CLEAN AND EFFICIENT –

OPTIMISATION OF EAF DEDUSTING SYSTEMS

Volker Knoth1), Torsten Rummler2) and Torsten Doninger3)

1) Senior Project Manager Environment – Badische Stahl-Engineering GmbH, Kehl, Germany
2) Managing Director – Badische Stahl-Engineering GmbH, Kehl, Germany
3) Manager Environmental Protection – Badische Stahlwerke GmbH, Kehl, Germany

Abstract:

Most of the EAF dedusting systems installed worldwide have been designed and built with
the mere intention to comply with certain environmental regulations and limiting values for a
determined process and production capacity – and this usually works as long as those varia-
bles are fix.
But reality shows that – ever since the recent financial crisis – steel producers are perpetually
forced to adapt their steelmaking process in order to meet the requirements of the market and
properly react to its fluctuations (e.g. by flexible use of input materials). Many installed de-
dusting systems cannot live up to this challenge.
Badische Stahl-Engineering GmbH (BSE) optimises dedusting systems to meet various pro-
cess requirements and thus increase the overall productivity and cost efficiency – along with
the strict compliance with all environmental standards and local legislations.
This paper further describes the basic considerations to be taken and the BSE approach to deal
with these challenges, emphasising it by examples of our latest projects world wide.

Keywords:

Dedusting System, EAF, Optimisation, Productivity, Cost Efficiency

1 BSE/BSW Profile

Badische Stahl-Engineering GmbH in conjunction with its subsidiary Bender Corporation is a

world-renowned consulting and engineering specialist for the layout of efficient melt shops,
optimisation of EAF melting practices and the associated emission control systems. The melt-
ing records achieved at the EAFs of Badische Stahlwerke GmbH (BSW), which is the
steelmaking plant of the group and belongs to the top efficient EAF steelmakers worldwide,
rely to a large extent on BSE’s expertise in these fields.
In the course of the last few years the environmental regulations in Germany have become
more and more stringent. In order to achieve leadership in this field, BSW started years ago to
improve its off-gas and water treatment system. Today the BSW melt shop building has a
totally closed roof with no dust emissions through any openings and a bag house clean gas
dust emission below 1 mg/Nm3. The dust concentration on the furnace mezzanine is far below
the governmental threshold. It guarantees good working conditions for the melt shop opera-
tors.
BSE’s objective is to define the design of an emission control system for the off-gas from a
modern, state-of-the-art basis with an eye towards future technologies to meet the local gov-
ernmental limits.
2 What triggers off-gas?

The design and layout of a dedusting system is depending on several technical factors and
pre-conditions. This includes considerations such as operational parameters, productivity,
input materials, existing layouts and equipment, dimensions and many other more.
On top of this there are non-technical factors which affect the design of a dedusting system,
for example official emission limits and other regulations set up by authorities like maximum
allowable workplace concentrations.
Compliance with these demands from inside and outside is important in many ways. With
regard to technical aspects, it helps to optimise the design of the systems in order to achieve
the maximum and most efficient results. On the non-technical side it gives the legal security
companies need to operate in an environment of increasing suspicion towards industrial com-
panies by people such as neighbours and authorities.
The following Figure 1 gives a schematic of the dependency matrix.

Figure 1: Dependency matrix

In the following example the consequences of introducing Hot Metal (HM) into the charge
mix are displayed.
As both, the increased oxygen input for refining and the additional post combustion lead to a
higher off-gas temperature level in and after the EAF, the gas inside the EAF and the post
combustion chamber has a higher actual volume. Consequently, the gas leaving the EAF and
the post combustion chamber has a higher temperature than without HM charging, resulting in
an increase of all temperature parameters (lower level, peak, average).
And even more, we find the following: In order to keep the exhaust efficiency from the EAF
at the same level (= constant level of fuming at EAF openings) the exhaust rate must be in-
creased, which additionally results in a higher off-gas flow rate by temperature level effects.
One additional effect to be considered is the fact that HM is charged at a higher temperature
level compared to e.g. scrap. This means that the input material temperature level is higher,
thus starting the heat from a higher average temperature with a faster increase of temperature.
The cooling capacity of the connected dedusting system is in most cases limited. This means
that the peak temperature level of the heat is increased, having a fundamental impact on the
overall system down to the stack, influencing all parts of the dedusting system.
In the end there is more off-gas at a higher temperature level to be evacuated.

For the impact of productivity it is assumed that productivity is increased by measures which
must not be defined in detail here. Basically it does not really matter which measure is taken
to increase productivity, the consequences are the same. The difference is just how severe and
in which way the modifications influence the dedusting system. In this paper we will look
again more closely at the impacts on temperature level and flow rate of the dedusting system.
The tap-to-tap time will be shorter which has two consequences. One is that the overall off-
gas system has less time to cool down between two peak heat load cycles, resulting in an in-
crease of the average (e.g. higher filter inlet temperature) and the low temperature level (roof
exhaust and EAF direct exhaust).
The second consequence is related to the melt shop building as such. Since there is a faster
sequence of the heats, the melt shop structure and atmosphere have less time for recreation,
thus resulting in a higher temperature level. This influences the inside conditions of the melt
shop, such as dust dispersion level, elevation of dust layers in relation to the crane runway and
the temperature on the EAF working platform. Since the target should be to keep the condi-
tions inside the melt shop after the production increase on the same level as before, the effects
as described above call for an increase of the overall melt shop evacuation rate. As the total
flow rate at the bag house is more than 80 % related to the melt shop building evacuation it is
obvious that there is a fundamental impact on the dedusting system.
The legal situation is becoming more and more important worldwide. Authorities have a
much closer look at industrial production companies than in former times. This is driven by
the increasing awareness and sensitivity of politics and the public in terms of environmental
pollution, such as dust emissions from stacks and buildings, noise, smell, organic matters and
many more. International trading also can influence the focus, for example if overseas cus-
tomers make their purchase depending on environmental standards applying to the local fabri-
cation (“green production policy”).
All in all the limits for any emissions are becoming more and more stringent. As an example,
Figure 2 shows the development of the emission limit for Dioxins (PCDD – PolyChlo-
rinedDibenzoDioxins) and Furans (PCDF – PolyChlorinedDibenzoFurans) using the example
of BSW/Germany. As it can be seen the limit was reduced by 80 % in three steps within only
seven years. Every two years a new limit was applied, putting heavy pressure on the steel
plant to catch up with these requirements and to stay within the limits in order to keep au-
thorities and the general public happy and the steel plant out of the headlines.

Figure 2: Emission level development

3 Verification of design

In order to describe how the design (size, set up, components, operational figures, etc.) of a
dedusting system is determined we look at a “standard” dedusting system as per Figure 3.

Figure 3: Standard dedusting system layout

The sources for off-gas in this case are the EAF (4th hole and melt shop evacuation through
canopy hood) and the ladle furnace (LF, assuming that the secondary emissions of the LF are
captured in the EAF canopy hood as well).
The EAF direct evacuation control system (DEC) comprises a down coming duct (DCD) in to
the drop out box (DOB) / post combustion chamber, followed by a piece of water-cooled duct
(WCD) leading the off-gas to the cooler (trombone cooler, forced draft cooler, evaporation
cooler, etc.). In case the WCD is extremely long and/or the overall flow rate at the bag house
is very large no cooler is required beside the WCD. After the cooler there is a piece of single
wall duct (SWD, steel plate duct) guiding the gases to the mixing area with the secondary off-
gas. A damper in the SWD allows flow control of the 4th hole extraction.
The EAF secondary emission control system (SEC) starts with a canopy hood which dis-
charges into a SWD, leading the exhausted off-gas to the mixing area with the primary off-gas
from the 4th hole. A damper in the SWD allows flow control of the canopy extraction.
For the ladle furnace there is usually a short piece of WCD followed by a SWD. A booster fan
is installed to deliver the LF off-gas into the main duct of the SEC.

The off-gas flow rate required for a proper EAF evacuation depends on many different pa-
rameters. The main preconditions and dependencies are:
1 EAF size (Ø, tap weight, type)
2 EAF geometry (gaps, doors, ports, etc.)
3 Input materials (scrap, HMI, HM, DRI, etc.)
4 Charge mix
5 Energy input rate (electrical, carbon, oxygen)
6 Dedusting system control system (damper, VSD, both)
7 Secondary emission control evacuation rate
8 Others (…)
Based on all these factors the required flow rate for a proper EAF evacuation is determined.
The dimensions of elbows and ducts is then a function of the off-gas flow rate and the tem-
perature levels during the different furnace operation steps (melting, refining, charging, tap-
ping, waiting, maintenance).
The heat content of the off-gas as a function of flow rate and temperature defines the required
water-cooled ducting (dimension, cooling water demand) and the cooler (if any) and SWD
dimensions.

Figure 4: Functionality of BSE High Temperature Quenching System (HTQ)

Main and critical equipment is investigated in detail. In the example displayed in Figure 4 the
functionality of an evaporation cooler (BSE High Temperature Quenching System, HTQ) is
investigated and proved. Main focus is the complete evaporation of the injected water inside
the chamber as well as the homogenous temperature pattern in the gas flow leaving the cham-
ber. The first is important to avoid liquid water leaving the chamber, resulting in dust deposits
on walls and in ducts. The second is to check on hot gas streams leaving the chamber with the
danger of reaching in extreme cases into the bag house causing damages at bags, valves or
fans.

Similar detailed investigations with engineering and the CFD analysis deliver the required
flow rate for a proper evacuation of the LF. Flow rate and temperature as well as pressure
drop calculations define duct diameters, cooling water flow rates and the dimensions and
specifications of the booster fan.

The off-gas flow rate required for a proper secondary EAF evacuation depends on many dif-
ferent parameters. The main preconditions and dependencies are:
EAF size (Ø, tap weight, type)
Input materials (scrap, HMI, HM, DRI, etc.)
Charge mix
Building clearance H
 Building size & geometry
Minimum updraft velocity vmin
Updraft expansion angle
Canopy hood size / volume (h x w x l) / shape
DEC evacuation rate
Limits & regulations
Others (…)

The parameters above define the required flow rate from the canopy hood. The combination
of flow rate and temperature defines parameters of the system such as duct diameters, pres-
sure drop etc.
As the flow rate from the melt shop building represents approximately 80 % of the total flow
rate of the dedusting system at main fans it is very important to be sure about calculations and
assumptions.
The state of the art in calculation-based analysis is not as accurate or as rapid as the fluid
modelling technique, which has been developed to a high state of accuracy. The model allows
a real-time solution of the effects of very non-steady state phenomena in conjunction with the
building geometry.
Therefore BSE uses the unique Fluid Dynamic Model (FDM) Technique (Figure 5) to verify
and optimise the design of the canopy hood, partition walls, section walls and other important
geometric structures influencing the melt shop and exhaust equipment design.
The FDM allows the simulation of all operating conditions such as charging, tapping and O2-
blowing. From this basis, it is possible to optimise the geometry of the canopy hood and any
building modifications such as separating walls.
The model is a Plexiglas replica of the real equipment, most likely in either 1:75 or 1:100
scales. The process emissions are buoyancy driven. The applicable model scaling calculations
will determine the process heat release to the environment and, with the present exhaust rate,
the required physical mass flow, heat flow and time scale of the model.
All this allows an easy determination of the relevant hardware conditions at lowest possible
cost plus the definition of the required off-gas flow rates.
 Figure 5: Fluid Dynamic Model (FDM) Technique

All flow rates, temperature levels and pressure drop data are combined and define the required
size of the filter bag house and the specification of the main fans. Furthermore the local con-
ditions and regulations (e.g. emission limits) are taken into consideration.

4 Customer benefit

The installation of a dedusting system is a cost intensive task. Investment cost for a dedusting
system can pile up to 10 Mio € or more, depending on the scope of supply. Considering that
the dedusting system is “not producing a single ton of steel”, the investment cost must be kept
as low as possible. Further, the operation of a dedusting system involves a decent amount of
energy as the main part of its operation cost, which can be in an area of 20 kWh/t – 50 kWh/t.
Optimisation in operational cost, either from the very beginning for a new system in an exist-
ing steel plant or a green field project or for an existing system in a revamping project can
have a fundamental impact on the overall commercial performance of a steel plant.
Two important key figures to estimate the efficiency of a dedusting system and judge the op-
eration cost level are the specific cost [Cost/Am³] and the specific flow rate [Am³/(h·kW)].
“Cost” means the total operational cost, which are mainly the cost for electrical energy to op-
erate the main fans, supply compressed air, maintenance and wear parts, etc. “Am³” / “Am³/h”
means the total flow rate at stack in actual cubic meters / actual cubic meters per hour and
“kW” means the power consumed by the electrical installations of the dedusting system (in
most cases this are the main fans and booster fans).

Figure 6: Customer examples

Figure 6 gives some examples of BSE customers with their achieved improvements and key
figures. In the diagram are both cases, new installed and revamped equipment.
5 BSE approach of dedusting system revamp

The BSE approach for a dedusting system revamp is based on a step-by-step analysis. Never-
theless it must be considered, that in a dedusting system all parts are connected in the true
sense of the meaning, therefore it is necessary to have a holistic approach. Focusing on single
parts of a system does not take into consideration the dependencies, interactions and influ-
ences between the different parts.
The BSE strategy is consisting of three steps. The first step is an on-site investigation during
which the following topics are hooked on:
Measurements & inspection of equipment (internal, external)
Observation of operation
Collection of data, drawings & specifications
A next very important step is the customer involvement because any modifications must be
made with the managing level and the operation people being involved. They usually know
the systems behaviour and specialities best. The following topics are tackled during this se-
cond phase:
Production targets & “View into the future”
Discussion with operating personnel (problems, wishes, expectations)
Check on preconditions (e.g. official requirements & regulations)
Having performed the first two steps the project jumps into the third phase, the conceptual
engineering. This engineering gathers all information and converts them into a concept under
the following aspects:
Feasibility & re-use
Optimisation & up-grade
Visualisation & control (measurements & HMI)

6 Summary

As it can be seen it makes much sense to care for the dedusting system. Both, the investment
cost as well as the operational cost bear decent potential for improvements and savings. BSE
can act in many ways to help steel plants make the most of their systems with the following
aspects:
Increase of efficiency
Reduction of specific cost
Limitation of investment cost by maximum possible re-uses
State-of-the-art design
Consideration of local requirements and regulations
Support for specification development and purchase process
BSE knowledge covers experience with many different dedusting systems
Supplier independent consultancy