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    Simetal Eaf Fast Dri en

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    Agustine Setiawan
    This document discusses a new technology from Siemens called SIMETAL EAF FAST DRI, which enables continuous direct reduced iron (DRI) melting in electric arc furnaces (EAFs) for steel production. The new technology allows for feeding, tapping, and refilling during power-on operation, increasing productivity and efficiency while reducing costs.

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    Simetal Eaf Fast Dri en

    Uploaded by

    Agustine Setiawan
    244 views6 pages
    This document discusses a new technology from Siemens called SIMETAL EAF FAST DRI, which enables continuous direct reduced iron (DRI) melting in electric arc furnaces (EAFs) for steel production. The new technology allows for feeding, tapping, and refilling during power-on operation, increasing productivity and efficiency while reducing costs.

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    steelmaking

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    Simetal Eaf Fast Dri En

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    This document discusses a new technology from Siemens called SIMETAL EAF FAST DRI, which enables continuous direct reduced iron (DRI) melting in electric arc furnaces (EAFs) for steel production. The new technology allows for feeding, tapping, and refilling during power-on operation, increasing productivity and efficiency while reducing costs.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    244 views6 pages

    Simetal Eaf Fast Dri en

    Uploaded by

    Agustine Setiawan
    This document discusses a new technology from Siemens called SIMETAL EAF FAST DRI, which enables continuous direct reduced iron (DRI) melting in electric arc furnaces (EAFs) for steel production. The new technology allows for feeding, tapping, and refilling during power-on operation, increasing productivity and efficiency while reducing costs.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 6
    At a glance
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    The key takeaways are that steel demand is growing globally, especially in developing countries, and DRI is a viable method for local steel production using abundant natural gas resources. Regions like the Middle East are well suited for DRI-based steelmaking.

    The steel industry currently faces growing global demand for steel, a need for more sustainable production methods, and weak power grids in some regions requiring advanced flicker compensation technology.

    DRI is direct reduced iron, a process that uses natural gas to reduce iron ore into a compact form suitable for melting in an electric arc furnace. DRI has advantages over scrap in regions with plentiful gas resources as it allows for local steel production using local iron ore reserves. It produces fewer emissions than traditional blast furnace production as well.

    siemens-vai.

    com

    SIMETAL EAF FAST DRI


    The future of DRI melting

    Answers for Industry.

    Local solutions for global demands

    80
    70.37 Mt

    70

    60

    50

    40

    30

    20

    10

    0
    1970 1980
    HDR

    HBI

    1990

    2000

    2010

    CDRI

    Asia
    Middle East
    North America
    South America
    Africa
    C.I.S.

    31.11 Mt
    20.95 Mt
    9.45 Mt
    6.92 Mt
    5.57 Mt
    5.54 Mt

    79.54 Mt

    Increasing world DRI production

    Middle East and Asia and especially India are the leading DRI producers

    Your challenge
    The world needs steel. Particularly in newly industrialized
    countries, the demand for structural steel is growing at
    a tremendous rate and these countries want to replace
    costly steel imports with local steel production.

    Todays market requirements:


    Growing demand for steel

    Regions that have easy access to gas are predestined for


    steel production using DRI, in either cold or hot conditions. The Middle East region is perfectly suited for DRI
    production, because abundant gas resources along with
    comparably low gas prices are the cornerstone of successful DRI-based EAF steelmaking. Other regions around the
    world also have a growing DRI-based EAF steel production:
    DRI can also be produced in a coal-based process.

    High gas resources in regions like the Middle East


    resulting in easy DRI-based steelmaking
    Weak power grids requiring the highest flicker
    compensation to ensure best power quality
    The need for sustainable steel production
    Use of local iron-ore resources
    To decrease conversion costs and receive an
    attractive ROI, the challenges are:
    Easy DRI access
    Reduced operational expenditures
    High productivity and efficiency
    Totally integrated automation
    Better steel quality

    26
    31
    11

    37

    In trillion m:
    117

    64

    Cumulative
    production

    3
    15

    5
    35

    3
    8

    Reserves

    7
    16

    75

    16

    Resources

    25

    Reserves:
    191.9 trillion m (=247.9 Gt SKE)
    Production:
    3.0 trillion m (=3.9 Gt SKE)

    World gas resources

    Boost your profits with FAST as


    a new solution or modernization

    FAST in working position

    FAST in tilting position

    FAST in new installation


    The SIMETAL EAF FAST DRI enables DRI melting in a large
    hot heel, which results in a pure flatbath operation. The
    process is characterized by continuous DRI feeding, efficient and process-related oxygen and coal injection, foaming slag control by means of roof lances, and eliminates
    the need for the installation of additional burner power.

    FAST for your existing EAF


    Increase the efficiency and productivity of your existing EAF.

    In combination with the furnace advanced slag-free tapping system (FAST) with a siphon design for slag-free tapping, the new furnace concept permits feeding, tapping,
    and taphole refilling during power-on continuous DRI.
    In addition, the continuous input of electrical energy not
    only improves productivity, it is also important for the
    energy infrastructure with respect to flicker problems in
    the regions power grids. The nearly constant heat load
    extends refractory durability and minimizes equipment
    wear through reduced thermal stress.

    Due to an EAF modernization which is replacing the existing lower shell, you can get the opportunity of the furnace
    advanced slag-free tapping system (FAST).
    It is not necessary to replace components like the roof,
    electrode-supporting arms, and dedusting system. With a
    new lower shell and FAST, the furnace can achieve higher
    productivity levels with a similar input of energy. Another
    option is to reduce energy input and still obtain similar
    productivity and improved efficiency.
    If you modernize your existing EAF with Siemens VAIs new
    technology, not only will your productivity and efficiency
    grow, your overall capital and operating expenditures will
    be reduced accordingly.

    All of the advanced technologies just described for


    Siemens VAIs new SIMETAL EAF FAST DRI will result in
    lower capital and operational expenditures for your plant.

    Competence in DRI melting

    ELECTRICAL POWER INPUT


    DRI Feeding (kg/min.MW)

    OXYGEN INPUT
    Nm/h

    MW
    100

    5,000

    1 heat

    80

    4,000

    60

    3,000

    40

    2,000

    20

    1,000

    0
    -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60
    TIME (min)
    Elec. Energy

    DRI

    O Lance

    Feeding, tapping, and taphole refilling under power-on conditions

    Leading position in DRI-EAF technology

    1
    5 6

    2
    3
    4

    10
    8 9

    = EAF DRI
    = EAF

    12

    11

    Rocky Mountain Steel, Pueblo, U.S.

    Altos Hornos de Mexico S.A. (AHMSA), Monclova, Mexico

    Saudi Iron & Steel Company EAF 2, Al Jubail, Saudi Arabia

    HYLSA, Monterrey, Mexico

    Saudi Iron & Steel Company EAF 3, Al Jubail, Saudi Arabia

    HYLSA, Puebla, Mexico

    Saudi Iron & Steel Company EAF 4, Al Jubail, Saudi Arabia

    Egyptian Sponge Iron & Steel Company ESISCO, Sadat City, Egypt

    Suez Steel, Suez, Egypt

    Scaw Metals, Johannesburg, South Africa

    National Steel Company Ltd./NASCO, Dammam, Saudi Arabia

    Qatar Steel, Mesaieed, Qatar

    10

    Saudi Iron & Steel Company EAF 1, Al Jubail, Saudi Arabia

    Saudi Iron & Steel Company EAF 5, Al Jubail, Saudi Arabia


    11

    Krakatau EAF 5, Cilegon, Indonesia


    Krakatau EAF 6, Cilegon, Indonesia
    Krakatau EAF 7, Cilegon, Indonesia

    12

    BMM ISPAT, Karnataka, India


    4

    Highly productive and


    low-cost DRI-based EAF steelmaking

    Increases productivity by 10%

    Our solution
    SIMETAL EAF FAST DRI provides a continuous DRI melting
    process. There is no need to stop electric power input or
    the DRI feeding during tapping: Tapping and tap-hole refilling are performed under power-on conditions. This
    achievement is possible thanks to a revolutionary mode
    of shell movement combined with FAST, a slag-free tapping system. Siemens VAI developed its new SIMETAL EAF
    FAST DRI as an improved DRI-based EAF process that can
    meet the growing demands of DRI-based steelmaking.

    Advantages of SIMETAL EAF FAST DRI,


    based on cold DRI:
    10% shorter tap-to-tap times

    Due to its improved shell design and extensive liquid heel


    operation, the DRI melting process is much more efficient.
    In addition, slag carryover is reduced to an absolute minimum as a result of its siphon-type tapping channel design.
    Thanks to its sophisticated modernization concept, even
    existing furnaces can benefit from the major improvements of the FAST DRI system.

    Slag-free tapping for better steel quality

    Virtually no power-off times thanks to FAST tapping


    Non-stop DRI feeding
    Tapping and taphole refilling during power-on
    20 kWh/t less energy consumption
    10% less electrode consumption
    10% higher productivity with a 150-ton EAF
    Lower consumption of ladle additions and refractory
    Higher alloy yield and better desulfurization
    Reduced temperature loss
    Lower tapping temperature

    To boost productivity even more, it is possible to use hot


    DRI with the FAST DRI system. Therefore, the hot link
    our own development feeds the DRI at a temperature
    of 600 C to the EAF.
    The development of the SIMETAL EAF FAST DRI is the
    outcome of our extensive experience and expertise with
    the DRI process, and confirms Siemens VAI as the worlds
    leaders in DRI EAF technology.

    Competence Center:
    Siemens VAI
    Metals Technologies GmbH
    Reithallenstr. 1
    77731 Willsttt-Legelshurst, Germany
    Phone: +49 7852 4100
    Fax:
    +44 7852 41141
    E-mail: [email protected]
    Headquarters:
    Siemens VAI
    Metals Technologies GmbH
    P.O. Box 4, Turmstr. 44
    4031 Linz, Austria
    Phone: +43 732 6592-0
    Fax:
    +43 732 6980-0
    E-mail: [email protected]
    www.siemens-vai.com
    Order No. E10001-M3-A143-V2-7600
    Dispo No.: 21661 K-No.: 28103 | Printed in Germany
    GB 120677 PP 08121.5 | 08.2012, Siemens AG

    The information provided in this brochure contains merely general


    descriptions or characteristics of performance which in actual case of
    use do not always apply as described or which may change as a result
    of further development of the products. An obligation to provide the
    respective characteristics shall only exist if expressly agreed in the
    terms of contract.
    All rights reserved. Subject to change without prior notice.
    SIROLL and SIMETAL are trademarks of Siemens AG.

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