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18 de abr de 2023 1
EXCELLENT FASTARC EAF OPERATING RESULTS WITH HOT DRI CHARGE AT ESI (EMIRATES STEEL INDUSTRIES)
DANIELI THE RELIABLE & INNOVATIVE PARTNER IN THE STEEL INDUSTRY
DANIELI CENTRO MET
Luca MottesVP Key Account Management
18 de abr de 2023 2
Electric Arc Furnace:> Process know-how> Equipment reliability> Process control > Fully automation> Ultra high power input> High chemical energy utilisation
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.
18 de abr de 2023 3
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
18 de abr de 2023 4
Energiron DR plant- 1,600,000 tpy DRI Direct
Reduction Plant
Meltshop- 150 ton AC DANARC® EAF- 150 ton LF- 6-strands 9 m radius FastCast CCM - 1,600,000 Nm³/h FTP
Rolling Mills- 620,000 tpy - 120 t/h Flexible bar mill- 480,000 tpy - 120 t/h Wire rod mill
18 de abr de 2023 5
HBI
DRI
EAF
HYTEMP® Iron
H2O
fuel
CO2
O2
Iron Ore
Reducing gas sources – Natural Gas– Reformed Gas– Coal Gasification– COG– others
Optional DR products
Only for cold DRI
Flexibility for energy sources and product type
18 de abr de 2023 6
– 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
The only proven technology for continuous transport/feeding of hot DRI to EAF
HYTEMP BRIDGE
EAF
HOT DRI STORAGE
HYTEMP BRIDGE
18 de abr de 2023 7
Machine type
Shell ID
Tap weight
Hot heel
Electrode Diameter
Pitch Circle
Electrode Arms
Tapping device
Transformer Power
Danarc Module
Raw material mix
Auxiliaries
Automation system
EAF UHPAC - 200 ton
7,000 mm
150 ton
50 ton
710 mm
1400 mm
Conductive type
EBT
130 MVA + 20%
5 x 2200 Nm³/h Oxygen Injectors
3 x 30 kg/min Carbon injectors
100 Hot DRI, Cold DRI, Scrap
Automatic temperature measuring &
sampling device
Levels 1, Level 2
18 de abr de 2023 8
DRI FEEDING
POINT
18 de abr de 2023 9
94,92
Met [%]
2,06
22:00
86,56 91,16 94,95
0,0082
HYTEMP
2,13
91,43 94,94 2,21
10:00
12:00
88,6 93,06
18:00
86,94
0,0087
91,68
86,29
0,0091
1,81
2,09
0,0102
0,01042,17
0,0094
2,16
0,01
0,0084
03:00
87,27
87,28
01:00
20:00
14:00
94,08HYTEMP
92,15
92,9187,98
HYTEMP
87,24
86,8
94,85
94,7
91,98
92,77
2,2
94,16
0,0077
0,0087
0,0069
94,87
2,12
2,07
DRI Analysis From Sampling Bin
0,011291,82
Fe Tot [%]
HYTEMP
Time
08:00
Via
87,24
AVG
HYTEMP
HYTEMP
HYTEMP
16:00
05:00
2,15
HYTEMP
HYTEMP
94,69
1,94
S [%]
95,62
91,56HYTEMP
HYTEMP
87,8
95,16
95,21
91,64
86,91
91,64
C [%]Fe Met [%]
Charging Mix: 90% Hot DRI - 10% Cold DRIHot DRI Temperature at EAF inlet: 600°C
18 de abr de 2023 10
Electrical power
0
20
40
60
80
100
120
0 5 10 15 20 25 30 35 40 45 50
Time[Min]
Po
wer
[M
W]
Oxygen
0100020003000400050006000700080009000
100001100012000
0 5 10 15 20 25 30 35 40 45 50
Time [Min]
Oxyg
en
[ N
m3/h
]
Coal
0
10
20
30
40
50
60
70
0 5 10 15 20 25 30 35 40 45 50
Time [Min]
Co
al [
Kg
/Min
]
Lime & Dololime
0
20
40
60
80
100
120
140
0 5 10 15 20 25 30 35 40 45 50
Time [Min]
Lim
e &
Do
lolim
e
[Kg
/min
]
LIME DOLOLIME
Flow rate DRI Kg/MIn
0
1000
2000
3000
4000
5000
6000
7000
0 5 10 15 20 25 30 35 40 45 50
Time [ Min]
Flo
w r
ate
[Kg
/Min
]
DRI Specific feed rate
0
10
20
30
40
50
60
0,00 5,00 10,00 15,00 20,00 25,00 30,00 35,00 40,00 45,00 50,00
Time [ Min]
DR
I S
pecif
ic f
eed
rate
[Kg
/Min
/KW
]
18 de abr de 2023 11
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
18 de abr de 2023 12
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.
