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Global EAF survey:The influence of metallics and EAF design

Article  in  Steel Times International · December 2017

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Jorge Madias Andrea Bilancieri

Metallon Tenaris
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 GLOBAL EAF SURVEY RESULTS 35

The influence of metallics and EAF design

There is an important variation in scrap quality and alternative iron sources depending on country and
region. esides, a variety of furnace designs are available. This paper looks at the in uence of metallics
type and A design on specific consumption of energy, o ygen and other inputs, as well as on some
productivity indicators, based on a survey of published figures of A s around the world. The results
obtained are analysed in detail. Jorge Madias1, Andrea Bilancieri2, Sara Hornby3

THE data base was selected from
publications in technical journals and
presentations in conferences, from 2010
to February 2017. All furnaces included are
intended for production of rolled products:
EAFs for steel castings, forgings and
powder are not included, nor are furnaces
producing e clusively stainless and tool
steels. Also e cluded are furnaces with heat
capacity lower than 30 t.
The universe surveyed includes 190
furnaces. Twin shell furnaces are counted
as one furnace (including the CONARC
furnaces). All steelmaking regions are
included (Fig 1). Charge types include from
100% scrap to 40% pig iron, 60% hot
metal, 100% DRI/HBI and 100% hot DRI.
Products include merchant long products,
, at products coil and plate and
seamless pipes.
The survey includes 28 DC vs. 162 AC
furnaces. Regarding tapping system, there
are 16 furnaces equipped with spout, and
174 with EBT. 31 furnaces have some form
of scrap preheating (15 Consteeel, 5 shaft
and 11 twin shell furnaces), while the other
159 furnaces have no scrap preheating
at all. In terms of charging, nine furnaces
are known to be single bucket. In Fig 2,
the distributions of these furnace features
within the survey are shown.
The relation between transformer power
and heat capacity within the survey is
shown in Fig 3. The line in the figure shows
the 1:1 ratio.
Survey
pecific consumptions are e pressed in
terms of metric tons of liquid steel in the
ladle. The data included are: company /
group; plant name; country; EAF type, heat
capacity; transformer (power in MVA);
electrode diameter; productivity; tap to
tap time; power on time; consumptions
power, o ygen, injected carbon, natural
gas, electrodes; metallic yield; charge type;
product type; published reference.
Information sources are cited in the
reference [1-46]. It is obvious that
published data corresponds usually to a
specific operation period, and consumption
figures as well as productivity times change
depending on demand and other situations
that may vary along time.
Power consumption
For the population of surveyed furnaces,
the specific consumption of electric energy
depends first on the raw materials, and the
thermal state of them when charged (hot
DRI, hot metal). Of the 10 top EAFs with
the lowest energy consumption (<300
kWh/t), nine charge more than 20% of hot

Africa 1% Fig 1. (left) Distribution of the surveyed furnaces by region

Oceania 2%

Twin shell Shaft 2%

Asia 10% 6%
Consteel 8%
Spout
DC 15% 8%

Europe 18%
North America 48%
No preheating
AC 85% EBT 92% 84%
Latin America 21%

Fig 2. (above) Distribution of furnace type within the survey.

Left (Fig 2 above): electric current type; centre: tapping system; right: no preheating and preheating systems

* 1metallon - 432, 9 de Julio Street, San Nicolas B2900HGJ, Buenos Aires Province, Argentina e-mail: jorge.madias@metallon.com.ar
2TenarisSiderca, Av. Dr. Jorge A. Simini 250, Campana 2804, Buenos Aires Province, Argentina e-mail abilancieri@tenaris.com
3Global Strategic Solutions, Inc.; 16317 Woolwine Road, Charlotte, NC 29278, USA e-mail drhornby62@gmail.com

www.steeltimesint.com Digital Edition - December 2017

36 GLOBAL EAF SURVEY RESULTS

350
650
300 600

Specific power consumption (kWh/Mt)

250 550
Transformer power (MVA)

500
200 Hot metal
450
150 400 Pig iron
350 Cold DRI/
100 HBI
300
Hot DRI
50 250
Scrap
200
0
0 50 100 150 200 250 300 350 150
0.000 0.500 1.000 1.500 2.000 2.500
Heat capacity (t)
Specific power (MVA/Mt)

Fig 3. Transformer power and heat capacity (steel in the ladle) for the surveyed furnaces Fig 4. Specific power consumption for furnaces with different metallic charge. Scrap-based
EAF applies for furnaces charging more than 80% scrap. Hot metal charging furnaces are
considered for those charging 20% or more hot metal.

metal (Table 1 and Fig 4). In these cases, preheating is observed (Fig 5). Consteel, From a technological point of view, this is
energy is consumed in the blast furnace, shaft furnaces and twin shell furnaces are associated with the use of injectors instead
and EAF CO2 emissions are larger than located within those with lower power of lances, as well as the changes in injector
usual. consumption, sharing this position with the design to allow for a larger o ygen ow
The furnaces charging an important share more efficient conventional A s. or this rate.
of pig iron, as well as those charging scrap purpose, to eliminate the aforementioned Although there is a large dispersion, it
that are managed more efficiently, have a in uence of the metallic charge, only those is worth mentioning the average o ygen
specific energy consumption of 3 EAF charging 80% of scrap or more were consumption related to the metallics
kWh/t (Fig 4). considered. charged:
Then, those furnaces of intermediate
efficiency with scrap based metallic charge, Other factors - 20% or more of hot metal: 36.3 Nm3/t
as well as those charging hot DRI, are ygen consumption. The distribution - 20% or more of pig iron: 43.3 Nm3/t
located in the range of 400 – 450 kWh/t of specific o ygen consumption in the - 20% or more of DRI/HBI: 31.7 Nm3/t
(Fig 4). Higher energy consumption (more surveyed furnaces is shown in figure . - 80% or more scrap: 31.7 Nm3/t
than 450 kWh/t) is typical of high cold DRI/ More than half of the surveyed furnaces
I share or of low efficiency scrap based consume 30 to 40 Nm3 t of o ygen. This As e pected, the higher the heat capacity,
EAFs. re ects the advance of chemical energy, the larger the electrode diameter (Fig 7).
A favourable in uence of scrap due to productivity and power cost. But two other aspects can be mentioned:

Country Heat Current Type Transformer Tap to tap Power cons. O2 (Nm3/tls) Met. other Product
capacity (t) (MVA) (min) (kWh/tls) than scrap (%)

China 50 AC Standard 67 132 54 HM LS

China 100 DC Standard 90 44 177 47 57.5 HM LS
China 110 AC Standard 80 33 220 33 30 HM LS
Russia 175 AC Standard 150 45 223 34 22 HM LC
Taiwan 155 AC Twin Shell 120 44 225 37 35 HM LC
China 110 AC Standard 80 35 240 33 30 HM SP
China 110 AC Standard 80 35 240 33 30 HM SP
Brazil 110 AC Standard 48 43 265 30 HM LC
Brazil 80 AC Standard 75 295 31 25 HM/5PI LC
Singapore 80 AC Shaft 48 295 0 LC
Turkey 195 AC Standard 47 300 38,5 0 LC
South Africa 170 AC Conarc 115 57,5 310 43 50 HM/ 50 cDRI FC
India 180 AC Conarc 137 57,5 310 50 HM/50 cDRI FC
Korea 120 AC Shaft 49 314 31 not known LC
Vietnam 63 AC Consteel 33 54 328 10 HM LC
Me ico A tandard 33 cD I
Italy 95 AC Standard 100 42 340 20 10 PI SP
Brazil 50 AC Standard 36 343 60 30 PI LC
Brazil 50 AC Standard 48 343 60 30 PI LC
Me ico A tandard 3 cD I

Table 1. Top twenty furnaces regarding power consumption. HM: hot metal; PI: pig iron; cDRI: cold DRI. LS: Long special; LC: Long carbon; SP: Seamless pipes; FC: Flat carbon.

Digital Edition - December 2017 www.steeltimesint.com

 38 GLOBAL EAF SURVEY RESULTS

650 50.0
45.0
Specific power consumption (kWh/Mt)

600
40.0
550
35.0
Standard 30.0
500
Spout 25.0
450
Consteel 20.0
400 15.0
Shaft
10.0
350 Twin shell
5.0
300 -
0.000 0.500 1.000 1.500 2.000 2.500 <20 20-30 30-40 40-50 >50
Specific power (MVA/Mt) Oxygen consumption (Nm3/Mt)

Fig 5. Specific power consumption for scrap preheating and conventional furnaces. Fig 6. Specific oxygen consumption in Nm3/t for the EAF surveyed
Only furnaces charging 80% scrap or more are considered

- There is a big concentration of furnaces 16 of them are dedicated to merchant long than 20% of hot metal
using 610 mm diameter electrodes, tapping products. The logic behind this situation is - 300-400 kWh/t: furnaces charging an
from 70 to 200 t per heat. that in general, these furnaces are linked important share of pig iron, as well as those
- DC furnaces, with one or two to billet casters equipped with metering charging scrap that are managed more
electrodes, present the larger diameter, for nozzle and oil lubrication, characterised efficiently
a given heat capacity. by casting speeds much higher than those - 400 – 450 kWh/t: furnaces of
used for SBQ, for the same billet size. Long intermediate efficiency with scrap based
Increased electrode consumption sequences are usual for these casters, most metallic charge, and those charging hot DRI
As e pected, there is a trend to increased of them equipped with automatic nozzle - >450 kWh/t: furnaces with high cold
electrode consumption for higher power changer. SBQ casters, instead, have limited D I I share or low efficiency scrap based
consumption (Fig 8 . D furnaces e hibit sequence length because of shorter SEN EAFs.
lower electrode consumption. life and a larger variety of steel grades. See
Productivity per hour is linearly related Table 2. References
to the heat size, although other factors Regarding furnace type, it is clear the
in uence, too Fig 9). Seven of the 10 top Conclusions favourable in uence of scrap preheating,
EAFs in productivity per hour are feeding There are four ranges of power with transporter, shaft or twin shell.
slab casters. consumption according to the metallic DC EAFs do not differ much on power
Regarding power on time, the twenty top charge: consumption, but are in the lower range of
EAFs have a varied heat size (35t to 220t); - <300 kWh/t: furnaces charging more electrode consumption.

Country Heat Current Type Transformer Tap to tap Power on Power cons. O2 (Nm3/tls) Metallics Product
capacity (t) (MVA) (min) (min) (kWh/tls) other than scrap

Spain 130 AC Standard 140 43 29 SC LC

Germany 100 AC Standard 90 41 30 365 38,6 SC LC
Germany 100 AC Standard 90 41 30 365 38,6 SC LC
Belgium 90 DC Standard 99 42 31 370 44 SC LC
Russia 175 AC Standard 150 45 32 223 34 HM LC
USA 35 AC Consteel 30 55 32 350 31 SC LC
USA 171 AC Shaft/Twin 140 38 32 372 50 PI FC
Brazil 110 AC Standard 48 43 33 265 HM LC
Norway 89 AC Consteel 75 41 33 384 26 SC LC
Turkey 220 AC Standard 230 41 35 360 35 SC LC
USA 154 DC Standard 180 40 35 386 41 CDRI FC
USA 154 DC Standard 180 45 35 386 41 CDRI FC
u embourg D Twin hell 3
China 100 DC Standard 90 44 36 177 47 HM LS
Brazil 80 AC Standard 75 37 295 31 HM LC
Korea 100 AC Standard 100 45 37 354 29 SC LC
France 92 DC Standard 72 54 37 375 44 SC LC
UAE 152 AC Standard 130 64 37 392 35 HDRI LC
Belarus 110 AC Standard 95 38 386 SC LC
Qatar 85 AC Standard 78 50 38 480 35 CDRI LC

Table 2. Twenty furnaces in the survey, with the shorter power on time. HM: hot metal; PI: pig iron; cDRI: cold DRI. LS: Long special; LC: Long carbon; SP: Seamless pipes; FC: Flat carbon.

Digital Edition - December 2017 www.steeltimesint.com

 BSE Spray
Cooling
Technology
Safe, simple, reliable
Cooling of EAF Components
Principles.
Support structure with
cooling elements consisting
of water header and spray-
bars providing a pressure-
less water flow.
Heat transfer through steel
plate cooled by a thin water
layer.
Water amount adjustable
according to individual heat
load areas.
Suitable for the furnace roof
and the elbow.
Tested and proven at BSW,
the steel plant of the Badische
group, and at many customers’
plants worldwide.
Spray bars with nozzles provi-
ding a pressure-less, balanced
and efficient water cooling
Badische Stahl-Engineering GmbH
Robert-Koch-Straße 13
D-77694 Kehl/Germany
Phone (+49) 78 51/877- 0
Fax (+49) 78 51/877-133
eMail info@bse-kehl.de
www.bse-kehl.de
BSE0370_Leaflet_Sprühdeckel_2017.indd 1
Concept.
Collector ring as an integral
part of support structure used
for water supply and return for
cooling elements; water-cooled
centre piece and fume take-off
adapter.
Area around electrode
openings designed for refrac-
tory-lined, easily exchangeable
centre piece.
Usage of clog resistant
spray nozzles and access
hatches.
Designed for lower weight,
thus increasing the lifetime of
the gantry bearing.
Top view of roof with holes
for the electrode centre piece
and the furnace elbow
Advantages.
Maximum safety in operation,
based on pressure-less function,
thus eliminating the risk of
explosions.
Reliable operation and long
lifetime due to proven design
with well-balanced cooling
performance.
Lower consumption of cooling
water compared to tubular design.
Reduction of production delays
– in many cases production can
continue until next shutdown.
Quick repair of minor damages
and good access to all areas.
Easy cleaning of roof surface
for an optimised maintenance.
Bottom view of the roof
equipped with centre piece
for the electrodes
14.09.17 09:18
40 GLOBAL EAF SURVEY RESULTS

900 2.5

800

Electrode consumptiuon (kWh/tls)

2.0
Electrode diameter (mm)

700
1.5
600
AC AC
1.0
500
DC DC

400 0.5

300 -
0 50 100 150 200 250 300 350 0 100 200 300 400 500 600
Heat capacity (t) Power consumption (kWh/tls)

350 Fig 7. (top left) Electrodes di- 16. Solver, Chr.; Roth, J.-L.; Hoffmann, M.; Stoltz, R.;

300 ameter vs. heat capacity, for Houbart, M.; “Dragon Steel Corp. in Taiwan boosted
AC and DC furnaces of any 150-ton EAF twin shell by continuous hot metal
250 design and metallic charge charging process”. AISTech 2011 Proceedings, pp. 799-
Productivity (t/h)

200 809.
Fig 8. (top right) Electrode 17. Gottardi, R.; Miani, S.; Partika, A.; SUber, M.;
150 consumption vs. energy Decarburisation efficiency in A with hot metal

100 consumption for AC and DC charge”. Iron & Steel Technology, January 2012, pp. 61-
furnaces 69.
50 18. Kim, D.S.; Jung, H.J.; Kim, Y.H.; Yang, S.H.; You,

- Fig 9. (left) Hourly production .D. ptimisation of o ygen injection in shaft A

- 50 100 150 200 250 300 350 400 versus heat capacity, for all through uid ow simulation and practical evaluation .
Heat capacity (Mt) EAFs Ironmaking and Steelmaking 2014 VOL 41 NO 5, pp.
321-328
9. Jones, J.A.T.; McClanahan, R.; Carraway, K.; 19. de Oliveira Paula, A.; Martins Araújo, A.; Renato
“Analysis of meltshop operating data at North Star Ribeiro, S.; Coelho Furtado, Th.L.; de Souza Lima, W.L.;
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