TECHNICAL MEETING REPORT

HBI USAGE IN ARC FURNACES

1.

PROPERTIES OF LEBIDINSKY GOK HBI

a. Chemical Composition Fe total Fe metallic Metallization C SiO2 CaO S P Guaranteed 90.00 min 83.00 min 92.00 min 1.00 min 4.50 max 0.80 min 0.02 max 0.02 max

b. Physical Characteristics Apparent briquette Density: Nominal Briquette Size: Fines Content less than 4mm min. 4.8 t/m 110 x 50 x 30mm 5% max.

2.

TYPICAL USAGE PROCEDURE a. Percentage of HBI in arc furnaces

HBI can be used up to 20% in arc furnaces. Special techniques will be needed for higher percentages, which may be necessary for high quality steel production. Major disadvantages of HBI will be minimized in case HBI is used up to 10% (suggested for the arc furnace mills producing commercial steel grades where the impurities are not important). Percentage of HBI may differ as a function of furnace size / quality of the scrap / other technological variances of melting equipment etc. HBI can be used together with BPI, which may be not only advantageous but also necessary in case of very high steel qualities are produced.

b. How to charge HBI in arc furnace

It is recommended to charge HBI into the furnace during the first charge. If necessary, small amounts (say 5%) can be charged during second charge which is not advisable. Ideally HBI should be charged on top of the scrap in the bucket, allowing HBI spread within the lower scrap layers. A small scrap layer can be charged on top of HBI to avoid direct contact of HBI with electrodes if preferred (see below pictures).

c. Anthracite (Carbon) addition

Considering the low carbon content of HBI (1-1.5%), additional anthracite has to be added together with HBI. The amount of additional anthracite is generally 15-20%.

d. Slag Control

Regular slag control is a must for successful usage of HBI. i. FeO content in the slag should range between 20 25%. If the percentage of FeO in the slag over 25%, more anthracite should be added or carbon blown into the furnace should be increased until FeO content comes down to normal limits. ii. Basicity of the furnace should range between 1.8 up to 2.0 percent. It will be necessary to add CaO together with HBI in order to keep the requested basicity level. Percentage of the CaO addition may vary, but generally it should be around 8-10 % of the HBI in the charge.

3.

Advantages of HBI a. Increases the density of the charge

Density of HBI is approximately 3.5 m3 /ton whereas the density of the scrap ranges between 0.700.80 m3/ton. Density of the charge increases with HBI addition and in some cases third charge may be avoided by adjusting the percentage of HBI or alternatively using HBI & BPI (density 5m3/ton) together. No need to mention the advantages of avoiding one charge to any arc furnace mill.

b. Purity of the steel

HBI is pure iron without impurities and also the Sulphur & Phosphorus contents are very low (in case of Lebidinsky Gok). This helps producing higher steel qualities by means of reducing the percentages of the impurities and unwanted elements like Cupper. In addition, Nitrogen content of HBI is very low (30 ppm), which is very important for quality steel production. Every mill can make its own calculation based on the chemistry of the HBI given on the first page of this report.

c.

Improved Properties of the final product

As a result of improved chemistry, HBI helps improving following properties of the final product; i. Improves elongation & yield ii. Improves the impact resistance at normal & reduced temperatures iii. Improves hardenability iv. Improves durability v. Improves plasticity during hot & cold deformation

d. Storage
Storage of HBI is very easy. Basic advantages are; i. HBI does not burn ii. HBI does not oxidize iii. HBI can be stored in wet weather conditions iv. Storage area is relatively small due to high density v. Can be easily discharged, transported and charged using magnets However, it is definitely not convenient to charge HBI under wet condition in the furnace.

4.

Disadvantages of HBI
There are few disadvantages of using HBI that can be summarized as follows:

a. Increased Energy Consumption

Melting point of ferrous part of HBI is lower than scrap. However, HBI has some gangue (up to 5%) in the composition, which is very difficult to melt (gangue dissolves in the pot & does not need to be melted). In case of HBI usage up to 10%, it is almost impossible to determine the difference in energy consumption. However, energy

consumption becomes an issue, when HBI is used around 20 30%.

b. Lower yield
Total Fe content of HBI is 90% whereas the Fe content in the scrap practically higher (up to 100% depending on the quality). This is just a matter of calculation, which may give different results in different applications.

c. Increased cost due to additives

As explained before, additional anthracite (carbon) and CaO have to be added together with HBI in order to guarantee successful usage of HBI in arc furnaces. Users of HBI have to calculate this cost when comparing the price of HBI against scrap or BPI.

Result
HBI will be widely used by the in future not only due to technical advantages, but also due to ever decreasing availability of scrap as well as consistently worsening of the scrap quality.