INGOT METALLURGY FORUM Winter Meeting, March 21, 2007 ... · SIEMENS VAI – Equipment Design Solutions for Specialty Steel and High Alloyed Steel Producers: 1. General Aspects of

INGOT METALLURGY FORUM Winter Meeting, March 21, 2007

Burnham, PA

Industrial Solutions and ServicesYour Success is Our Goal

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onverter_Standard.ppt

19.09.2005Folie 2

Metals Technologies

SIEMENS VAI – Equipment Design Solutions for

Specialty Steel and High Alloyed Steel Producers:

1. General Aspects of SIEMENS VAI EAF Design

2. Haynes Int’l Kokomo – Replaceable Shells

3. Refining Combined Burner (RCB) Technology for

Burner and Supersonic Oxygen Injection Management

4. Installation RCB’s at Stahlwerke Bous/Germany

5. General Aspects of SIEMENS VAI AOD Converter Design

6. Layout Aspects


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Metals Technologies

1. General Aspects of SIEMENS VAIEAF Design

EAFOUTOKUMPU Stainless

Compact design of the furnace gantry and tilting device (VAI-FUCHS Patent)

Single Point Roof Lift

Prismatic Roller Guide Concept for precise, stiff and torsion resisting electrode column guidance

Current conducting arms VAI FUCHS Patent

Large size “air tight” EAF concept realized

Electrode regulation for optimum energy utilization and improved power input

Energy Optimized – Eccentric Bottom Tapping (EO-EBT) Lower Shell for C- and Specialty Steel

Spout tapping for Stainless Steel


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Metals Technologies � Exchangeable Shells - Designed for MaximumFlexibility, Availability and Productivity

Project Objectives:

� Reduce cost by avoiding wash heats whenswitching from one base alloy to the other

Project Solution:

� Introduction of exchangeable shells with watercooled panels, replacing the existing refractorylined furnace shell

Scope of Supply:

� 1 Tilt platform with rocker assembly

� 3 Upper Shell Assemblies with w/c panels

� 4 Lower Shell Assemblies each with spout

� 1 Roof Lift and Swing Assembly

� 2 W/c Roof Assemblies

� 1 Three Point Lift Beam for lower and upper shells

2. HAYNES International Kokomo Plant Producer of Ni- and Co- based Alloys:

Benefits:

� Eliminating wash heats – material,time and cost savings

� W/c panels – cost reduction due toreduced refractory consumption

� Increased productivity


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Metals Technologies 2. HAYNES International – Shell Exchange:1. Waiting Position


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Metals Technologies 2. HAYNES International – Shell Exchange:2. Lifting Beam

Attachment


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Metals Technologies 2. HAYNES International – Shell Exchange:3. Transport


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Metals Technologies 2. HAYNES International – Shell Exchange:4. Positioning in

Tilt Platform - 1


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Tilt Platform - 2


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Tilt Platform - 3


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Tilt Platform - 4


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Metals Technologies 2. HAYNES International – Shell Exchange:5. Ready for

operation


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Metals Technologies

RCBModule

Oxy / Gas Burner (using Natural &

Coke oven Gas or LPG)

Supersonic Oxygen Injection

Post Combustion with Oxygen

Injection of Filter dust or Solid

Materials(Lime, FeSi, Cr...)

Carbon Injection for Re-Carburisation

Contact-Free Temperature Measurement

Carbon Injection for Foamy Slag Technology

Introduction

Design & Technology

Decarburization

Operational Results

Special Operation

3. RCB Injection ProcessManagement


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Metals Technologies

A long lasting experience& proven oxygen injection technology

Introduction

Design & Technology

Decarburization

Operational Results

Special Operation


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19.09.2005Folie 15

Metals TechnologiesHigh Oxygen efficiency

Operation with a closed door

in terms of safety and Energy losses

Elimination of consumable lance pipes

Full automatic operation resulting in a

reproducible and automated process

Optimised foaming slag control

Improved Metallic yield

Decreased Electrical energy consumption

Reduced Electrode consumption

Reduction of Operation Costs

Introduction

Design & Technology

Decarburization

Operational Results

Special Operation


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19.09.2005Folie 16

Metals Technologies

Multi-points oxygen injection

0,025

0,050

0,075

0,100

0,125

0,150

0,175

0,200

0 250 500 750 1000Nm3 Oxygen

% C

Door lance operationRCB Operation

C+1/2O2=CO

Bath strong stirring and homogeneityHigh oxygen efficiency for decarburizationIntroduction

Design & Technology

Decarburization

Operational Results

Special Operation


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Metals Technologies

0,0

50,0

100,0

150,0

200,0

250,0

300,0

350,0

4,5 5,0 5,5 6,0 6,5 7,0 7,5 8,0

Diameter steel bath (m)

Dec

arbu

rizat

ion

rate

(kg

C/m

in)

6 8 10 12

Nm³ CO / min / m²

MMK - RUSSIAEAF 180t - 150 MVA60% scrap - 40% HM5 x 2.400 Nm³/h O²

COLAKOGLU - TURKEYEAF 250t - 240 MVA

100% scrap5 x 2.750 Nm³/h O²

DSF 100t - 100 MVA100% scrap

3 x 2.400 Nm³/h O²

High and safe decarburization rates for Hot Metal,

Hot DRI and any high productive process

300 Kg C/h/m²

Decarburization Rate

Introduction

Design & Technology

Decarburization

Operational Results

Special Operation


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19.09.2005Folie 18

Metals Technologies

Stahlwerk Bous is located in Bous, Germany, close to French border. The steelplantbelongs to the Georgsmarienhütte Holding and is equipped with a 70 t EAF and a VD plant. Bous casts ingots for forging and rolling.

In December 2004, 3 Refining Combined Burners (RCB) were installed in the EAF of Stahlwerk Bous.

The Production is 100% Quality Steel ranging from low alloyed up to high alloyed steel (max. 13% Cr) which is supplied mainly to the Mannesmann Vallourec Pipe Making facility.

A new VAI Fuchs Ladle Furnace was commissioned later in September 2005.

Introduction

Project Information

Furnace data

RCB & C, Layout

RCB Comm.

Results

4. RCB Injection Process Managementat Stahlwerke Bous


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Metals Technologies PROJECT TARGETS

Boost productivity with

possibility to achieve higher power input without increasing refractory consumption and costs

more efficient thermal and metallurgical process

feed additional fossil energy combined with oxygen

Reduce conversion costs with

higher productivity and production

decrease of electrical energy consumption

increase of oxygen efficiency

elimination of consumable pipes

Introduction

Project Information

Furnace data

RCB & C, Layout

CommissioningResults



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Metals TechnologiesEAF TECHNICAL DATA

Tap size: 70 t

Furnace type: EBT type

Diameter: 5,0 m

Electrode Diameter: 508 mm

Transformer: 45 MVA - AC

Power Input: 34,8 MW

Tap Temperature: ≥1730 C°

Number of RCB : 2X Wall, 1X EBT

RCB Power : 3x3,5 MW

Carbon injection : 1Xwall, 1XEBT

Introduction

Project InformationFurnace data

RCB & C, Layout

CommissioningResults



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Metals Technologies

Introduction


RCB & C, Layout

Commissioning

Results

RCB 1

RCB 3 & C

RCB 2 & C

RCB 1&3 47 ° Inclined

RCB 2 65° Inclined



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Metals Technologies

Introduction


RCB & C, Layout

Commissioning

Results

Ignition Test ( 1,7 MW burner power)

RCB at EBT in Stand By Mode (0,8 MW)



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Metals Technologies

6,713.4

13,126.2

8,917.8

kg/tlslbs/sh tCarbon Consumption

17313147.8

17313147.8

17313147.8

°C°FAverage Tap Temp

8,5272.9

6192.6

3,5112.4

Nm³/tlscuft/sh tGas Consumption

301059

341090

23,8764

Nm³/tlscuft/sh t

Total oxygen Consumption

2,24.4

3,16.3

3,36.6

kg/tlslbs/sh tElectrode Consumption

434.4395.0

445404

480437

kwh/tlskWh/sh t

Electrical Energy consumption

474752,3min.Power On time

Performance Test Values

Guarantee Values

Reference Values

Introduction


RCB & C, Layout

Commissioning

Results



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Metals TechnologiesProductivity curve of Stahlwerk Bous in February 2005

Introduction


RCB & C, Layout

Commissioning

Results



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Metals Technologies MAIN PROJECT RESULTS

Reduction of power on time by 6,3% as high power input is now feasible

under smooth and reliable operation.

Electrode consumption decreased by 33 %.

Electrical energy reduced by 9,5 %

Production is increased about ~5 %

Productivity increased from 39 t/h to 45 t/h (by 15%)

Reduced tap to tap time by approx 30% for High Cr steel grades (Cr≥ 10%) (TTT 120 min. 85 min.)

Introduction


RCB & C, Layout

Commissioning

Results



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19.09.2005Folie 26

Metals TechnologiesEAF TTT reduction in production of high Cr content steel

High Chromium grade steel production requires very low level of P and C before deslagging and alloying FeCr in the furnace. These targets were achieved in shorter time. Thanks to RCBs´ efficiency.

Requirements of P and C in Steel before Alloying

P : 10 - 20 ppm C : 100 – 200 ppm

Introduction


RCB & C, Layout

CommissioningResults POWER INPUT - MW

0

10

21

31

42

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85TIME ( min )

MW

0

1000

2000

3000

4000

5000

6000Elec.Power Total Oxygen

Tapp

ing

Taph

ole

Ref

illin

g - R

epai

r

Del

ays

TTT

1 ° B

atch

cha

rgin

g

2° B

atch

cha

rgin

g

Tem

pera

ture

&S

ampl

e

Tem

pera

ture

&S

ampl

e

Allo

ying

1 &

Hea

ting

5t ~

%6

Allo

ying

2 &

Hea

ting

4 t ~

%5,

5

Des

lagg

ing

& L

anci

ng

Deo

xida

tion



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19.09.2005Folie 27

Metals Technologies

5. SIEMENS VAI AOD DesignConcepts

Preconditions

Process optimisation in terms of bath temperature, CO partial pressure

Optimized slag performance and process temperature

Process automation

Target

Decarburization with optimised metal oxidation (Cr)

Reduction of metal oxides after decarburization and simultaneous desulfurization

[N] content adjustment

AOD Process - Metallurgical Targets


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19.09.2005Folie 28

Metals Technologies

AOD – Main Features

Different type of the converters available

Single line control concept for tuyere cooling for optimum tuyere performance (VAI Patent)

On line temperature measurement for advanced process control

Quick converter exchange via VAI-CON® Quick

Dynamic process control model


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19.09.2005Folie 29

Metals Technologies

AOD ProcessReferences

O + Inert Gas

O + Inert Gas

Tuyeres (O+ Inert Gas)

Tuyeres(O , Inert Gas, C H)2nm n

Tuyeres(O , Inert Gas, Steam)2

O

AOD(Side blowing)

K-OBM-S(Bottom blowing)

CLU(Bottom or side blowing)

Revamped to AOD

POSCO, Pohang Works (ROK)ACCIAIERIE, Bolzano (I)ACESITA, Timoteo (BR)OUTOKUMPU Stainless, Tornio (FIN)ALZ, Genk (B)BÖHLER EDELSTAHL, Kapfenberg (A)TISCO, Taiyuan (PRC)CARINOX, Carlam (B)TISCO No. 4, Taiyuan (PRC)LISCO Lianzhong (PRC)ZPSS Zhangjigang (PRC)OUTOKUMPU Stainless, Avesta, SwedenSANDVIK, Sandvik, Sweden

ISCOR Pretoria Works (RSA)KAWASAKI Chiba Works (J)TISCO, Taiyuan (PRC)

COLUMBUS Stainless (RSA)


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Metals Technologies

AOD Old DesignOutokumpu Stainless 150 t L= 8400 mm

AOD New DesignCARINOX 180 t L = 8330 mm

New VAI AOD Design


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Metals Technologies

Advantage New VAI AOD Design

The Conventional AOD Design: Bath height > 2 m, Relation of bath diameter tobath height D/H of max. 2

New VAI AOD Design: Bath height < 2 m D/H = 2.2–2.4

The main advantages of the flat bath design are as follows:

Lower ferrostatic pressure on gas bubbles in the bath therefore lower CO partial pressure resulting in faster decarburization speed, higher decarburization efficiency and lower Cr-oxidation.

Lower Si-red consumption therefore higher refractory life in the slag line and lower slag volume

No knapsack in the tuyere area therefore easier bricklaying in the round shape lower cone vessel, longer tuyere bricks possible for longer lining life in the tuyere zone.

Lower vessel height and therefore lower refractory weight per lining


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Metals Technologies

AOD Design

VAI-CON® Simple Suspension System:• VAI-CON® Simple (for heat size < 50 t)• Wedge type suspension

VAI-CON® Quick Suspension System:• VAI-CON® Simple (for heat size > 50 t)• Hinge Double Bolt Type Connection• Three-point suspension• Engineered to compensate thermal expansion

and contraction of vessel and trunnion ring butyet to allow easy nut tightening and un-tighteningfor minimum vessel exchange times


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19.09.2005Folie 33

Metals TechnologiesThe VAI-CON® Joint System:• Automatic connection of all media supply lines• No manual work for medial supply connections• Reduction of converter exchange time• Proven concept for fast, safe and reliable

connection


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19.09.2005Folie 34

Metals Technologies

Fixation rod

Vessel bracket

Spring package

Guidance

Knee lever systemPneumatic cylinder

Fixation rod

Vessel bracket

Spring package

Guidance

Knee lever systemPneumatic cylinder

The VAI-CON® Auto Fix System:• Based on concept of VAI-CON® Quick

Suspension System• No manual work for bolt connections• Fully Automatic System• Fixation of Suspension Elements by knee lever

system activated by Pneumatic Cylinder


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19.09.2005Folie 35

Metals Technologies

Ladle transfer to LF directly w/o OH crane to limit crane cyclesand to make ladle transfer independent from the crane.

One bucket charge concept,to be considered for Scrap Yard Management

- into pit with dumper trucks

- or with sufficient crane capacity to load the bucket on the transfer car.

Ladle Furnace as Twin LF to allow sufficient treatment time and tocope with the fast TtT of the EAF.

6. Layout Aspects


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19.09.2005Folie 36

Metals Technologies

EAF ttt = 35‘

With the two cars, each car has a total available occupation time of 65‘ + 5‘spare time.LF treatment time = 45‘

Treatment starts with finishing tapping.

For normal heats 45‘, layout allows up to 55‘ treatment time for buffer function or longer treatment.

Casting Time time = 30‘ - 35‘

Required Restranding Time to be defined and elaborated on Project Basis

Assumption Sequence 10 – 15 Heats, Restranding 45‘

Process Cycle


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Metals Technologies Parallel Bay Concept


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19.09.2005Folie 38

Metals Technologies ONE BAY Concept

Contact:

Thomas DaumSIEMENS E&A Metals Technologies Division501 Technology DriveCanonsburg, PA 15317 USA

+1 (724) [email protected] you very much for your attention.

Documents

INGOT METALLURGY FORUM Winter Meeting, March 21, 2007 ... · SIEMENS VAI – Equipment Design Solutions for Specialty Steel and High Alloyed Steel Producers: 1. General Aspects of