EUROPEAN STEEL TECHNOLOGY AND APPLICATION DAYS 2017 - ESTAD 2017

Modern EAFs require enhanced Safety and improved, consistent Performances; these features should be linked together, if possible. Both modern well-designed furnaces and more dated ones can benefit from the latest technology and equipment for removing operators from hazardous places, thus leaving dangerous activities to automated systems, while other technologies can read actual performances...

When the scrap charge in EAF melts, the heat transfer between the arc and side panels increases until slag foaming is started or arc length is reduced. However, the slag accumulated on the side panels acts as a kinetic barrier between the arc and cooling water. Previously, only estimates of the cause of slag has been obtained due to lack of reference measurement. In this work side panel...

For Electric Arc Furnaces (EAF) high performance and productivity can be reached by fully utilized equipment and products and with the associated process knowhow for a mostly uniformed and safer operation. The furnace components, also associated with supporting products have to be designed for a maximum power input, utilization and safe operation. Cycle times during power off and power on...

In the Electric Arc Furnace (EAF) chemical and electrical energy is used for melting and superheating of scrap and DRI/HBI. Although the fluid-dynamic and thermodynamic phenomena during the different furnace steps are qualitatively known, some of these effects may cause process problems. To serve as an example, a free-burning electric arc not covered by foamy slag overheats the furnace walls...

With the objective to further optimize the Electric Arc Furnace process, Vallourec Star installed the ZoloSCAN Laser Off Gas Analyzer in late 2015. Being one of the most efficient EAFs in North America, the integration of the off gas sensor with the AMIGE SmartFurnace system, required precise algorithms and reliable technology in order to provide consistent results. With a design that allows...

The recycling and treatment of radioactively contaminated scraps, mostly from the nuclear industry, are becoming more and more prominent issues facing the iron and steel sector. A proposed treatment route of steel containing radionuclides is with the Electric Arc Furnace (EAF). However, a deep understanding of the behavior of radionuclides (mostly cesium and strontium) during arc melting has...

Today the possibility to run EAFs at optimal energy efficiency is limited due to lack of information on the scrap melting progress and steel temperature inside the furnace. This paper describes results from a research project with the aim to improve the estimation of these essential parameters through taking advantage of new experimental measurement techniques (sound, vibrations, harmonic...

Electric Arc Furnaces (EAF) used for steel production are characterized by high and strongly erratic consumption of reactive power, substantial harmonic generation, as well as asymmetrical loading of its three phases. As conventional generation are being replaced by renewables the power systems will become more sensitive to these disturbances. To compensate for these adverse effects Static var...

This paper shows an overview on state of the art chemical injection systems at the EAF. Modern injection solutions, lower consumption costs, increased productivity and safety. These systems are easily upgradable to any EAF. Within a short shut down time, the installation of modern combined injection systems will lead to huge productivity and process improvements. The chemical injection...

Steelmakers strive for a high degree of effectiveness combined with efficient energy. Equally important are productivity of the process and the quality of the product. Hellenic Halyvourgia, Greece (HLV) and SMS group have developed a completely new and unique process for scrap preheating: the SHARC furnace (shaft arc furnace) process. This process minimizes energy consumption to a minimum...

During the last years CRM has developed a dynamic on/off-line model for the EAF process. Contrary to calculations using statistical inputs, CRM model uses a fundamental set of calculations based on thermodynamics and kinetics that takes dynamically into account furnace operating data. The purpose of the on-line application is to provide the operator with a better estimation of the melting...

The scrap used as charge material in the Electric Arc Furnace (EAF) is characterised by a high variability in yield, chemical composition, bulk density and melting behaviour. This is essential to be considered in context with online monitoring and control of the EAF process. The objective of the Pilot & Demonstration project AdaptEAF, funded within the European Research Fund for Coal and Steel...

The steel scrap melting rate in an electric arc furnace (EAF) is directly related to energy consumption and furnace productivity. In this paper, the melting time of steel bars of varying size in a liquid steel bath has been predicted using computational fluid dynamics (CFD) simulation. A three-dimensional CFD model has been developed with detailed consideration of fluid flow and the melting...

With the increasing number of high productive EAF, and the variability in raw materials and product demand, the need for a system capable of adapting to the operation conditions in real time is essential. With state of the art technology, the AMIGE SmartFurnace system, featuring optimization tools like the DigitARC PX3 Electrode Regulation System and the ZoloSCAN Laser Off Gas Analyzer, has...

With the ILTEC Technology, Mettop´s patented water-free cooling solutions, it is possible to overcome the disadvantages of water by using an alternative cooling medium, namely the ionic liquid IL-B2001. The main characteristics, which makes IL-B2001 so favourable, are the neglectable vapour pressure, the wide liquidus range and the not flammable, non-explosive and atoxic behaviour. Since it...

In metallurgical plants you will find lots of areas with dust, smoke gases and easily accessible liquid steel. To carry out manual work in this environment is very dangerous and should be avoided. Nowadays more and more manipulators and robotic solutions are used to substitute tasks in hazardous areas. One example for such a dangerous work is tap-hole-opening in electric arc...

After 7 years and 14 installations worldwide of the Condoor (aka Texas Tailgate), the results achieved and the lessons learned leading to the present technical solution are presented, in 3 major steps summing up hundreds of technical improvements, each born from steelmaker experiences and requirements. Not all stories have been positive but each experience, especially when shared by the...

Cost competiveness and productivity management achieved safely and meeting high quality standards are paramount to the success of steelmaking in the current market. In recent years, a tool to perform three phase power system analysis of alternating current electric arc furnaces – SGL PRO ARC – was developed and successfully deployed to optimize mast control systems and electrical operating...

Abstract A steel making factory with a DC EAF and LF requires a reliable and stable supply system to allow the correct and efficient operation of the overall plant. Not always these conditions can be fully guaranteed giving rise to the need of more flexible operating modes for the steel making factory, foreseeing the operation in different configurations: synchronous mode with the main public...

The slagdoor is the part of the electric furnace for the slag bleeding occurs. This door is closed by a metal door that rises at the time of casting slag, dropping back to its initial position to continue the process of steelmaking. During the casting, the erosion or attrition of the refractories lining that cover the sidewalls of the furnace takes places, so it is necessary to apply a...

The EAF process reach different results during the different production periods depending by variabilities in operating practices applied, equipment’s efficiencies, scraps charged and hot heel present. A mathematical tool for continuous monitoring of process performances and technological phenomena in EAF has been developed in collaboration between Feralpi Group and CSM to monitor steel/slag...

The experiences to optimize and control the single steps of steelmaking process as EAF LF and continuous casting has shown that a through process approach is necessary to take into account the previous and subsequent process steps as constrains for optimization. In this way Feralpi Siderurgica has developed a new approach of through process modelling and monitoring coupling simulation...