DANIELI
THE RELIABLE & INNOVATIVE
PARTNER IN THE STEEL INDUSTRY
EXCELLENT FASTARC
EAF OPERATING
RESULTS WITH HOT DRI
CHARGE AT ESI
(EMIRATES STEEL
INDUSTRIES)
Luca Mottes
VP Key Account Management
DANIELI CENTRO MET
9-abr-15
1
FASTARC™ is the trademark for a state-of-the-art steelmaking process
technology, including also auxiliary systems, optimised with respect to
available types of ferrous charge materials.
Since 1985 Danieli Centro Met has supplied 182 Electric Arc Furnace plants
on a turnkey basis or revamped existing EAF, developing both design,
process and automation technology.
Electric Arc Furnace:
> Process know-how
> Equipment reliability
> Process control
> Fully automation
> Ultra high power input
> High chemical energy utilisation
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Danieli 2010: Micromill…makes a minimill smaller and more profitable
Productivity range from 200,000 to 500,000 tpy of straight bars, wirerod, spooled coils
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Energiron DR plant
Meltshop
- 1,600,000 tpy DRI Direct Reduction
Plant
- 150 ton AC DANARC® EAF
- 620,000 tpy - 120 t/h Flexible bar mill
- 150 ton LF
- 480,000 tpy - 120 t/h Wire rod mill
- 6-strands 9 m radius FastCast CCM
- 1,600,000 Nm³/h FTP
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Rolling Mills
4
Iron Ore
Reducing gas sources
– Natural Gas
– Reformed Gas
– Coal Gasification
– COG
– others
H2O
CO2
Only for cold
DRI
fuel
O2
HYTEMP® Iron
EAF
Optional DR products
DRI
HBI
Flexibility for energy sources and product type
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5
HYTEMP BRIDGE
The only proven technology for
continuous transport/feeding of hot
DRI to EAF
HOT DRI
STORAGE
EAF
– Pneumatic transport of hot DRI to
EAF
– Flexible configuration and layout
– Simple operation
– Totally enclosed, from ore to liquid
steel
– Savings of power related costs in
EAF
– EAF productivity increase
HYTEMP BRIDGE
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Machine type
Shell ID
Tap weight
Hot heel
Electrode Diameter
Pitch Circle
EAF UHPAC - 200 ton
7,000 mm
150 ton
50 ton
710 mm
1400 mm
Electrode Arms
Conductive type
Tapping device
EBT
Transformer Power
Danarc Module
130 MVA + 20%
5 x 2200 Nm³/h Oxygen Injectors
3 x 30 kg/min Carbon injectors
Raw material mix
Auxiliaries
100 Hot DRI, Cold DRI, Scrap
Automatic temperature measuring &
sampling device
Automation system
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Levels 1, Level 2
7
DRI
FEEDING
POINT
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DRI Analysis From Sampling Bin
Time
Via
Fe Met [%]
Fe Tot [%]
Met [%]
C [%]
S [%]
08:00
HYTEMP
87,8
91,82
95,62
2,07
0,0112
10:00
HYTEMP
86,29
91,64
94,16
2,15
0,0087
12:00
HYTEMP
86,94
91,64
94,87
1,94
0,0077
14:00
HYTEMP
88,6
93,06
95,21
2,12
0,0087
16:00
HYTEMP
86,91
91,56
94,92
2,2
0,0069
18:00
HYTEMP
87,24
91,68
95,16
2,16
0,0084
20:00
HYTEMP
86,56
91,16
94,95
1,81
0,0094
22:00
HYTEMP
86,8
91,43
94,94
2,21
0,01
01:00
HYTEMP
87,27
92,15
94,7
2,13
0,0082
03:00
HYTEMP
87,28
92,77
94,08
2,17
0,0104
05:00
HYTEMP
87,98
92,91
94,69
2,06
0,0102
87,24
91,98
94,85
2,09
0,0091
AVG
Charging Mix: 90% Hot DRI - 10% Cold DRI
Hot DRI Temperature at EAF inlet: 600°C
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9
Flow rate DRI Kg/MIn
Electrical power
7000
6000
Flow rate [Kg/Min]
120
Power [MW]
100
80
60
40
20
5000
4000
3000
2000
1000
0
0
0
5
10
15
20
25
30
35
40
45
0
50
5
10
15
20
25
30
35
40
45
50
30,00
35,00
40,00
45,00
50,00
Tim e [ Min]
Tim e[Min]
DRI Specific feed rate
60
DRI Specific feed rate
[Kg/Min/KW]
12000
11000
10000
9000
8000
7000
6000
5000
4000
3000
2000
1000
0
0
5
10
15
20
25
30
35
40
45
50
40
30
20
10
0
0,00
50
5,00
10,00
15,00
20,00
25,00
Tim e [ Min]
Tim e [Min]
Lime & Dololime
LIME
DOLOLIME
Coal
70
140
60
120
Lime & Dololime
[Kg/min]
Coal [ Kg/Min]
Oxygen [ Nm3/h]
Oxygen
50
40
30
20
100
80
60
40
20
10
0
0
0
5
10
15
20
25
Tim e [Min]
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30
35
40
45
50
0
5
10
15
20
25
30
35
40
45
50
Tim e [Min]
10
90% Hot DRI +
100 % cold
10% Cold DRI
DRI
Tap to tap
(min)
45,5
58,5
Power on time
(min)
35
48,9
Electrical energy
(kWh/t)
392
533
Oxygen
(Nm3/tsl)
34,8
33,3
Coal injected
(kg/tls)
9,7
17.3
Coal V hole
(kg/tls)
3,2
10.0
Average power
(MW)
102
98
Tapping temperature
(C)
1640
1640
Steel liquid tapped
(tls)
152
150
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11
The good cooperation between ESI and Danieli has brought FASTARC™ operation at
Emirates Steels Industries beyond the contractual figures, demonstrating an excellent
thermal efficiency.
The consolidated consumption figures with 90% Hot DRI and 10% Cold DRI in charge are
comparable with the ones of 100% scrap charged:
 Electrical Energy: 392kWh/tls
 Tap to tap: 45.5 min
 Productivity: 197.8 ton/hour
This has been achieved exploiting the quality of the HOT DRI charged, its high degree of
metallization and its high enthalpy content.
With 100% Hot DRI charging, Tap to Tap of 41 min and Electrical Energy consumption of
380 kWh/ton of have already been reached.
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OBRIGADO!
Luca Mottes
l.mottes@danieli.it
9-abr-15
13