2016 Joachim D Souza.ppt

“We see the Future”
3rd India International DRI Summit, Aug 2016
Paper presentation at
3rd India International DRI Summit 2016
New Delhi, India
August 19, 2016
Joachim D Souza, Acting CEO & GM
SULB Steel Company, Bahrain
Innovative Use of High Percentage Quality DRI in EAF
&
it’s Benefit in Cost Reduction

Steel Production and Per Capita Consumption
* India is the 3rd highest steel producer in the world
• The 12th 5 year plan projected 91.46 MTPA in 2015-2016
• Per capita consumption in India is 60kg which is one fourth of
international average.
3rd India International DRI Summit, Aug 2016 2

Mini – Mill concept based on DRI (Direct Reduced Iron)
• First commercial plant built by Willy Korf at Hamburg Stahlwerke /
Germany in early seventies which was based on:
 Process selected:
• Midrex Direct Reduction shaft furnace for iron ore reduction
• Continuous Feeding of highly metallized DRI into UHP-Electric Arc Furnace
• Continuous billet caster
• Wire/rod rolling mill
 Other important features:
• Located close to sea for receiving iron ore directly by ship and shipping finished
products or supplying into local market
• Availability of natural gas at competitive price
• Scrap supply either by ship or from closeby local market
• Close to power grid for supply of EAF
• Close to market for finished products
This was a major step to have fully integrated steelmaking based on a combination of Direct Reduction
and scrap in various ratios depending on market prices of scrap/cost of producing DRI and melting in
UHP-Electric Furnaces that revolutionized the world in the seventies.
3

Mini – Mill concept based on DRI (Direct Reduced Iron)
• In parallel, enormous developments in UHP-Electric Arc Furnaces
starting in USA (Schwabe).
 Further developed in Japan (water cooled side walls and foaming slag).
 Perfected in Germany in the early eighties.
 That pushed the share of Electric Furnace Steelmaking to close to 40% on
world wide basis. Compare this to conventional Integrated Steelworks based
on Coke ovens, Blast Furnaces and BOF-converters.
 This new route allowed creation of new integrated steelmaking capacity based
on:
• Much lower capital costs
• Shorter erection and commissioning time
• Less environmental issues
• Smaller incremental steps to start a new plant and to expand later
• Much less space required
• Closer to the market
However, this integrated steelmaking route based on DRI can only be justified in regions where cheap
natural gas reserves are available. (Mexico, Venezuela, Middle East, Russia)
4

World DRI Production by Region
million
tons
Source :www.midrex.com
5
India is the largest producer of DRI in the world (17.68MT)

Present status of DR processes
• India produce 17.68 Million tons of DRI and Iran 14.55 Million tons
• Large quantity of DRI made in India is by rotary kilns using Coal
• But compared to 2010 the coal based production down by 20% due
to coal availability & Environmental cost.

Comparison between scrap and DRI properties
Scrap:
• Large variation in quality, depending on source and processing (e.g.
shredder, mill returns, baling scrap)
• Scrap selection and processing is required for more demanding steel
grades (e.g. wire drawing, high carbon)
• Quality is mainly measured with regard to
– Residual content (Cu, Ni, Cr, Mo…)
– Density
– Cleanliness
• Quality will influence all main conversion costs, yield and productivity on
scrap based EAF-operation
• Scrap contains carbon and metallics that are oxidized during steelmaking,
thereby contributing to additional chemical heating with oxygen
DRI:
• Consistent quality depending on ore feed mix into DRI plant
• Virtually free of residuals (Cu, Ni, Mo)
• Very low in sulfur
• Ore supply determines amount and composition of gangue, S and P
7

Advantages of DRI
• Can be continuously fed via roof into EAF
• High carbon supplies additional energy when reacting with oxygen
(exothermic reaction)
• Nitrogen and hydrogen low because of continuous CO – boil
• Quality depends mainly on iron ore selected (Total Fe-content, gangue
content and composition including P, S) and operation of DRI-plant
(Metallization and carbon content)
• Better foaming slag and more stable and higher power input during
continuous feeding.
• Low residual, high quality steel can be produced
• The development HOT DRI charge has revolutionized DRI melting in EAF
8

Disadvantages of using DRI
• If quality of ore is low in particular Fetotal, and if gangue contents high and
mainly acidic, melting costs will increase substantially and yield drop
because of high slag volumes
• There are no metallics that can be oxidized during melting. (e.g., Si, Al,
Mn) to supply additional chemical heat with oxygen, only carbon is
available for oxidation to CO
• Acid gangue components must be slagged with large additions of
lime/dololime to achieve required basicity.
• There is always remaining FeO in DRI which must either be reduced with
carbon (endothermic reaction) or it is lost in slag (reduction in yield).
• High percentage DRI usage up to 100% can only be economically justified
when using highest quality DRI.
• High grade iron ore resources are limited and come with higher price
9

DRI Processes
A. Natural gas and coal are the two primary fuels used in DRI production.
Whereas more than 90% of the global DRI plants use (lower grade) natural
gas, production in India is primarily coal based.
B. DRI processes can be divided up by the type of reactor employed, namely:
• Shaft furnaces (Midrex®, HyL)
• Rotary kilns (SL/RN process)
• Rotary hearth furnaces (Fastmet®/Fastmelt®, and ITmk3®)
• Fluidized bed reactors (Circored® (IPPC, 2009)
• In DRI production, India deserves special attention not only because the
country is the larges producer of DRI, but also because production is
primarily coal based. In India DRI plants can be easily erected with the help
of local suppliers, and the investment in a 100 t/d capacity DRI plant can be
recovered in 12 to 18 months. There is a large number of DRI producers in
India, and their numbers are continuously increasing.
10

Coal vs gas based direct reduction
How does it influence the conversion costs in EAFs
11
Coal vs gas based direct reduction

Rotary kiln process – Main features
Developed by Lurgi, Stelco and Krupp in the 1970s
Maximum production: 180 000 tons/year
Reduction kiln with peripheral air tubes for combustion of coal and
reduction of ore
Ore and 50 % of coal introduced on feeding side, 50 % of coal blown in
from exit side
Mostly lump ore used (8 – 16 mm)
Reduction temperature 1050 °C in the bed, gas 1150 °C
Courtesy of JRP
Courtesy of Outotec

Shaft furnace process – Main features
• Commercialised by Midrex & Korf (Hamburger Stahlwerke)
• Hyl (Mexico) initially worked with 3 stage retort process, later single
shaft
• Reformer for converting natural gas to CO/H2 reduction gas
required (with Ni-catalyst at Midrex plant)
• Oxygen enrichment to increase reduction temperature and gas
heating with recuperators from 850 to over 1000 °C
• Mostly iron ore pellets and some lump ore to avoid sticking
• Carbon enrichment in cooling zone (up to 3 %!)
Hot briquetting (HBI)
Hot charging into adjacent EAF
Upscaling from 400 000 t/a to over 2 500 000 t/a
13

Shaft furnace process

HYTEMP system for hot charging
15

Iron Ore Quality
FeTotal
Only ore with FeTotal > 66 % shall be used
Gangue content and composition, basicity
High basicity
High MgO content
Low Al2O3 content
Sulfur and phosphorus content
Sulfur: Generally very low. May increas in rotary kilns depending on
the used coal
Phosphorus: High contents may cause problems to end products with
low P limitations
16

Iron Ore Properties
Type Lump Ore Iron Ore Pellets
Supplier Kumba LKAB Vale GIIC SAMARC
O
South-
Africa
Sweden Brazil Bahrain Brazil
Fetot 66.2 67.9 68.0 67.6 68.0
Gangue
SiO2 3.18 0.85 1.43 1.60 1.35
CaO 0.12 0.86 0.60 0.33 0.74
Al2O3 1.21 0.25 0.55 0.47 0.40
MgO 0.11 0.72 0.38 0.55 0.20
Basicity
CaO/SiO2 0.04 1.01 0.42 0.21 0.55
P 0.055 0.026 0.021 0.030 0.043
S 0.014 0.002 0.0015 0.002 0.002 17

DRI Properties
Degree of metallisation
 High degree of metallisation decreases costs in EAF
Gangue content, composition and basicity
 The less gangue and the more basic, the better
Carbon content
 Coal based process: No carbon present in DRI
 Gas based process: Deposited as Fe3C in cooling zone
Hot charging
 Only possible with gas based DRI (one of the main advantages)
Hot briquetting (HBI)
 Easy to handle, transport and ship
 Only possible with gas based DRI
 In most cases charging to EAF via scrap buckets
18

Comparison of operating results
EAF A EAF B EAF C
Coal based Gas based Gas based
1 bucket charge 1 bucket charge 100 % DRI
Production details
Heats per day [1] 20 27 29
Daily production [tons/day] 1460 2260 2416
Average tap weight [tons] 74.6 83.7 83.3
DRI ratio [%] 51.2 84.1 99.4
100 % DRI heat [1] 0 6 28
EAF yield [%] 85.0 91.5 91.5
Time balance
Power on [min] 50.7 42.8 39.6
Turnaround [min] 7 10.4 8.5
Delays [min] 13.2 2.8 2.9
Tap-to-tap time [min] 70.9 56 51
Time utilization [%] 71.5 76.4 77.6
Plant utilization [%] 95.4 95.1 97.1
Consumption figures
Energy [kWh/t] 671 548 500
Oxygen [Nm³/t] 23.7 14.0 32.5
Tap C [%] 0.05 0.12 0.12
Tap O2 [ppm] 650 348 341
Foaming carbon [kg/t] 5.5 5.0 15.0
Electrodes [kg/t] 2.10 1.45 1.35 19

Comparison of operating results
EAF A EAF B EAF C
Coal based Gas based Gas based
1 bucket charge 1 bucket charge 100 % DRI
DRI Quality
Iron ore blending ratio [%] Sishen = 100 LKAB = 50 LKAB = 35
[%] GIIC = 20 GIIC = 30
[%] Others = bal. Others = bal.
Metallization [%] 91.5 95.8 96.3
Carbon [%] 0.1 1.9 2.7
Total gangue [%] 6.5 3.8 3.8
Basicity of DRI gangue [1] 0.05 0.77 0.64
Slag analysis and control
Average FeO [%] 28.0 24.9 21.0
Average MgO [%] 13.0 15.8 18.5
Slag basicity [1] 1.8 2.0 1.8
Consumption figures
Energy [kWh/t] 671 548 500
Oxygen [Nm³/t] 23.7 14.0 32.5
Tap C [%] 0.05 0.12 0.12
Tap O2 [ppm] 650 348 341
Foaming carbon [kg/t] 5.5 5.0 15.0
Electrodes [kg/t] 2.10 1.45 1.3520

Compared to coal based DRI the following has been observed:
Higher and consistent metallisation
Beneficial for energy consumption
Lower total gangue with less SiO2 and higher basic
components
High basicity is beneficial for energy consumption
Continuous carbon boil results in lower nitrogen and
hydrogen levels
High carbon content in DRI is beneficial for chemical heating
(up to 35 Nm³/t O2)
Operating experience with gas based DRI
from Midrex plant
21

DRI – Quality parameters
1. Gangue in iron ore feed material
 This is the largest factor and depends solely on the quality of the iron ore (cannot be influenced in
DRI-plant)
• Fe total of iron ore – the higher the better
• Total gangue and composition of gangue
 There is a large difference between acid/basic/neutral gangue which will influence steelmaking to
a large degree.
 Since EAF-steelmaking requires a basic slag of 1.6 – 1.8 (CaO/SiO2) for phosphorus removal and
12~14% MgO for protection of refractories, substantial flux additions are required with lower
quality ore.
 Higher acid gangue ore will reduce Fe-yield and increase melting time and energy/electrode
consumptions because of additions of nearly twice the volume of lime/dololime, which needs to
be melted and is lost.
2. Degree of Metallization
 Second most important parameter – the higher the better.
 Qatar Steel aims to produce highly metallized DRI for use in steelplant because of downstream
benefits regarding yield, energy, electrode and refractory consumption (95.5 – 96.5%)
3. Carbon in DRI
 Third most important factor – between 2.5-3.0% depending on oxygen usage
 Carbon is in form of iron carbide (Fe3C) which is exothermic when combined with oxygen,
supplying additional chemical energy
 Some carbon is used up to reduce remaining FeO in DRI, remaining carbon available for oxygen
blowing.
 Contributes to continuous CO – boil, good foaming of slag and low nitrogen/hydrogen in steel.
There are three main quality aspects that have largest influence on steelmaking
productivity/conversion costs.
22

Effect of DRI Metallization on Melting Power
(QS BOP 2004)
+ 1% Metallization will result in + 15 kWh/ton of melting power. This will change to +20 Kwh/t when the
Metallization goes below 94%

Effect of DRI Metallization on Electrode
Consumption
+ 1% Metallization will result in + 0.07Kg/ton to 0.12Kg/t of electrode consumption. The consumption goes
higher when the Metallization goes below 94%

Effect of DRI Metallization on Power on Time
+ 1% Metallization will result in + 2~3 minutes per heat power on time.

Effect of DRI Acid Gangue on Melting Power
+ 0.5% Acid gangue in DRI result in approximately + 20 Kwh/t melting power in EF

Effect of DRI Acid Gangue on Electrode
Consumption
+ 0.5% Acid gangue in DRI result in + 0.09 kg/t Electrode consumption in EF
27

Effect of DRI Acid Gangue on Power On Time
+ 0.5% Acid gangue in DRI result in approximately + 2~4 minutes of Power On time
28

Advantages of 100% DRI- Heats with Liquid Heel
• No opening of roof for charging a bucket (reduce heat losses)
• Faster Turnaround after tapping to start next heat
• Much smoother melting when starting on higher liquid heel
 With liquid heel start-up, stable arc is established within short time – Higher Cos Phi
• Improved Foaming of slag right from start – Higher O2
 This allows to increase power level faster – Less Power On time
• Reduced Refractory consumption
 Refractories are protected all the time by foamy slag and will last longer with more
even wear.
• No electrode breakages due to scrap cave-in or too slow electrode
regulation.
• Much less stresses on mechanical equipment with less wear and tear
because electrodes hardly move up and down
• Less electrical flicker disturbances on supply line
• No damage to water cooled panels in side walls/roof due to arcing,
backflash etc.
• Much easier power program, only variable is DRI quality and liquid heel.
29

Advantages of 100% DRI- Heats with Liquid Heel
• Lower electric energy consumption
 Because roof is not opened in between heats, and turn-around time after tapping is
much shorter
 Arc is better protected in foamy slag which increases effective power input and
reduces radiation losses.
 Higher Time Utilization and less power-off times/ delays
 Higher productivity (t/h)
• Lower electrode consumption
 Less side oxidation because electrodes are two thirds under roof within a CO-rich
reducing atmosphere
 Electrodes are less exposed to mechanical stresses with up and down movements,
 Arc length can be increased during continuous feeding of DRI because of excellent
foaming.
• Better prediction and more constant Tap to Tap times which makes
planning of downstream LF and CCM easier.
• Increase in Roof delta life
 Less radiation from open arcs during initial melting of scrap and better foamy slag
• Lower average Nitrogen levels
 Because there is continuous carbon boil from beginning and foamy slag protection,
no open arc melting.
30

Care to be Taken with 100% DRI & Heel
• Liquid heel must be larger, can be as much as 40% of tapping weight, but
the distance between burner and steel level is to be taken care of.
• Selection of Oxy Jets - Must be effective in early stages because of larger
distance to lower bath level( For Supersonic & Coherent flow effect)
• DRI feeding to be controlled carefully not to over heat or cool down liquid
heel especially start up after tapping.
• As the wall life increases the Hot Heel can be increased by another 5 tons
• Furnace to be tilted 3O Tap side till 50% of DRI feed to retain slag(less flux)
• Temp through wall by Laser is helpful tool to have closed door operation.
• When the liquid heel is increased by lowering the hearth thickness, the
bottom shell temperature to be monitored for a few refractory campaigns
31

Carbon in DRI, Hot Heel & Foamy Slag
• For Cold DRI melting EAF, the Content as high as 3% is favorable. But for
Hot DRI 2.5% is optimum, since there is limit for the decarburization rate
for safe DRI melting operation.
• Decarburization rate is measured as CO generation in steel bath which is
12CO Nm3/min/m2 max. This results in Carbon reduction of 300kg/h/m2
• The max carbon in DRI to be calculated, considering the time required for
decarburization in particular designed EAF and the “power on” time.
Decarburization time must not be larger than the ‘Power On” time.
• Liquid hot heel can be around 40% of Tapping weight which will enable
faster arc stabilization, faster Foamy slag generation and quick start of
Oxygen/Carbon injection resulting in shorter Power On times.
• Good foamy slag will help in submerging the arc in the bath, reduce
refractory erosion, increase Cos phi, facilitates higher power input,
thereby reduces the Tap to Tap time
• Slag sample once a shift will have better control over the slag chemistry

33
Why of Foamy Slag
Important Note: When energy is not transferred to the steel, it is either goes to furnace
wall refractory and panels or to the offgas

Slags in EAF
Steelmaking

Benefits of Slag on furnace operation
Shorter tap to tap times
 Better heat transfer to the load & less losses to the w/c panels,
protection of the refractory
 Higher average power input
Lower electrode consumption
 Lower currents
 Shorter tap to tap times
Cleaner steel
 Removal of Nitrogen & Hydrogen due to gas bubbling (CO)
 Pick up / absorption of Oxides in the slag
 Removal of inclusions
 Phosphor & Sulphur removal

Efficiency = 35% Steel 0% Slag
Efficiency = 90% 100% Slag
Efficiency = 60% 50% Slag
Efficiency of electric energy transfer with foaming slag

The Gas:
Depending on the (literature) source, the oxidation of Iron in the bath & the
subsequent reduction of the Iron-Oxide in the slag by Carbon according to
O2 + 2 Fe = 2 (FeO) and (FeO) + C = Fe + COgaseous
is considered the main contributing factor for foaming or the direct Oxidation of
Carbon in the bath is also taken into account :

Effective Viscosity ( e)
Fully Liquid "Creamy" to "fluffy" "Fluffy" to "Crusty"
Liquidus
Boundary
 
Optimum
Slag
Over-
Saturated:
Too much
second phase
particles
Foaming
Index
()
[G]
Slag foamability (continued):
This means that these "optimum" slags are not completely liquid
("watery") but are saturated with respect to CaO (Ca2SiO4)
and/or MgO (Magnesia -wustite solid solution). These second
phase particles serve as gas nucleation sites, which lead to a
high amount of favourable small gas bubbles in the foaming
slag.
The term effective
viscosity was defined
to relate the amount of
second phase particles
in the slag and
viscosity as follows:
e =  (1 –1.35 )-5/2
e - effective viscosity of the slag  -
viscosity of the molten slag  -
fraction of precipitated solid phases

&
FeO

Remember: Take care of your slag
&
the steel will take care of itself...
40

QSC - DR Modules
Direct Reduction Plant – Qatar Steel
SULB DR Module
Cold DRI
41

Qatar Steel EAF #4 Commissioned in 2007
Design Details
Furnace Type 80 EBT -Danieli
Nominal steel capacity 80 t
Holding capacity 100 t (Increased to 115 tons)
Shell diameter 6.1 M
Transformer rating 78 MVA
Primary voltage 33 kV
Tap to tap time 45 mins per charge (Design 56’)
Charge mix 10% scrap+90% DRI or 100% DRI
Hot heel Design 20t, increased to 35t
Electrode dia 600 mm
Power on time 37 min
Oxygen 34Nm3/t
Injection carbon 18kg/t
42

EF4 Designed 3 Layer Bottom Bricks for 20 t Hot heel
43

Modified 2 Layer bottom Bricks for 35 ton Hot heel
(Bottom shell temp monitored initially)
44

Arc Stability: SBR & Liquid Heel
45

Effect of Hot Heel on EAF Parameters
(Qatar Steel EF4:Tap weight 80 tons)
Items 20t Hot heel 35t Hot heel
( 500 heats) (500 heats)
Power On time(min) 39 37
Power Off time(min) 9 8
Melting Power Kwh/t 495 485
O2 consumption(Nm3
/t) 32 34
Electrode Kg/t 1.3 1.07
Gunning Kg/t 2.1 1.64
Fettling Kg/t 0.76 0.61
Bottom material Kg/t 0.34 0.305
Roof Kg/t 0.2 0.24
Wall Kg/t 0.58 0.46
Average Lime
Consumption is
15Kg/t and
Dololime 25 kg/t
46

Hot Heel Performance in Plant “A” in KSA
(Tap weight 140 tons & 150 MVA Trafo)
Items
Power On time(min) 57 48 40% scrap(2 B)
Power Off time(min) 25 19 various reasons
Melting Power Kwh/t 630 540 High quantity Fluxes
O2 consumption(Nm3
/t) 10 25 3 x 2200Nm3
/hr
Carbon injection Kg/t 5 18 3 x 22Kg/min
Lump Coke Kg/t 0 12
Tapping Carbon % 0.04 0.12
FeO in Slag % 35~45 25~30
50t Hot heel
(Feb 2014)
Bottom stamping
height reduced by
55mm
30t Hot heel
(Jan 2014)
47

Furnace #5 Commissioned in Feb 2014
EAF Design Details
Nominal steel capacity 110 t –SVAI EOBT
Holding capacity 150 t
Transformer rating 125 MVA
Shell diameter 6600/6500mm
Tap to tap time 44 mins per charge with cold DRI
Charge mix 80% DRI(50%) or 100% DRI(50%)
Hot heel 40t, increased to 45 tons
Electrode dia 600 mm
Power on time 36 min
Oxygen 37Nm3/t
Productivity (tons per hour) 150 tons per hour with cold DRI
Annual Production 1,200,000 t/y (Cold DRI)
48

DRI Performance in Middle Eastern Plants
Item QS Cold DRI Hot DRI
(Benchmark)
Sulb Future
Target
DRI Metzn 95.5% >95% >95%
Acid gangue 2.7% 2.9% <3.0%
Carbon 2.8% 2.1% 2.5%
DRI Ratio 80 or 100% 100% 100%
DRI Temp oC 30 ~ 45 600 600
Power On (min/ ch) 37 (64.5MW) 34.0(103.3MW) 31.6 (95MW)
Power Off(min/ ch) 8 10.5 8.0
Tap to Tap(min/ ch) 45 44.5 39.6
Melting Kwh/t 485 385 385
Tap weight(t) 82 152 130
Oxygen Nm3/t 34 34.8 32
Carbon Kg/t 18 13 10~15
Electrode Kg/t 1.07 0.8 <1.0
Transformer 78 MVA 130 MVA 120 MVA (?)

Future for 100% DRI Operation
• Optimization of Process – Consistency & Reproducibility
• Material recovery – Yield with Improved aux equipment design – Oxygen
injectors, Burners, Flux injectors, foamy slag injectors, temp/oxy probes
• Closed door operation to retain slag & minimize fluxes, minimize air
ingress into furnace & door cleaning equipment without loosing time.
• Further reduction of turnaround time – power on during tap and EBT
maintenance with power on. Gunning robots will reduce repair times
• Furnace bottom shell designed for high hot heel to reduce tap to tap time
• Technology for hot heel measurement & Off gas measurement online
• MIDREX has to develop high C% DRI which will reduce cost in Meltshop
• Good Operator training tools
50

INDIAN STEEL INDUSTRY-Challenges
• DRI is the preferred raw material for special steels
• By 2020 the projected steel production is 180 million tons, 2nd to China
• 60% BF-BOF, 33% DRI-EF/IF & 7% other routes.
• Iron ore & Coal together make up 72% of Input material
• The increase in cost of input materials is a great challenge
• There is shortage of good quality Iron ore & shortage of non coking coal
• Inadequate supply of natural gas
• Poor infrastructure & transport facilities
51

• It is favorable to adopt DRI-BF-EAF route, Rotary hearth Furnaces &
vertical shaft furnaces to produce DRI in India
• Gas based DR Plant in India is uneconomical with the present prices
• Extensive use of hot metal will reduce expensive Electricity consumption
• New technologies provide alternatives for NG & Metallurgical Coke.
• DR Plants – Midrex & HYL (Energiron), Corex, Finex, Hismelt,
Fastmelt/Fastmet & ITmk3 are a few examples favorable for India as they
can utilize lower quality input materials.
• Use of COG as reducing gas in DR Plants is an alternative like JSW &
JSPL
• Alternative fuels like Syn-gas, CBM, Shale gas, Corex export gas & coke
oven gas are good options & cost effective
52

• Shale gas scenario, total CBM reserve & UCG are future hope for gas
based DRI Plants. Use of indigenous high ash, low rank non coking coal
for syn gas is a cost effective measure.
• Beneficiation and agglomeration of input materials is the need of the
hour
• Use of 40 to 50% hot metal will reduce power consumption below
380Kwh/tls
• Coke consumption to be reached below 300 kg/t of hot metal. Recent
innovations adopted in coke making at Tata Steel has reduced cost,
increased productivity and environment friendly.
• Adoption of latest technologies in all aspects of
production facilities will cut down cost considerably.
• Tata Steel, JSPL Angul, JSW Ispat and ESSAR
are good example to follow

CONCLUSION - i
• Lurgi Gasification technology with Midrex
Direct Reduction Process is a viable solution in
India due to:
• Uses well-proven Lurgi Gasification and
Rectisol® technologies.
• The Lurgi Gasifier can readily use the low rank,
high ash domestic Indian coals as feed
material.
• Uses well-proven Midrex direct reduction
process. This technology can readily use
domestic Indian iron oxides as feed material.
54

CONCLUSION - ii
• Produces DRI with quality comparable to
natural gas-based Midrex plants
• The DRI can be hot charged into a nearby EAF
to significantly reduce electricity requirement
and significantly increase EAF productivity.
• The Lurgi Gasification plant + Midrex plant
combination can be paired with an EAF- based
minimill to produce high quality long or flat
steel products.
• No coke, coke ovens, or sinter plant required.
55

CONCLUSION - iii
• Lower specific capital cost than BF –
BOF Plants
• Lower air emissions than integrated
plants
• Ability to capture high purity CO2
• Much larger capacity than Rotary
kilns(~2.5MT)
• Higher quality DRI product than
rotary kilns
56

New Technologies
to
Improve Productivity and Cost
in
DRI-EAF
57

Gunning Robot in Operation
58

Overview of the Gunning Robot

Laser Measurement of Furnace Wall
60

Scanning Wall Contour
Metallization %
61

Item Before Robot After Robot Remarks
Wall Ref Life 275 heats in 2004 1215 heats in 2014 March 2014
Wall Ref Kg/t 0.96 kg/tls 0.28 kg/t
Cost of Ref
(Gunning, fettling &
Bottom)
*US$ 3.64/t US$ 2.17/t *RHI Contract
EF turnaround 14 mins/heat 8 mins/heat
Results
62

Other Benefits
1. The exact thickness of bricks in EF is available
2. Turnaround time is less due to high discharge rate and
precise area of repair, thanks to laser scanner
3. Wall brick erosion is maintained uniform
4. The hot heel can be estimated and compared to eye
estimation
5. EAF Safety as the sudden breakout of metal is eliminated
6. Relaxed operation for the Operator.
63

On line Temp - principle
Burner
Flame
Supersonic Oxygen /
Inert Gas Stream
Water Cooled
RCB
Oxygen /
Inert Gas
Optical
Sensor
Gas / Oxy
Online Temperature through the Wall
The system can be used as burner, O2 injector and
temperature measurement
64

Good reasons for Adoption-1
 Reliable and accurate measurement
- Same precise temperature measurement → Due to continuous temperature measurement
than with standard cartridges.
- No pieces in movement → The sensory devices have a longer service life
- The Temp lance is completely → Accessible, easy-to-maintain
sheltered in the water cooled and protected measurement place
modular injection panel
→ No scrap damages are possible
during scrap basket charging
- Reduction of wrong → Fast and precise measurement
temperature measurements

Good reasons for Adoption-2
 Increased productivity
 The system is sampling under power
 The right time for tapping can be determined more precisely
 Faster temperature measurements results are achieved
 Very short time in between two consecutive measurements are
possible
 Safety improvements
 Elimination of hard physical and dangerous works
 Measurements may be performed during arcing
- with closed slag door
- avoiding the dangerous flaming out through slag door
due to scrap collapsing, heavy chemical reactions
 No additional space consuming device in front of the EAF is
requested

Good Reasons for Adoption-3
 Profitable investment
 Extreme short ROI
 Low installation costs
 Short implementation time
 Installation during regular maintenance shutdown
 Cost reduction
 Elimination of temperature cartridge cost
 Reduction of personnel cost & Manipulator Maintenance cost
 Energy saving thanks to closed door operation
 Averaged reduced tapping temperature
 Shorter Tap to Tap time and higher productivity

68
Tires Charging in DRI Melting EAF
1.Environmental Considerations of
disposal problem of used tires in
Qatar
2.To use scrap tires as a source of
chemical energy & charge carbon
3.Recovery of carbon, energy and
the steel in tires.
OBJECTIVE

69
Tires from Qatar Municipality

70
Weight content of used tires
Carbon black 21.5%
Elastomeric compound 47.0%
Steel
16.5%
Textile 5.5%
Zn Oxide 1%
Sulfur 1%
Others 10%

72
Mean values in Dust & Fumes (Dust & Stack)
Parameter Without tire With tire Consent to op
Dust mg/Nm3 0.82 1.60 40
O2 % 19.6 19.9
CO2 g/Nm3 15 18
CO mg/Nm3 189 356
TOC mg/Nm3 0.68 0.72
Cd ug/Nm3 0.99 0.27 0.5 mg/Nm3
Cr ug/Nm3 0.76 0.70 1.5mg/Nm3
Cu ug/Nm3 0.83 2.02 Cr+Cu+V
Pb ug/Nm3 6.19 3 5mg/Nm3
Zn ug/Nm3 11.7 359

73
Mean values in Dust & Fumes (Dust & Stack)
Hg ug/Nm3 0.49 2
PAH ng/Nm3 74 6097 0.04mg/Nm3
Dioxins pg/Nm3 15 18 100.0

74
Mean values at Furnace working Floor
Dust mg/Nm3 2.2 3.30 10
Pb ug/Nm3 2.9 3.2 50
Zn mg/Nm3 0.018 0.045 5.0
Cd mg/Nm3 0.002 0,001 0.05
Cr mg/Nm3 0.002 0.001 0.50
Cu mg/Nm3 0.005 0.003 1.00
PAH mg/Nm3 0.003 0.007 0.04
PAH analysis by NILU, Norway.
Gravimetric analysis by Molab as, Norway

75
Method of charge in Basket
LIME / DOLOLIME
DRI
TIRES
DRI
SCRAP

April 2010
1
“We
Recycled
Everything
of Value in a
Tire but the
HOLE”
14,000 Tons tires Charged

April 2010
THANK YOU
Special thanks to:
1. Yousef Q Al Emadi, Qatar Steel
2. Bernd Strohmeier of Strohmeier Consulting
3. Jeremy T. Jones & Ms. Sarah Anderson (USA)
4. Said Alameddine of Graftec & now at Sangraf
5. Amit Chatterjee, Deependra & Chinmoy from India

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