SIMETAL EAF QUANTUM - SEAISIseaisi.org/file/S5 P1 EAF Quantum_SEAISI_FORUM_2018.pdf · 2018-11-30 · The transfer car is acting as tapping car as well as shell transfer car. In order

Restricted © Primetals Technologies 2018 All rights reserved. primetals.com

EAF QUANTUM

Innovative and cost advanced Electric Steelmaking

for the Construction Sector

SEAISI FORUM

26th / 27th November 2018 Ho Chi Minh City

Restricted © Primetals Technologies 2018 All rights reserved.

Why EAF Quantum?

Major Cost Drivers at Electric Steelmaking

is Energy beside the raw material

In Vietnam as in other countries,

Electrical Energy costs are

tremendously increasing….

EAF Quantum will be the proper

answer in terms of running cost

reduction, flexibility in production,

safety and enviroment.

Page 2

8%

9%

8%7% 8%

SGA

37%Energy

Electrodes

RefractoryConsumables

12%Maintenance

10%Personnel

Others

Steel Plant

Significant OPEX Advantage for QEAF

against Induction and Conveyor Furnace

290 kWh / t

0,9 kg / t

1,8 – 2,2 kg / t


Why EAF QUANTUM?

More than 130 EAF yearly energy consumption figures shows an

average of 425 kWh/t

NatSteel

Page 3

ONLY

Quantum & Shaft Preheating


Industry Benchmark of EAF and EAF Quantum

Page

4

Energy Consumption in kWh/t Tap-to-Tap Time in min

Pon-Time in minPoff-Time in min

Source: PRIMETALS Technologies Data Base

EAF Quantum

EAF Quantum

EAF Quantum


EAF Electrode consumption varies from 0,8 to 4 kg/t

Page

5

Best Practice

Quantum


China’s Total Scrap Supply

2015 – 2030 development

340

285

225

180

25,0%

2030 FC2025 FC2020 FC2015 act.

26,7%

19,3%

Scrap act.

Scrap FC

Growth of annual scrap rate in China domestic market

Source:

McKinsey Metals and Mining / March 2017 / Page 12

Page 6


EAF forecast for the Chinese market

EAF Production in mio. tpy

485057657066566358

44

87

30

223

14 15 20 25

156

6 7 8 9 10 11 12 13

• Industry is driven towards higher percentage of steel

making through EAF route. This is politically

motivated to target pollution and implement

“Greener” solutions for steel production. Electric

steelmaking is expected to increase from 6% in

2015 to 33% in 2030 of the Chinese yearly steel

production.

• Availability of quality scrap is growing steadily as

China is entering a phase where more and more of

the earlier consumable products are ending their life

cycle.

• China has pledged to eliminate another 30 million

mt/year of crude steel capacity in 2018 in a bid to

achieve its capacity elimination target of 150 million

mt/year for 2016-2020. A big portion of long-idled or

inefficient steel capacity was phased out during

2016-2017.

Source: WSA, McKinsey

Source: Steel Price Report; S&P

Page 7


1

2

34

5 6

7

Scrap loading automation

• Information to crane driver about execution of

scrap loading to scrap bucket.

• Control of scrap cars by crane driver

• Continued position information of scrap cars

• Automated transfer of scrap bucket to elevator

unloading position.

• Automated unloading to elevator bucket

• Standard IWLAN with PROFINET for

communication

• Safety functions controlled with safety PLC

• Automated transfer of scrap to

furnace according status of heat

• Automated unloading procedure

• Scrap weight

monitored during

loading of bucket and

transmitted to crane

drivers and QEAF

control

Scrap handling

and logistics

Scrap loading

Scrap charging

Off gas treatment

Power supply

Scrap preheating

1

2

3

4

5

6

EAF steelmaking7

Page 8


New Electric Steelmaking – Technological Highlights

3

2

1

Fully

automated

scrap yard

Optimized

shaft design

for preheating

over 600°

Elevator

system

Automatic

tap hole sand

filling system

FAST Siphon

Tapping System

for slag-free

tapping

Off-gas

Treatment

for Clean

Steelmaking

Combined car

for shell

and tapping

for fast shell

exchange

Lowest flicker

due to flat bath

operation

Automatic and

high efficiency

Oxygen Top

Lance System

Patented

Long Life

Finger

System

Page 9


EAF Quantum based on proven technology

Elevator System Shaft System FAST Tapping

• All Blast Furnaces

run with an elevator

system

Off-Gas Treatment

• Improved design

based on 30 Shaft

furnaces

• Best EAF

performances at

NatSteel world wide

• Over 20 years FAST

experience at

Buderus Edelstahl

• Tilting system run at

Shearness Steel

• Long experience at

Stahl Gerlafingen

and Nervacero

• Current revamps at

Diler, Turkey and

Suez Steel, Egypt

Page 10


New Shaft & Finger Concept: Optimized Shaft design and

retaining system lead to best preheating conditions

Features:

• Holding scrap during preheating

• Trapezoidal shaft shape design

• Modular cooling panel structure

• Improved tightness

• Water cooled finger system

• Grab-type finger arrangement – fully retractable

out of the shaft

• New scrap impact absorber technology (finger

damping system)

Advantages:

• Optimized scrap distribution and scrap fall

• Improved off gas-routing for improved heat

transfer and increased preheating efficiency

• Avoiding scrap sticking and blocking inside shaft

• No movements of shaft structure and furnace roof

• Maintenance friendly

Page 11


Shell Design / FAST reduces Power-off time

Features:

• FAST - Furnace Advanced Slag-

free Tapping

• Integrated siphon system

• Pure flat bath operation

Advantages:

• Target of charging, tapping and tap

hole refilling under power on /

under arcing

• Reduced power off time

• Lowest flicker and net disturbances

Page 12


Movement Concept enables fast shell exchange

The transfer car is acting as tapping car as well as shell transfer car. In order to pick up the shell from

the frame, the car has to be placed into the exchange position, underneath the shell. The shell will be

lowered by means of the cylinder and guide system. When sitting on the car, the shell is free and can

be moved outside the furnace area for refractory maintenance or shell exchange.

Page 13


Movement Concept enables fast shell exchange

Page 14


Process steps at EAF Quantum with automation

Process step Mode of operation Comment

Scrap loading in bucket manual Crane driver on scrap yard

Scrap loading into skip on elevator automatic Moveable hopper

Charging of skip into shaft automatic According to operating diagram

Charging from finger into bath automatic According to operating diagram

Oxygen/carbon injection automatic Top lances controlled by slag monitoring

Tapping semi automatic Proposed by system done by operator

Tap hole filling automatic Automatic sand filling device

Off-gas system and post combustion automatic Controlled by continuous off-gas and temperature

measurement

Sample and temperature taking automatic By manipulator through a roof opening

Slag door cleaning manual With forklift

Page 15


In average 8 dB(A)

less sound pressure

level at Quantum

furnace due to flat

bath operation.

Average noise level is

94 dB(A) 5 m from

slag door from

Quantum EAF.

Average 94 dB(A)

Average 102 dB(A)

Performance Parameters: Noise Emission

Page 16


Principles of dioxin and furan emission reduction at EAF

in three steps

Post combustion

• Post combustion of volatile organics, CO andDioxin and Furan with natural gas burners.

• Dilution air injection for reaction

Quenching

• Quick cooling through quenche cooling.

• Injection of water into quenching chamber

Temperaturecontrol

• Temperature at filter below 100 °C

• Dioxin and furan adsorbed to EAF dust

Page 17


Schematic arrangement off-gas system

850 °C to burn

PCDD and VOC

Short water

cooled duct to keep

high temperature

Quick cooling

Option:

Activated carbon

injection for PCDD

adsorption

Low temperature

through mixing

with sec. fumes

Page 18


Why Quantum?

Serving future demand of OPEX savings vs. high productivity

QEAF 80

low power

QEAF 80

high power

Tapping weight 80 t 80 t

Hot Heel 60 t 60 t

Transformer Power 40 MVA 60 MVA

Electrode Diameter 0,61 m (24“) 0,61m (24“)

Oxygen Injection

(Consumption)

Top Lances

2 x 1.300 m³/h

(40 Nm³/t)

Top Lances

2 x 2.000 m³/h

(31 Nm³/t)

Charge Mix 100% Scrap 100% Scrap

Tap-to-Tap Time 60 min 40 min

Power On Time 56 min 36 min

Power Off Time 4 min 4 min

Productivity 80 t/h 120 t/h

Maximum Yearly

Production

576.000 t/y

@7.200 hours

864.000 t/y

@7.200 hours

Electrical Energy

Consumption

250 kWh/t 290 kWh/t

Electrode

consumption

1,1 kg/t 0,9 kg/t

Page 19

GPH

solution


References of Quantum & Shaft EAF in operation

(most representatives)

EAF-Quantum

Tyasa,

Mexico

EAF-Shaft

Natsteel,

Singapore

EAF–Shaft

Gerlafingen,

Switzerland

EAF-Quantum

GPH,

Bangladesh

Charge Mix Scrap, DRI Scrap Scrap Scrap, DRI, HBI

Transformer 80 MVA + 20 % 57 MVA 75 MVA + 20 % 60 MVA +20 %

Tapping weight 100 t 80 t 80 t 80 t

Oxygen total 35 Nm3/t 43 Nm3/t 30 Nm3/t 39 Nm3/t

Gas 4 Nm3/t 5,0 Nm3/t 7,5 Nm3/t 2,3 Nm3/t

TTT 45 min 43 min 46 min 41 min

Electrical energy 310 kWh/t 270 kWh/t 320 kWh/t 300 kWh/t

Productivity 133 t/h 112 t/h 105 t/h 117 t/h

Production 1.000.000 t/yr 750.000 t/yr 720.000 t/yr 840.000 t/yr

Year of installation 2014 2013 (M) 2007 (M) 2018

Page 20


GPH Mini Mill

Highlights of the Project (Start-up Jan. 2019)

USP

1. Minimum OPEX cost from

Scrap to Finished Products

2. Compact layout design for

minimal footprint

3. Fast Payback Time

Quantum290 kWh/t

WinlinkUp to 5.85m/min

High Capacity

Mill

Up to 30m/s

MINIMILLLATEST

TECHONLOGIES

IN ONE PLACE

Page 21


Asian References of EAF Quantum

China:

• Pinggang

• Henan Yaxin #1

• Henan Yaxin #2

• Guangxi Guixin

• Anhui Hongtai

• Wuhan Shunle #1

• Wuhan Shunle #2

• Guangdong

• Chengdu Changfeng

Bangladesh:

• GPH


EAF Quantum – Short Video

Page 23


Benefits of QEAF - Summary

Conversion Cost Productivity Automation

290 KWh/t TTT < 40 min Scrap Yard

0,9 kg/t Electrodes Lowest Poff < 4min Charging Process

Yield Improvement Full raw material flexibility High Efficiency Top lancing

Refractory 1,8 – 2,2 kg/t Reduced Flicker Tap Hole Sand Filling

Dust Emissions <12kg/t FAST Siphon Tapping Combined Shell Ladle Car

Low noise emissions High Availability Temperature & Sampling

Page 24


The information (including, e.g., figures and

numbers) provided in this document contains

merely general descriptions or characteristics of

performance based on estimates and assumptions

which have not been verified.

It is no representation, does not constitute and/or

evidence a contract or an offer to enter into a

contract to any extent and is not binding upon the

parties. Any obligation to provide and/or

demonstrate respective characteristics shall only

exist if expressly agreed in the terms of the contract.

These estimates and assumptions have to be

analyzed on a case-to-case basis and might change

as a result of further product development.

Primetals Technologies excludes any liability

whatsoever under or in connection with any

provided information, estimates and assumptions.

The provided information, estimates and

assumptions shall be without prejudice to any

possible future offer and/or contract.

Any use of information provided by Primetals

Technologies to the recipient shall be subject to

applicable confidentiality obligations and for the own

convenience of and of the sole risk of the recipient.

Contact

Joerg Schwoerer

Head of Sales Electric Steelmaking

Primetals Technologies Germany GmbH

Reithallenstraße 1

77731 Willstaett-Legelshurst

E [email protected]

primetals.com

Page 25

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SIMETAL EAF QUANTUM - SEAISIseaisi.org/file/S5 P1 EAF Quantum_SEAISI_FORUM_2018.pdf · 2018-11-30 · The transfer car is acting as tapping car as well as shell transfer car. In order