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Decarburization Efficiency in EAF With Hot Metal ... - Steel Library

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<strong>Decarburization</strong> <strong>Efficiency</strong> <strong>in</strong> <strong>EAF</strong> <strong>With</strong><br />

<strong>Hot</strong> <strong>Metal</strong> Charge<br />

Among the available tools for<br />

liquid steel melt<strong>in</strong>g, the electric<br />

arc furnace (<strong>EAF</strong>) demonstrates<br />

the highest flexibility with respect<br />

to the selection of charge materials.<br />

This particular feature of the<br />

<strong>EAF</strong> allows for the selection of the<br />

charge mix that is least dependent<br />

on the level of the market<br />

price fluctuations. The feasibility<br />

of us<strong>in</strong>g steel scrap, direct reduced<br />

iron (DRI), hot briquetted iron<br />

(HBI) and hot metal <strong>in</strong> a wide<br />

0–100% range has already been<br />

confirmed by a large number of<br />

reference <strong>in</strong>stallations.<br />

The addition of hot metal <strong>in</strong>to<br />

<strong>EAF</strong> charge is popular <strong>in</strong> areas<br />

where shortage of scrap and/or<br />

electric power is observed. Recently,<br />

a new trend has appeared on the<br />

market show<strong>in</strong>g a grow<strong>in</strong>g number<br />

of steel plants us<strong>in</strong>g both BOF and<br />

<strong>EAF</strong> steelmak<strong>in</strong>g routes. The <strong>EAF</strong><br />

can utilize the excess production<br />

of hot metal from blast furnaces.<br />

Besides, <strong>EAF</strong> allows for a boost <strong>in</strong><br />

steel production <strong>in</strong> case the quantity<br />

of hot metal is <strong>in</strong>sufficient to run<br />

the BOF process at full scale, with<br />

a m<strong>in</strong>imum of 80% of hot metal<br />

be<strong>in</strong>g required for a s<strong>in</strong>gle charge.<br />

Much lower <strong>in</strong>vestment requirements<br />

and reduced environmental<br />

impact of <strong>EAF</strong>-based production<br />

Table 1<br />

Design and Process Issues for <strong>EAF</strong> <strong>With</strong> <strong>Hot</strong> <strong>Metal</strong> Charge<br />

are a clear advantage, already be<strong>in</strong>g<br />

an alternative to the traditional<br />

BOF steelmak<strong>in</strong>g route. 1 Last but<br />

not least, the use of hot metal<br />

ensures a low level of residual elements<br />

and allows an <strong>EAF</strong> to be used<br />

<strong>in</strong> the production of steel grades<br />

which traditionally were reserved<br />

for <strong>in</strong>tegrated steelmakers.<br />

The use of hot metal significantly<br />

decreases the demand for electrical<br />

energy; 2 however, an <strong>in</strong>creased carbon<br />

content <strong>in</strong> the charge may result<br />

<strong>in</strong> additional process time required<br />

for oxygen <strong>in</strong>jection. Furthermore,<br />

due to elevated contents of silicon<br />

and phosphorus, lime consumption<br />

is typically double the consumption<br />

<strong>in</strong> a 100% scrap operation.<br />

Recent developments proved that<br />

<strong>EAF</strong> with hot metal charge can<br />

operate with very short tap-to-tap<br />

times, reach<strong>in</strong>g productivity that is<br />

comparable to the BOF process. To<br />

reach this goal, the design and process<br />

management of the <strong>EAF</strong> work<strong>in</strong>g<br />

with hot metal charge require<br />

particular attention. The ma<strong>in</strong><br />

issues are highlighted <strong>in</strong> Table 1.<br />

<strong>Hot</strong> <strong>Metal</strong> Charg<strong>in</strong>g Into the<br />

Furnace<br />

In order to utilize the advantage of<br />

hot metal temperature, its charg<strong>in</strong>g<br />

<strong>in</strong>to the furnace should be done<br />

<strong>Hot</strong> metal charg<strong>in</strong>g Safe, reliable and fully controllable<br />

<strong>EAF</strong> shell volume S<strong>in</strong>gle bucket charge with 65% scrap<br />

Liquid bath surface Increased for higher decarburization rates<br />

Oxygen <strong>in</strong>jection High specific flowrates<br />

Process management Independent control of each <strong>in</strong>jector<br />

Abstract<br />

This paper presents furnace<br />

configuration, hot metal charg<strong>in</strong>g<br />

techniques and oxygen <strong>in</strong>jection<br />

practices. Performance results<br />

related to various charge mixes<br />

are discussed.<br />

Authors<br />

Riccardo Gottardi<br />

manag<strong>in</strong>g director, bus<strong>in</strong>ess unit steelmak<strong>in</strong>g,<br />

SMS Concast AG, Zurich, Switzerland<br />

<strong>in</strong>fo@sms-concast.ch<br />

Stefano Miani<br />

technical director, SMS Concast Italia SpA,<br />

Ud<strong>in</strong>e, Italy<br />

Adam Partyka<br />

senior process metallurgist, SMS Concast Italia SpA,<br />

Ud<strong>in</strong>e, Italy<br />

Maurizio Suber<br />

commission<strong>in</strong>g eng<strong>in</strong>eer, bus<strong>in</strong>ess unit steelmak<strong>in</strong>g,<br />

SMS Concast Italia SpA, Ud<strong>in</strong>e, Italy<br />

<strong>in</strong>fo@concast.it<br />

AIST.org January 2012 ✦ 61


Figure 1<br />

Schematic of ways of feed<strong>in</strong>g hot metal <strong>in</strong>to the furnace.<br />

with a closed roof. Usually steel plant logistics and<br />

layout limitations do not allow the freedom to select<br />

the place where hot metal ladles are delivered to the<br />

meltshop, i.e., on the charg<strong>in</strong>g or tapp<strong>in</strong>g side of the<br />

furnace. The furnace design itself imposes additional<br />

limitations. Position of the transformer, offgas exhaust,<br />

material handl<strong>in</strong>g system, etc., seriously limit the available<br />

space where a hot metal runner can be <strong>in</strong>serted<br />

<strong>in</strong>to the furnace shell. The actual charg<strong>in</strong>g method and<br />

hot metal runner position<strong>in</strong>g are a compromise among<br />

various considerations. 3<br />

The runner <strong>in</strong>serted through the slag door must be<br />

movable (by means of a dedicated hot metal charg<strong>in</strong>g<br />

car). In other positions, the runner can be fixed<br />

on either the furnace shell or on a charg<strong>in</strong>g car or<br />

manipulator.<br />

The most serious disadvantage of charg<strong>in</strong>g through<br />

the slag door is that pour<strong>in</strong>g of hot metal is done<br />

aga<strong>in</strong>st the flow of slag. In some cases, this can result<br />

<strong>in</strong> poor phosphorus removal from the liquid bath. The<br />

runner has to be moved <strong>in</strong>to charg<strong>in</strong>g position before<br />

scrap load<strong>in</strong>g to avoid scrap build<strong>in</strong>g up on the sill level.<br />

Sidewall position of the runner can be very problematic<br />

<strong>in</strong> case of possible hot metal overflow. At that<br />

particular location, it is difficult to collect spilled metal.<br />

Furthermore, hot metal overflow from the runner creates<br />

a risk for all pip<strong>in</strong>g <strong>in</strong>stalled <strong>in</strong> neighbor<strong>in</strong>g areas.<br />

The runner located on the EBT balcony seems to be<br />

the most advantageous. Thanks to limited scrap presence<br />

<strong>in</strong> that area, charg<strong>in</strong>g of hot metal can be started<br />

very early. In case of overflow, spilled hot metal can be<br />

collected <strong>in</strong> the tapp<strong>in</strong>g pit below the furnace.<br />

<strong>Hot</strong> metal charg<strong>in</strong>g operation requires great<br />

care, s<strong>in</strong>ce contact with highly oxidized furnace<br />

slag or cold scrap can result <strong>in</strong> violent<br />

reactions. The same usually happens if large<br />

carbon-concentration gradients develop <strong>in</strong> the<br />

liquid bath dur<strong>in</strong>g the superheat<strong>in</strong>g phase.<br />

Loss of control dur<strong>in</strong>g hot metal charg<strong>in</strong>g will<br />

result <strong>in</strong> overflow of slag and steel from the<br />

furnace; however, <strong>in</strong> extreme cases, damage to<br />

the electrode arms can also be observed dur<strong>in</strong>g<br />

violent eruptions <strong>in</strong> the furnace.<br />

Summariz<strong>in</strong>g the issue of trouble-free charg<strong>in</strong>g<br />

of hot metal <strong>in</strong>to the furnace, the follow<strong>in</strong>g<br />

preferences have been def<strong>in</strong>ed:<br />

• <strong>Hot</strong> metal pour<strong>in</strong>g should be carried<br />

out with power on to avoid productivity<br />

losses.<br />

• Tilt<strong>in</strong>g of the hot metal ladle should not<br />

<strong>in</strong>volve a crane.<br />

• <strong>Hot</strong> metal ladle tilt<strong>in</strong>g control should be<br />

precise enough to ensure stable pour<strong>in</strong>g<br />

rates.<br />

• <strong>Hot</strong> metal runner length should be as<br />

short as possible to avoid freez<strong>in</strong>g of hot<br />

metal.<br />

• The runner should be preheated<br />

between pour<strong>in</strong>g operations.<br />

Customized <strong>EAF</strong> for Operation <strong>With</strong> <strong>Hot</strong> <strong>Metal</strong><br />

In November 2007, Concast commissioned a new furnace<br />

at Zhangjiagang Hongchang Wire Rod Co. (ZHW),<br />

belong<strong>in</strong>g to Shagang Group <strong>in</strong> Jiangsu Prov<strong>in</strong>ce, P.R.<br />

Ch<strong>in</strong>a. This furnace, designed for tap-to-tap times of<br />

less than 35 m<strong>in</strong>utes, is the heart of a new production<br />

l<strong>in</strong>e <strong>in</strong>clud<strong>in</strong>g LF, VD and 6-strand billet caster with an<br />

annual output of 1.1 million tons of SBQ steels for the<br />

expand<strong>in</strong>g automotive <strong>in</strong>dustry <strong>in</strong> Ch<strong>in</strong>a. 4<br />

In 2009–2010, two other furnaces with hot metal<br />

charge were supplied to Tianj<strong>in</strong> Iron & <strong>Steel</strong> Group,<br />

P.R. Ch<strong>in</strong>a, where they are a part of 2.2 million tpy<br />

m<strong>in</strong>i-mill equipped with two ladle furnaces, one tw<strong>in</strong>-<br />

VD station, bloom and billet caster. Another two <strong>EAF</strong>s<br />

for customers <strong>in</strong> Ch<strong>in</strong>a are <strong>in</strong> the eng<strong>in</strong>eer<strong>in</strong>g phase.<br />

The furnaces of Shagang and Tianj<strong>in</strong> are almost<br />

identical; the ma<strong>in</strong> difference between them is related<br />

to the hot metal charg<strong>in</strong>g method. The Shagang <strong>EAF</strong><br />

is fed with hot metal from the EBT balcony, while both<br />

Tianj<strong>in</strong> furnaces have been equipped with charg<strong>in</strong>g<br />

cars with refractory-l<strong>in</strong>ed spouts which are <strong>in</strong>serted<br />

through the slag door.<br />

The ma<strong>in</strong> data of the Shagang and Tianj<strong>in</strong> furnaces<br />

are shown <strong>in</strong> Table 2.<br />

Shagang Group runs several meltshops equipped<br />

both with BOF and <strong>EAF</strong> units and has ga<strong>in</strong>ed solid<br />

experience of us<strong>in</strong>g hot metal <strong>in</strong> the <strong>EAF</strong> process. The<br />

design solutions adopted for that furnace have been<br />

<strong>in</strong>tensively tested <strong>in</strong> practice. This particularly relates to<br />

the hot metal charg<strong>in</strong>g system. Although the <strong>EAF</strong> was<br />

orig<strong>in</strong>ally designed for 30–40% hot metal utilization,<br />

Shagang already tested operation with up to 70% hot<br />

62 ✦ Iron & <strong>Steel</strong> Technology A Publication of the Association for Iron & <strong>Steel</strong> Technology


Table 2<br />

Data for the Shagang and Tianj<strong>in</strong> <strong>EAF</strong>s<br />

<strong>EAF</strong> type AC, full platform<br />

Average tap weight 110 tons<br />

<strong>Hot</strong> heel 15–30 tons<br />

Shell diameter 6,500 mm<br />

Shell volume 130 m 3<br />

Flat bath area 27 m 2<br />

Transformer rate power 80 MVA + 20%<br />

Electrodes 610 mm<br />

Burners 6 x 6 MW (6 x 610 Nm 3 /hour natural gas)<br />

Supersonic oxygen 6 x 2,500 Nm 3 /hour<br />

Carbon <strong>in</strong>jection 3 x 50 kg/m<strong>in</strong>ute<br />

metal without a significant decrease of the designed<br />

productivity.<br />

For Tianj<strong>in</strong>, <strong>EAF</strong> technology is a new challenge.<br />

However, through an extensive exchange with other<br />

Ch<strong>in</strong>ese steelmakers also work<strong>in</strong>g with hot metal, a<br />

background for thorough test<strong>in</strong>g of the delivered <strong>EAF</strong><br />

flexibility and capability has been created there.<br />

Shagang <strong>EAF</strong> Operations<br />

The <strong>EAF</strong> has been equipped with a dedicated system for<br />

hot metal charg<strong>in</strong>g from the tapp<strong>in</strong>g side.<br />

The hot metal ladle is placed on a tilt<strong>in</strong>g stand.<br />

The tilter has its own runner with a buffer conta<strong>in</strong>er,<br />

improv<strong>in</strong>g flow control. Dur<strong>in</strong>g hot metal pour<strong>in</strong>g, the<br />

tilter is rotated by 90° above the EBT balcony, where it<br />

meets another short runner permanently attached to<br />

the furnace shell.<br />

Hydraulic tilt<strong>in</strong>g of the hot metal ladle is fairly precise.<br />

For reference, the whole pour<strong>in</strong>g operation for<br />

an <strong>EAF</strong> charge configuration with 35% (40 tons) hot<br />

metal can be completed with<strong>in</strong> 3–4 m<strong>in</strong>utes, as hot<br />

metal can be charged safely with average rates of 7–10<br />

t/m<strong>in</strong>ute.<br />

A very efficient dephosphorization, thanks to a lime<br />

discharge po<strong>in</strong>t above the hot metal pool and extended<br />

reaction time between hot metal and highly basic slag,<br />

has proved to be an additional benefit of hot metal<br />

pour<strong>in</strong>g from the EBT side.<br />

The furnace shell volume permits the use of a<br />

s<strong>in</strong>gle-bucket scrap charg<strong>in</strong>g practice if the m<strong>in</strong>imum<br />

hot metal share is above 30%. Except for at least 15%<br />

reduction of the power-off time, s<strong>in</strong>gle-bucket charg<strong>in</strong>g<br />

practice allows also for the utilization of heat generated<br />

through hot metal decarburization and post-combustion<br />

of carbon monoxide for a very efficient preheat<strong>in</strong>g<br />

of a scrap column <strong>in</strong>side the shell. 5<br />

The key issue of the furnace is its decarburization<br />

capacity. High carbon content <strong>in</strong> the charge may<br />

require additional time for decarburization. <strong>EAF</strong>s cannot<br />

utilize the oxygen <strong>in</strong>jection rates typical for BOF<br />

practice. Accord<strong>in</strong>g to literature data, a hot metal share<br />

of 40% has been considered as a maximum limit, above<br />

which the <strong>EAF</strong> productivity is reduced due to <strong>in</strong>sufficient<br />

oxygen <strong>in</strong>jection capacity. 6 The exist<strong>in</strong>g oxygen<br />

<strong>in</strong>jection limits are usually related to problems with<br />

extensive splash<strong>in</strong>g phenomena, backfire, electrode<br />

consumption <strong>in</strong>crease and erosion of refractory l<strong>in</strong><strong>in</strong>g,<br />

as well as reduced life of roof panels and refractory<br />

delta centerpiece.<br />

The Shagang <strong>EAF</strong> has been equipped with CONSOtype<br />

comb<strong>in</strong>ed <strong>in</strong>jectors, allow<strong>in</strong>g operation with up<br />

to 15,000 Nm 3 /hour of oxygen flow <strong>in</strong> supersonic<br />

<strong>in</strong>jection mode. The CONSO <strong>in</strong>jectors are proprietary<br />

SMS Concast design, and their effective performances<br />

have been demonstrated on more than 50 <strong>EAF</strong>s. The<br />

CONSO system is also a platform of an <strong>in</strong>tensively<br />

developed chemical energy package called ultrahigh<br />

chemical power (UHCP) <strong>EAF</strong>, for which the power of<br />

<strong>in</strong>stalled burners equals 40% of effectively used electrical<br />

power. 7 Before Shagang, the high decarburization<br />

capacity of the CONSO system was verified <strong>in</strong> practice<br />

on a furnace operat<strong>in</strong>g with up to 35% pig iron <strong>in</strong> the<br />

charge.<br />

In total, six CONSO units have been <strong>in</strong>stalled on the<br />

furnace. Their distribution on the shell perimeter has<br />

been decided, with the aim to reach perfect thermal<br />

equilibration of the furnace volume, elim<strong>in</strong>ation of the<br />

cold spots and enhancement of the metallurgical reactions<br />

by <strong>in</strong>tensive bath stirr<strong>in</strong>g and homogenization.<br />

Each <strong>in</strong>jector can use up to 600 Nm 3 /hour of natural<br />

gas and 1,250 Nm 3 /hour of oxygen <strong>in</strong> burner mode.<br />

The lance, which is supplied from a separate oxygen<br />

l<strong>in</strong>e, can operate with 800–1,300 Nm 3 /hour <strong>in</strong> subsonic<br />

<strong>in</strong>jection mode and 1,700–2,500 Nm 3 /hour of oxygen<br />

<strong>in</strong> supersonic <strong>in</strong>jection mode.<br />

Injectors 3, 5 and 6 are coupled with carbon <strong>in</strong>jection<br />

tuyeres, allow<strong>in</strong>g the precise <strong>in</strong>jection of carbon <strong>in</strong>to<br />

the oxygen jet. Except for slag foam<strong>in</strong>g purposes, early<br />

carbon <strong>in</strong>jection is needed for process safety aspects.<br />

Equilibration of FeO content <strong>in</strong> slag prevents the occurrence<br />

of carbon and oxygen gradients <strong>in</strong>side the liquid<br />

bath volume.<br />

After scrap charg<strong>in</strong>g, all <strong>in</strong>jectors are switched to<br />

a low-power preheat<strong>in</strong>g burner flame with a gradual<br />

<strong>in</strong>crease of the power <strong>in</strong> the burner-cutt<strong>in</strong>g mode.<br />

Pour<strong>in</strong>g of hot metal is usually <strong>in</strong>itiated with<strong>in</strong> the first<br />

m<strong>in</strong>ute of power-on. For a short time, <strong>in</strong>jectors 3, 4 and<br />

5 are used very <strong>in</strong>tensively to melt scrap rema<strong>in</strong><strong>in</strong>g <strong>in</strong><br />

the hot metal discharge area. At the same time, the<br />

AIST.org January 2012 ✦ 63


Figure 2<br />

Pour<strong>in</strong>g of hot metal through the EBT balcony runner.<br />

<strong>in</strong>jectors on both sides of the slag door are still kept <strong>in</strong><br />

lower-power burner mode to preheat bigger scrap quantities<br />

deposited there.<br />

<strong>With</strong> about half of the hot metal be<strong>in</strong>g already<br />

charged, the supersonic oxygen lanc<strong>in</strong>g starts — <strong>in</strong>itially<br />

us<strong>in</strong>g <strong>in</strong>jectors 2, 3, 4 and 5. At that time, <strong>in</strong>jectors<br />

1 and 6 are operated with full burner power, followed<br />

by subsonic oxygen flow for the delivery of oxygen for<br />

post-combustion of large volumes of carbon monoxide<br />

generated dur<strong>in</strong>g the reaction of hot metal.<br />

After completion, silicon oxidation and liquid bath<br />

temperature <strong>in</strong>crease, and all <strong>in</strong>jectors are switched to<br />

supersonic lance operation. About 3 m<strong>in</strong>utes before<br />

tapp<strong>in</strong>g, temperature and oxygen activity <strong>in</strong> the liquid<br />

bath are measured. Depend<strong>in</strong>g on the actual carbon<br />

content, the oxygen flow can then be reduced or<br />

<strong>in</strong>creased to obta<strong>in</strong> the target value at tapp<strong>in</strong>g.<br />

The electrical power <strong>in</strong>put program is fully <strong>in</strong>tegrated<br />

with the operation of the CONSO <strong>in</strong>jectors <strong>in</strong><br />

the profile executed by the <strong>EAF</strong> automation. The same<br />

applies to the carbon <strong>in</strong>jection system. Usually two carbon<br />

<strong>in</strong>jections are <strong>in</strong> operation, while the third one is<br />

kept <strong>in</strong> standby mode. Slag control system (SCAD) is<br />

further used to modify <strong>in</strong>jection carbon flow set po<strong>in</strong>ts<br />

<strong>in</strong> function of the actual coverage of the electric arcs.<br />

Tianj<strong>in</strong> <strong>EAF</strong> Operations<br />

The practice of pour<strong>in</strong>g hot metal through the slag<br />

door is the pr<strong>in</strong>cipal difference between the Shagang<br />

and the Tianj<strong>in</strong> furnaces. Due to layout limitations,<br />

the <strong>EAF</strong> charg<strong>in</strong>g bay was the only available hot metal<br />

delivery po<strong>in</strong>t, so slag door charg<strong>in</strong>g had to be selected<br />

as a compromise.<br />

The hot metal ladle is loaded onto a car equipped<br />

with onboard hydraulic station power<strong>in</strong>g hot metal<br />

ladle tilt<strong>in</strong>g frame movements. <strong>Hot</strong> metal is poured <strong>in</strong>to<br />

a flow-control buffer conta<strong>in</strong>er with a fixed outlet diameter,<br />

which ensures uniform flow of hot metal <strong>in</strong>to the<br />

runner. The runner is l<strong>in</strong>ed with a typical iron throughrammed<br />

refractory material and can be exchanged<br />

completely <strong>in</strong> case of excessive wear.<br />

The hot metal ladle is placed on a charg<strong>in</strong>g car dur<strong>in</strong>g<br />

furnace turnover, so the spout enters the slag door<br />

tunnel before scrap bucket charg<strong>in</strong>g, thus avoid<strong>in</strong>g<br />

problems with a possible scrap presence <strong>in</strong>side. Beh<strong>in</strong>d<br />

the slag door sill, an impact pad is made to avoid <strong>EAF</strong><br />

refractory erosion caused by hot metal flow.<br />

As soon as the <strong>EAF</strong> roof is closed after scrap charg<strong>in</strong>g,<br />

the hot metal can be tilted. The average pour<strong>in</strong>g<br />

rates are 5–8 t/m<strong>in</strong>ute and may be slightly reduced <strong>in</strong><br />

cased of <strong>in</strong>tensive reactions between the hot metal and<br />

highly oxidized slag and low-carbon-conta<strong>in</strong><strong>in</strong>g metal<br />

of the hot heel.<br />

For safety reasons, oxygen lanc<strong>in</strong>g is not used dur<strong>in</strong>g<br />

hot metal charg<strong>in</strong>g. Consequently, the decarburization<br />

of the liquid bath has to be delayed. This is the<br />

most significant disadvantage when compared with the<br />

Shagang furnace and hot metal charg<strong>in</strong>g practice from<br />

the EBT side.<br />

Both Tianj<strong>in</strong> furnaces have also been equipped with<br />

six CONSO <strong>in</strong>jectors of similar size, i.e., 6 MW <strong>in</strong> burner<br />

mode and 2,500 Nm 3 /hour of oxygen <strong>in</strong> supersonic<br />

<strong>in</strong>jection mode.<br />

The location of <strong>in</strong>dividual <strong>in</strong>jectors has been optimized<br />

for the simulated advancement of melt<strong>in</strong>g process.<br />

The <strong>in</strong>jectors located <strong>in</strong> the scrap melt<strong>in</strong>g area are<br />

64 ✦ Iron & <strong>Steel</strong> Technology A Publication of the Association for Iron & <strong>Steel</strong> Technology


more <strong>in</strong>tensively used as full-power burners, while those<br />

close to the hot metal pool are switched to lanc<strong>in</strong>g<br />

mode immediately after charg<strong>in</strong>g car withdrawal <strong>in</strong>to<br />

the park<strong>in</strong>g position. Injector No. 6 helps to melt scrap<br />

accumulated above the hot metal spout, after which it<br />

delivers oxygen for CO post-combustion.<br />

Execution of the melt<strong>in</strong>g program is fully automatic.<br />

Several programs are available for different percentages<br />

of hot metal <strong>in</strong> the charge.<br />

Figure 4<br />

Figure 3<br />

CONSO <strong>in</strong>jectors layout and melt<strong>in</strong>g zone distribution.<br />

<strong>Hot</strong> metal charg<strong>in</strong>g with slag door spout.<br />

More or less <strong>in</strong> the middle of the superheat<strong>in</strong>g phase,<br />

the first steel sampl<strong>in</strong>g and temperature measurement<br />

are done. Depend<strong>in</strong>g on the result, the rema<strong>in</strong><strong>in</strong>g programmed<br />

oxygen volume is updated to ensure targets<br />

at tapp<strong>in</strong>g. Such practice is very similar to <strong>in</strong>-blow sampl<strong>in</strong>g<br />

<strong>in</strong> the BOF process. In case of excess steel bath<br />

temperature, additional lime is charged through the<br />

fifth hole to cool down the bath, prevent<strong>in</strong>g phosphorus<br />

reversion from slag.<br />

AIST.org January 2012 ✦ 65


Comparison of the performance results of the<br />

Shagang and Tianj<strong>in</strong> furnaces clearly <strong>in</strong>dicates that the<br />

hot metal charg<strong>in</strong>g method has rather significant <strong>in</strong>fluence.<br />

Slag door charg<strong>in</strong>g is a less favorable solution,<br />

mostly due to the uneven mix<strong>in</strong>g pattern of the liquid<br />

bath <strong>in</strong> the furnace, reduced reaction area and lower<br />

efficiency of the available chemical energy utilization.<br />

For the same share of hot metal <strong>in</strong> the charge, the<br />

specific energy consumption is about 20 kWh/ton<br />

higher, with a 2-m<strong>in</strong>ute power-on time <strong>in</strong>crease and<br />

consequent loss of productivity.<br />

Figure 6<br />

Figure 5<br />

CONSO <strong>in</strong>jectors layout and melt<strong>in</strong>g zone distribution (Tianj<strong>in</strong> <strong>EAF</strong> No. 2).<br />

CONSO <strong>in</strong>jector profiles dur<strong>in</strong>g melt<strong>in</strong>g (a) and superheat<strong>in</strong>g (b) phases (40% hot metal).<br />

Evaluation of <strong>Decarburization</strong> <strong>Efficiency</strong><br />

The furnaces presented <strong>in</strong> this paper were orig<strong>in</strong>ally<br />

designed for a reference charge configuration with a<br />

maximum 40% hot metal.<br />

The average decarburization rates of 0.12% C/m<strong>in</strong>ute<br />

were calculated to be achieved with average specific<br />

oxygen <strong>in</strong>jection rates of 300 Nm 3 /hour/m 2 of liquid<br />

bath surface, correspond<strong>in</strong>g to four CONSO lances<br />

operated at 2,000 Nm 3 /hour each.<br />

Consider<strong>in</strong>g that with 40% hot metal, the carbon<br />

content <strong>in</strong> the liquid bath is about 2% (1.7% C from hot<br />

metal and 0.3% C from scrap), the required cont<strong>in</strong>uous<br />

(a) (b)<br />

66 ✦ Iron & <strong>Steel</strong> Technology A Publication of the Association for Iron & <strong>Steel</strong> Technology


Figure 7<br />

In-blow sample carbon content (250 heats from commission<strong>in</strong>g<br />

phase)<br />

oxygen lanc<strong>in</strong>g time with the earlier def<strong>in</strong>ed decarburization<br />

rate should be about 16 m<strong>in</strong>utes. S<strong>in</strong>ce<br />

the calculated average power-on time was 25 m<strong>in</strong>utes,<br />

about 7 m<strong>in</strong>utes were reserved for burner operation<br />

and oxygen <strong>in</strong>jection at subsonic flowrates. Accord<strong>in</strong>g<br />

to melt<strong>in</strong>g process simulations, all heats could be<br />

completed without extra power-off time for additional<br />

decarburization.<br />

<strong>Decarburization</strong> rates achieved <strong>in</strong> practice proved<br />

to be better than the earlier assumed values. Figure 6<br />

shows the results of the <strong>in</strong>-blow carbon sampl<strong>in</strong>g from<br />

the early days of the Shagang <strong>EAF</strong> operation. In some<br />

cases, the results <strong>in</strong>dicate slightly higher carbon values,<br />

which can be expla<strong>in</strong>ed by <strong>in</strong>consistency <strong>in</strong> the carbon<br />

and silicon contents <strong>in</strong> hot metal, which deviated the <strong>in</strong>/<br />

out oxygen balance. Nevertheless, thanks to a correctly<br />

def<strong>in</strong>ed moment of sampl<strong>in</strong>g, sufficient time was always<br />

reserved for eventual oxygen blow pattern update with<br />

oxygen flowrate <strong>in</strong>crease, if required. However, <strong>in</strong> most<br />

of the cases, the f<strong>in</strong>al phase of superheat<strong>in</strong>g was done<br />

with a reduced oxygen <strong>in</strong>jection rate to avoid too-low<br />

carbon at tapp<strong>in</strong>g.<br />

The CONSO <strong>in</strong>jection system operation fully confirmed<br />

expectations regard<strong>in</strong>g high decarburization<br />

efficiency. It was also concluded that the capacity of the<br />

system can be further <strong>in</strong>creased us<strong>in</strong>g higher supersonic<br />

oxygen flowrates.<br />

Fac<strong>in</strong>g shortage and <strong>in</strong>consistency of scrap supplies,<br />

the <strong>EAF</strong> users were forced to <strong>in</strong>crease the share of hot<br />

metal <strong>in</strong> the charge — <strong>in</strong>itially to 50% and later even<br />

to 70%. New melt<strong>in</strong>g programs with higher specific<br />

oxygen flowrates were established for such occasions.<br />

Precise evaluation of the actual decarburization rates<br />

is an extremely difficult task for several reasons. Among<br />

them, the experienced variations <strong>in</strong> hot metal parameters,<br />

i.e., carbon, silicon and manganese contents, as<br />

well as its temperature at the moment of pour<strong>in</strong>g <strong>in</strong>to<br />

the <strong>EAF</strong>, play a key role. Diversified hot metal deliveries<br />

from different blast furnaces additionally <strong>in</strong>creased the<br />

deviation range of the start<strong>in</strong>g conditions.<br />

In view of that, the follow<strong>in</strong>g evaluation procedure<br />

was adopted:<br />

• Start<strong>in</strong>g carbon content was calculated based on<br />

the composition of furnace charge components.<br />

Figure 8<br />

<strong>Decarburization</strong> results.<br />

• Start of decarburization time was identified as the<br />

moment when <strong>in</strong>tense flames were seen (spontaneous<br />

carbon “ignition”).<br />

• <strong>Decarburization</strong> time was counted until the time<br />

of the first sampl<strong>in</strong>g, when end carbon value was<br />

analyzed.<br />

• Actual decarburization rates were calculated from<br />

carbon content difference and recorded time.<br />

Figure 8 shows the results from about 1,300 heats<br />

produced with variable hot metal share <strong>in</strong> the charge.<br />

Available results demonstrate the fact that — except<br />

for earlier identified factors — the actual decarburization<br />

rates also depend on the <strong>in</strong>itial carbon content <strong>in</strong><br />

the liquid bath. Some analogies to the decarburization<br />

reaction <strong>in</strong> VOD or AOD processes can be noted at this<br />

po<strong>in</strong>t.<br />

Interdependence between carbon content and decarburization<br />

<strong>in</strong>tensity is a precious observation which<br />

can be used for sett<strong>in</strong>g up the process conditions for a<br />

high share of hot metal <strong>in</strong> the furnace charge. It can<br />

be assumed that the decarburization rate can be very<br />

high, provid<strong>in</strong>g that sufficient oxygen <strong>in</strong>jection density<br />

is ensured.<br />

For higher carbon contents <strong>in</strong> the charge, the deviation<br />

of the actual decarburization rates is limited. This<br />

can be expla<strong>in</strong>ed easily by the fact that available oxygen<br />

Figure 9<br />

<strong>Decarburization</strong> rates by sample-to-sample method.<br />

AIST.org January 2012 ✦ 67


<strong>in</strong>jectors had to be always operated at maximum available<br />

capacity. In case of lower charge carbon contents<br />

(20–40% hot metal), the deviations are more significant.<br />

It is believed that the deviations were caused by<br />

<strong>in</strong>consistent process conditions, among them manual<br />

control of power and chemical energy <strong>in</strong>put, as well<br />

as <strong>in</strong>correct identification of decarburization reaction<br />

launch.<br />

The decarburization reaction efficiency was also evaluated<br />

us<strong>in</strong>g an alternative method, based on sampleto-sample<br />

carbon content difference and elapsed time<br />

between the samples. This method could not be used<br />

for higher carbon contents.<br />

The first sample used to be taken when more or less<br />

flat bath conditions were identified, i.e., when the progress<br />

of decarburization reaction reached 60% or more<br />

for charges with 35–40% hot metal. The second sample<br />

was usually taken close to the superheat<strong>in</strong>g end.<br />

Although the accuracy of carbon content evaluation<br />

<strong>in</strong> the first sample can be questionable, the obta<strong>in</strong>ed<br />

results (Figure 9) are very <strong>in</strong>terest<strong>in</strong>g. Similarly, as <strong>in</strong><br />

the previous case, the relation between carbon content<br />

<strong>in</strong> the liquid bath and the actual decarburization rate<br />

is rather clear. Moreover, the trendl<strong>in</strong>e for all available<br />

results is almost identical to the one <strong>in</strong>dicated <strong>in</strong><br />

Figure 8.<br />

The decarburization rates estimated by the second<br />

method are higher than <strong>in</strong> the first case. This can<br />

probably be expla<strong>in</strong>ed by too-high carbon content<br />

analyzed <strong>in</strong> the <strong>in</strong>itial samples, which were not fully<br />

representative of the whole volume of the liquid bath<br />

<strong>in</strong> the furnace.<br />

Performance Data<br />

All three furnaces presented <strong>in</strong> this paper are almost<br />

identical from the design po<strong>in</strong>t of view. The difference<br />

between adopted hot metal charg<strong>in</strong>g practice has<br />

been considered less significant for such performance<br />

<strong>in</strong>dexes as specific energy consumption, lance oxygen<br />

consumption and productivity. Therefore, the available<br />

performance data have been evaluated jo<strong>in</strong>tly.<br />

Figure 11<br />

Specific lance oxygen consumption.<br />

Figure 10<br />

Specific energy consumption results (to liquid steel).<br />

The specific electrical energy consumption results<br />

are shown <strong>in</strong> Figure 10.<br />

For the most frequent charge configuration of<br />

30–40% hot metal, the energy consumption is 220–180<br />

kWh/ton, respectively. <strong>With</strong> 70% hot metal, it is practically<br />

“zero consumption.” For this charge configuration,<br />

practically observed, very limited energy was consumed<br />

<strong>in</strong> the <strong>in</strong>itial part of the heat or before tapp<strong>in</strong>g for the<br />

f<strong>in</strong>e adjustment of required tap temperature.<br />

The lance oxygen consumption results are shown <strong>in</strong><br />

Figure 11. The deviations observed on the graph are<br />

related to the fact that oxygen consumed for silicon<br />

oxidation could not be filtered out <strong>in</strong> a predictable way.<br />

Also, the earlier mentioned <strong>in</strong>consistency <strong>in</strong> <strong>in</strong>jection<br />

system operation with manual control is significant.<br />

Increase of the hot metal share <strong>in</strong> the furnace charge<br />

to 70% dramatically <strong>in</strong>creases the oxygen consumption.<br />

The required oxygen volume <strong>in</strong> lance mode is about<br />

6,000 Nm 3 per heat. <strong>With</strong> six CONSO units operat<strong>in</strong>g<br />

at 2,500 Nm 3 /hour, lance oxygen <strong>in</strong>jection can be<br />

completed <strong>in</strong> less than 25 m<strong>in</strong>utes, with the average<br />

decarburization rates of 0.12–0.14% C/m<strong>in</strong>ute, which<br />

corresponds to the values practically observed dur<strong>in</strong>g<br />

normal operation.<br />

Figure 12<br />

<strong>EAF</strong> productivity results.<br />

68 ✦ Iron & <strong>Steel</strong> Technology A Publication of the Association for Iron & <strong>Steel</strong> Technology


Evaluation of the <strong>EAF</strong> productivity leads to <strong>in</strong>terest<strong>in</strong>g<br />

conclusions as well. The graph <strong>in</strong> Figure 12 was plotted<br />

comb<strong>in</strong><strong>in</strong>g tap-to-tap time results (with unexpected<br />

delays filtered out for higher regularity) and tapped<br />

steel weights.<br />

The designed productivity of discussed furnaces was<br />

close to 200 t/hour for reference charges with 35% hot<br />

metal. Increase of hot metal share to 45% gives an additional<br />

productivity boost to the level of 210–215 t/hour.<br />

The most important observation is related to the fact<br />

that, even with a 55% share of hot metal <strong>in</strong> the charge,<br />

the orig<strong>in</strong>al <strong>EAF</strong> design productivity can still be ma<strong>in</strong>ta<strong>in</strong>ed.<br />

This conclusion is a breakthrough <strong>in</strong> view of the<br />

traditional op<strong>in</strong>ions say<strong>in</strong>g that the <strong>in</strong>crease of the hot<br />

metal percentage <strong>in</strong> the <strong>EAF</strong> charge above 40% results<br />

<strong>in</strong> losses of the furnace productivity.<br />

Conclusions<br />

The operational results achieved by the Shagang and<br />

Tianj<strong>in</strong> furnaces clearly demonstrate that the <strong>EAF</strong> is an<br />

<strong>in</strong>terest<strong>in</strong>g alternative or supplement to BOF steelmak<strong>in</strong>g<br />

shops. Short melt<strong>in</strong>g cycle and extremely high productivity<br />

can be guaranteed even with a high hot metal<br />

share <strong>in</strong> the charge above the traditional limits.<br />

Customized furnace design, an appropriate method<br />

for hot metal charg<strong>in</strong>g, and reliable and efficient oxygen<br />

<strong>in</strong>jection technology, allow<strong>in</strong>g for achievable high<br />

decarburization rates, form the base of success.<br />

Liquid steel production with hot metal allows for a<br />

wide range of steels with low levels of residual elements.<br />

In common with effective secondary ref<strong>in</strong><strong>in</strong>g and cast<strong>in</strong>g<br />

technologies, the new m<strong>in</strong>i-mills have confirmed<br />

Shagang and Tianj<strong>in</strong>’s expectations concern<strong>in</strong>g high<br />

process efficiency and high productivity comb<strong>in</strong>ed with<br />

outstand<strong>in</strong>g quality of end products.<br />

Nom<strong>in</strong>ate this paper<br />

Summary<br />

For many years, hot metal share <strong>in</strong> the <strong>EAF</strong> charge was<br />

limited to ensure maximum furnace output. Increase<br />

of hot metal quantity above 40% usually required additional<br />

process time to conclude decarburization of steel.<br />

Recently, <strong>in</strong> P.R. Ch<strong>in</strong>a, SMS Concast has commissioned<br />

furnaces work<strong>in</strong>g with mixed scrap and hot<br />

metal charges. The customers’ demands to <strong>in</strong>crease<br />

hot metal share to 70% and above <strong>in</strong>tensified studies<br />

on possible improvements of decarburization efficiency.<br />

References<br />

1. L. Iperti, “Do Russian <strong>Steel</strong> Producers Really Have a Competitive<br />

Advantage?” La <strong>Metal</strong>lurgia Italiana, Vol. 97, October 2005, p. 58.<br />

2. S. Köhle, “Recent Improvements <strong>in</strong> Model<strong>in</strong>g Energy<br />

Consumption of Electric Arc Furnace,” 7th European Electric<br />

<strong>Steel</strong>mak<strong>in</strong>g Conference Proceed<strong>in</strong>gs, Venice, 2002, p. 1.305.<br />

3. R. Gottardi, S. Miani and A. Partyka, “The <strong>Hot</strong> <strong>Metal</strong> Meets<br />

the Electric Arc Furnace <strong>Steel</strong>mak<strong>in</strong>g Route,” 9th European Electric<br />

<strong>Steel</strong>mak<strong>in</strong>g Conference Proceed<strong>in</strong>gs, Cracow, 2008.<br />

4. J. Liu, G. Bünemann, P. Rivetti and A. Partyka, “S<strong>in</strong>gle Bucket<br />

<strong>EAF</strong> <strong>With</strong> <strong>Hot</strong> <strong>Metal</strong> Charge,” 3rd International <strong>Steel</strong> Conference<br />

on New Developments <strong>in</strong> <strong>Metal</strong>lurgical Process Technologies<br />

Proceed<strong>in</strong>gs, METEC 2007, Düsseldorf, p. 402.<br />

5. S. Laurenti, R. Gottardi, S. Miani and A. Partyka, “High<br />

Performance S<strong>in</strong>gle-Bucket Charg<strong>in</strong>g <strong>EAF</strong> Practice,” Ironmak<strong>in</strong>g &<br />

<strong>Steel</strong>mak<strong>in</strong>g, Vol. 32, No. 3, 2005, p. 195.<br />

6. X. Xiaohong, R. Xiaojiang, Z. Guowei, D. X<strong>in</strong>g, M. Grant and C.<br />

Tao, “High-<strong>Efficiency</strong> Production Practice of a 100 t DC EBT <strong>EAF</strong> at<br />

X<strong>in</strong>g Cheng <strong>Steel</strong> Works,” AISTech 2006 Conference Proceed<strong>in</strong>gs,<br />

Vol. 2, pp. 413–422.<br />

7. R. Gottardi, S. Miani, H. Novak and A. Partyka, “Ultrahigh<br />

Chemical Power <strong>EAF</strong>,” AISTech 2006 Conference Proceed<strong>in</strong>gs,<br />

Vol. 2, p. 246. ✦<br />

Did you f<strong>in</strong>d this article to be of significant relevance to the advancement of steel technology? If so, please consider nom<strong>in</strong>at<strong>in</strong>g it for the<br />

AIST Hunt-Kelly Outstand<strong>in</strong>g Paper Award at AIST.org/huntkelly.<br />

This paper was presented at AISTech 2011 — The Iron & <strong>Steel</strong> Technology Conference and Exposition, Indianapolis, Ind., and published <strong>in</strong> the Conference Proceed<strong>in</strong>gs.<br />

AIST.org January 2012 ✦ 69

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