hoses for leaks and wet
spots.
 Verify that sufficient volume is available in the storage tank or truck.
 Secure the tank vehicle with wheel chocks and interlocks.
 Verify that the vehicle’s parking brakes are set.
 Verify proper alignment of valves and proper functioning of the
pumping system.
 Establish adequate bonding/grounding prior to connecting to the
fuel transfer point.
 Establish of Truck Earth connection and check Feedback to HMI.

2. During loading and unloading

 Driver must stay with the vehicle at all times during loading/unloading
activities.
 Manager or designee should observe the delivery driver during
loading/unloading.
 Periodically inspect all systems, hoses and connections.
 When loading, keep internal and external valves on the receiving tank open
along with the pressure relief valves.
 When making a connection, shut off the vehicle engine.
 When transferring materials, shut off the vehicle engine.
 Nitrogen pressure is 1.5 bar during unloading.

3. Loading and Unloading

 Driver must stay with the vehicle at all times during loading/unloading
activities.
 Facility manager or designee should observe the delivery driver during
loading/unloading.
SL Focus area SOP Description
no

 When loading, keep internal and external valves on the

receiving tank open along with the pressure relief valves.
 Periodically inspect all systems, hoses and connections.
 When making a connection, shut off the vehicle engine. Maintain
communication with the pumping and receiving stations.
  Monitor the liquid level in the receiving tank to prevent overflow.
  Monitor flow meters to determine rate of flow.
 When topping off the tank, reduce flow rate to prevent overflow.

4. After Loading and Unloading

 Make sure the transfer operation is completed.
 Close all tank and loading valves before disconnecting.
 Securely close all vehicles internal, external, and cover valves before
disconnecting.
 Secure all hatches.
 Disconnect grounding/bonding wires.
 Make sure the hoses are cleaned before moving them away from the
connection. Cap the end of the hose and other connecting devices
before moving them to prevent unwanted foreign materials.
 Remove wheel chocks and interlocks. Lowermost drain and all outlets
on tank truck prior to departure.
 If necessary, check tighten, adjust, or replace caps, valves, or other
equipment to prevent leaking while in transit.

2 SOP for Truck  Select a vessel which has the capacity, pressure rating, corrosion
Vessel resistance and design

 Features that is suitable for its intended use. Operate the vessel
within a suitable safety devices and controllers

 Establish training procedures to ensure that any person handling

the equipment knows, how to use it properly. Maintain the
equipment in good condition, and test periodically by safety
Manager

 Assessment of any intermediates, side-products and products that

may form and their behavior within the vessel, including their
corrosive nature and their tendency to violently decompose at
elevated temperature and pressure.

 Run preliminary experiments using small quantities of reactants

when starting work with new or unfamiliar materials. Use
appropriate PPE, including safety glasses, chemical resistant
gloves, a lab coat, and also a face shield for operations that present
particular hazards. Keep a log of usage for each vessel.

3 Handling of  Wash thoroughly after handling.

 Reagents
 Remove contaminated clothing and wash before reuse.
( silo and
Dispenser)  Purged with nitrogen.

 Never add water to this product.

 Avoid shock and friction.

 Use spark-proof tools and explosion proof equipment.

 Do not get in eyes, on skin, or on clothing.

 Keep the truck vessel tightly closed.

 Do not ingest or inhale.

 Do not pressurize, cut, weld, braze, solder, drill, grind, or expose

the truck- vessel. Sparks or open flames keep away from heat,
sparks and flame. Use only with adequate ventilation or
respiratory protection.


4 Spills/Leaks  The reagent truck cannot unload during heavy rain.

(silo, Dispenser and
pipe line)  Remove all sources of ignition.

 Do not get water inside containers.

 Approach spill from upwind (if outdoors).

 Isolate discharged material for proper disposal (if outdoors).

5 Water logging in Regular upkeep to be done & standby Fire Extinguishers to be made
the area available, Ensure area is free from water

Fire catch,
Explosion

6 Moisture 1. Periodical Calibration of Acetylene analyser,

entrapment in the
silo 2. Continuous monitoring of readings along with alarms

Fire catch 3. Dry Sand in Buckets & Fire Extinguishers always kept on every
Explosion platform of silo building and Injection area.
 Storing & Handling Silos and Dispenser

7 Silo,  DO NOT proceed in this operation unless appropriately instructed

and permission to operate has been given.
Injection  Use Compulsory PPE and needed PPE
Dispenser,
1. Pre-operational safety
Transport
Dispenser
 Incoming Nitrogen pressure-10 bar, dew point -600C to -800C
 Assess the prevailing weather conditions for the worksite and the
work being carried out.
 Wear long sleeve shirt, long trousers, safety shoe, helmet, goggles,
and hand gloves, breathing and hearing protection when working into
silo building.
 Wear Personal Protective Equipment (PPE) as required for allocated
work or as described
 DO NOT enter or work inside any silos or Confined Spaces without
being trained, have a Confined Spaces Entry Permit
 Ensure the area is clear of overhead trip and fall hazards.
 Check EOT, wire rope and swaging is not damaged and is working
properly.
 Check that the Emergency Stop button is not damaged and
functioning properly.

2. House Keeping

 Clean away any foreign material,

 Clean the floor of Silo building to prevent hazards and damage.
 Safely repair any damaged parts and equipment
 Keep Clean every floor of Silo Building

3. Maintenance

 Any type of hot work cannot be allowed inside and outside of Silo

 Do not work with pressure vessel,

 Before start any type of job, related to silo Building, follow the
work Permit which was duly singed by Shift In charge.

 Maintain the silo pressure 50mbar(max)

 Clean the bag house and bag filter replacement on desire process.

 Maintain 100mbar(max) pressure between clean and dust air of

across the filter

 Ensure that filter pulsing run continuously to clean the bags.

  Bag filer vent lines always open.

 Bag filter monitoring every 90 days, dirty bags clean properly and
reinstall.

 Check and report damaged parts of silos on daily basis to your

supervisor/manager

 Monitor LECO analyzer (C2H2 & Mg) concentration -

C2H2 – 1.9%
O2 – 4%
 Prevent and arrest any type of leakages.

8 Reagent Transport
from TD to ID 1. Pre-operational safety and condition parameter

 Any type of hot work cannot be allowed inside and outside of Silo
and dispenser

 Do not work with pressure vessel,

 Before start any type of job, related to silo Building, follow the
work Permit which was duly singed by Shift In charge.

 Maintain the silo pressure 50mbar(max) and dispenser top

 pressure 4.5bar (as per operation condition).

 Ensure that filter pulsing run continuously to clean the bags.

 Bag filer vent lines always open.

 Check and report damaged parts of silos and dispenser on daily

basis to your supervisor/manager

 Monitor LECO analyzer (C2H2 & Mg) concentration -

C2H2 – 1.9%
O2 – 4%
 Prevent and arrest any type of leakages.
 All vales and instrument working properly.
 Inlet Nitrogen pressure is 10bar, dew point is -600C to -800C

INJECTION SEQUENCE and condition parameter

9 Injection area  Keep injection line clean and free of reagent after short flusing of
Nitrogen
 Check any leakages from injection line during treatment.
 Lance health condition
 Ladle free bore
 Ladle temperature
 To keep the Car track clean.
 To prevent lance chock back pressure should be min at 2.5 bars and
max 6 bar depends upon ladle capacity.

1. Pre condition of injection and fault monitoring

 Check ladle top crust condition and ladle level (Freeboard up to

minimum 500mm).If there is top crust, inform S/I and move
ladle to for lancing or anchoring.
 Pre checks: Slag pot condition.
 If required then complete Initial Slag Skimming followed by
metal sample &temp.
 Start Injection, Pre checks: Before starting Injection ensure that
all the dispensers are filled and all PLC interlocks should be in
healthy condition.
 Dispenser Filling at set parameter
 Set Injection top pressure
 Set transport gas pressure
 If temp , 1280 - 13400C start Injection with reagent.
 Continuously monitor Conveying pressure and Flow and if
conveying pressure increasing continuously.
 Stop Injection and check lance nozzle condition and conveying
line condition
  Boom of SRM in parking position
 Combined car at Injection position
 Inlet Nitrogen pressure is 10bar, dew point is -600C to -800C
 All vales and instrument working properly.
 Check the injection gas pressure (cleaning the line) before start
injection.
 Proper fluidizing of injection dispenser.
 Any type of Fault alarm display on HMI.
 All drives are functional healthy.
 After completion of Injection take sample &temp and complete
final raking.
 If Aimed Sulphur is achieved, inform Mixer incharge and move
ladle to outward resting position.

2. Pre condition of back blow process

 Blowback of the reagent is done whenever it is required to

vacant the injection dispenser and filling the reagents back to
silo.
 For this procedure at first the material conveying hose pipe
connected with injection lance is isolated and fitted to the
alternative conveying line of silo which will take the material
back to silo.
 At first nitrogen purging is done in order to check any leakage in
the entire conveying line thoroughly manually.
 After this injection process is followed which will allow the
reagents to come out of the injection dispenser and it will divert
to silo conveying line as the hose pipe is connected to the same.
 During this process it is required to keep the N2 flow at
optimum level i.e. 60-75 Nm3/mn and minimum N2 Pressure 10
Bars
 Keep the id top pressure 4-5 bars as per the requirement of
different reagents.
 Silo should have as much more space as the material is required
to be sent
 Back filter of the silo should be in operation throughout the
process along with all the analyzer working in healthy condition
 Keep monitoring the entire process till the injection dispenser
gets empty.

3. Emergency Condition In Puncture Of The Injection

Lance Or Bursting Of Injection Lance Inlet Hose
During Treatment.
 Stop injection immediately.
 Take out the Hot metal ladle to parking position.
  Change the hose or take necessary steps in order to arrest the
leakage.
 Check the injection lance nozzles, if chocked change the lance.
 If reagent spill on the platform dilute with sand. Do not use
water, foam, CO2 or Dry powder for Mg. Use sand, drySalt or
fire metal-ex powder.
 Collect the scattered reagents into jumbo bags
 Proper housekeeping to the area must be done.

4. CONTROL POINTS/ PROCEDURE FOR INJECTION LANCE

PUNCTURE

 Stop the injection immediately.

 Take out the Hot metal ladle to parking position.
 Inform shift Engineer regarding this issue.
 Arrange new lance to be placed.
 Remove the punctured lance through crane and park it on LRC.

5. INJECTION LANCE REPLACEMENT

 Once it is decided to replace the running faulty injection lance,

before that S/I should be assured of ready healthy injection
lance on Lance holder.
 Check all communication gadgets working in healthy condition.
 Send skilled technicians on lance holder with all proper ppe’s
and safety belt mandatorily.
 The process may occur from local control cabin which was
instructed by S/I.
 Unhook the damaged lance by proper tools and hook fresh
healthy lance with proper tightness and measure the straight
alignment with injection hole.
 Control room floor observer will ask the control room operator
to pass nitrogen through purging process to check any leakages.
 Instruct all men to come down safely from lance holder to
control room once all working in healthy condition .

6. Fire of electrical drives and any equipment.

 Relocate immediately to the safe zone.

 Call emergency number to fire department.
 Fire proof panel to be used for interior works.
 Smoke detection should be installed and common alarm system to be
monitored
 AC or Ventilation system should be installed
 Proper means for access/ exit to be made for emergency situations.
10 Injection lance Injection Lance fell into the hot metal ladle during
treatment
 This may happen when Risk :
injection lance carriage
 Availability of heat or fire
rope gets
chain getssheared
shearedor ordue
due
resource will ignite fire
to electrical
electricalfault
faultsuch
suchasas
immediately
encoder problem, limit
 It may also damage eyes
switch problem or ,, drive
injection
or skin when comes in
lance getsoreroded
problem injection
fromlance
the
direct contact.
middle.
gets eroded from the
 If this occurs during
 middle.
treatment then stop the
 During treatment if treatment immediately
happens, allow the purging  Wear proper safety ppe’s
of N2 – gas continuously in while working in this area
order to avoid the chocking  Shut off the nitrogen line
of lance nozzles. immediately if reagent
puncture through hose
 Immediately inform to pipe occurs
mechanical and electrical
shift in charge about the
incident and tell them to
SPECIAL PPE:
lift the injection lance by
lifting the injection lance  wear all proper safety
carriage by using sling and ppe’s as there may be
EOT crane. (Once the chance of material leakage
carriage is lifted up to the during unloading.
locking position and it
should be locked.
 SPECIAL TOOLS/ EQUIPMENTS:
 Replace new lance and  Fire extinguisher
make station ready for  Sand bucket
injection
11 Slag Raking (Pre raking / Post raking)
&
Skimming parameter
 Trained or skilled skimmers run the machine.
 Splashing of  Operators Cabin to be provided to prevent splashes.
Metal
 Fire Extinguishers to be in standby.
 Fire hazard  Start hydraulic system before racking.
 Check hydraulic system any leakages or fault, then immediately
 Hydraulic inform to S/I.
system  Checking tank desire oil level.
 Inform S/I , if any abnormality on SRM.
 operation
 Tilting ladle as less necessary to avoid hot metal loss.
 Continuous check the racking plate.
 Cleaning the jumped spout of ladle for smooth racking and racking
plate life.
 Always dipping the racking plate as less needed during skimming. (For
good practice 200mm dipping is sufficient for racking.)
 Immediately inform to mechanical and electrical shift in charge
about any type of incident like drive fault, hose break, oil tank
leak, DC valve leak, pressure line leakages and arrest those as soon
as possible.
 Check randomly of oil temperature. (max 600C)
 Check oil level indicator
 Periodic check of Joy sticks operation of SRM
 Set the boom travel length as required.
 Set max swiveling parameter as required.
 Checking Excessive Vibration during Racking.
Temperature and Sample taking
12

 Heat,  Auto online temperature measurement is beneficial.

 Dust,  Manual sampling with all protective PPE’s

 Splashes  Eye protection with goggle and face shield is mandatory
 Contact  Proper jacket and leather hand glove is mandatory
with hot
materials
13 Ladle and slag pot in transfer car
 Position of ladle on transfer car by proper signaling.
 Metal  Focus lights to be provided for proper visualization for crane
spillage operators
due to  Crane cabin glasses to be maintained for better visibility.
improper  Proper Operators signalling / marking systems for ladle handling.
positioning  Ladle is lifted slowly and very carefully before and after treatment.
  Shop floor below the ladle movement and loading area shall be
cleared of any personnel during operation.
 The pathway for overhead filled ladle movement shall not have any
facilities involving.

 Visual inspection of ladle refractory & Life monitoring / Thermography

 Puncture of
transfer ladle

 Free board to be measured to ensure dipping of lance.

 Depth of immersion to be measured.
 Slag and  Minimum 500 mm dipping of vessel inside the steel bath is essential.
metal over Measurement system to be incorporated.
flowing out
of the ladle
Fire
 Slag & metal overflowing from the treatment ladle may result in fire
hazard, subsequent injury and stuck on track way.

 Adequate ladle freeboard to be ensured while tapping the heat. Ladle

 Metal
skull formation & mouth jams to be removed with better ladle
treatment
during management.
degassing
 Adequate refractory lining to be provided in the tank for ensuring non
occurrence of fire hazards in case of metal overflow
13 Puncture of HM
 Ladles Fire i. Ladle will not be moved till metal flow stops
hazard
 Hook Wire ii. Fire extinguishers and water spray systems to be available to
rope cut extinguish any fire breakout. Ladle to be moved to crane approach
Spillage of after clearing the tracks.
Hot metal iii. Proper communicate with crane operator for such this type of
scenario.
iv. Barricaded the designated area.
v. Call fire department immediately.

Slag dumping
 Metal entry 1. Ensure steel is not drained into the slag pot.
into pot /
Red spot of 2. Foaming of slag should be avoided by adding any reagents.
slag pot 3. Dumping the slag pot into the slag pit - Explosion due to
 Break out water accumulation in pits during slag cooling for digging
of slag pot 4. Slag transportation to processing yard -
and slag
spillage  Spillage on road can cause slip, fall & Fire catch of tippers;
 Fire  Forming of cold slag bed in the vehicle before loading
hot slag

 Slag pot shifting carefully to avoid spillage during

movement

 Speed restriction to 16km/hr or as per rules.