Capacity Enhancements and new Developments at Emirates Steel

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1 Abu Dhabi, United Arab Emirates Capacity Enhancements and new Developments at Emirates Steel Appala Naidu Poodi Manager- Direct Reduction Plants

2 INTRODUCTION Emirates Steel is wholly owned by SENAAT, the UAE s largest industrial conglomerate and a driving force for implementing the Abu Dhabi government s industrial diversification policy. Strategically located in the Industrial City of Abu Dhabi. Phase 1 expansion completed in Direct Reduction Plant /Steel Melt Shop/ Two Rolling Mills Phase 2A expansion completed in 2011 Direct Reduction Plant /Steel Melt Shop Phase 2B expansion completed in Heavy Section Mill Phase 2 Capacity enhancement was executed in December 2013 to increase DRI Plant Capacity from 1.6 to 2.0 MTPA. Also Phase 1 Capacity enhancement is planned in June 2014.

Emirates Steel Products Direct Reduction

Million TPA EAF and LF of 150 Mt per heat

48 Million TPA Production sizes: - Plain 5.

02 Million TPA Production sizes: 8-40 mm

3 Emirates Steel Products Direct Reduction Plants 3.8 Million TPA HYL Technology Pneumatic Transfer of hot 530 C Steel Making Plants 3.5 Million TPA EAF and LF of 150 Mt per heat Continuous caster: 6 strands Production sizes: 130 mm and 150 mm Square Billets Beam Blanks Wire Rod Mill 0.48 Million TPA Production sizes: - Plain mm - Deformed 8-16 mm Bar Mills 2.02 Million TPA Production sizes: 8-40 mm Heavy Section Mill - 1 Million TPA Beams, Sheet Pile, Channels and Angles Production sizes : PFC200/75 UN1016/305

Hot DRI from Reactor is transported to Electric Arc Furnace as well as to the DRI

4 Salient Features of DRI Plant Largest Operating DRI plant of HYL3 Technology with production capacity of 2.0 MTPA. Hot DRI from Reactor is transported to Electric Arc Furnace as well as to the DRI Cooler through Pneumatic Transport System. First Tenova HYL Reactor with Flow Feeders in the World. Ongoing Project with MASDAR to utilize by-product CO2.

5 D.R. Plants Capacity Enhancement & Modifications Installed Higher Capacity Pneumatic Transport Compressor. Operating Capacity Operating Pressure Nm3/Hr 7.18 Barg Installed Higher Capacity Cooling Gas Compressor. Operating Capacity Operating Pressure Nm3/Hr 6.06 Barg Installed additional Oxygen lances to increase Oxygen flow. Operating Capacity Operating Pressure 4500 Nm3/Hr 13.0 Barg

6 DRI PRODUCTION Year DRI Production in Metric Tons 143,535 1,104,250 2,166,976 2,717,520 3,074, DRI PRODUCTION (MT)

DRI Plants Performance Highest Yearly Production : 1602000 MT (Phase-2, FY 2013) Highest Monthly Production : 156473 MT (Phase-1, May

7 DRI Plants Performance Highest Yearly Production : MT (Phase-2, FY 2013) Highest Monthly Production : MT (Phase-1, May 2011) Highest Daily Production : 6399 MT (Phase-2, 6 th April 2014) Continuous Plant Operation : 117 Days.(Phase-2 1 st July 28 th Oct 2014)

DRI Plant Operation after Capacity Enhancement Production Rate : 260 TPH Process Gas Flow : 425000 Nm3/Hr Oxygen Flow :

8 DRI Plant Operation after Capacity Enhancement Production Rate : 260 TPH Process Gas Flow : Nm3/Hr Oxygen Flow : 4500 Nm3/Hr Reactor I/L Temp. : 1010 Deg C Bed Temps : Deg C Feed Mix : SAMARCO: 50 %, VALE : 30 %, LKAB : 20 %

9 Hot DRI EAF HDRI EAF : 534 Deg C Quality : Metallization : % Carbon : 1.96 %

D.R.I. Quality CHEMICAL ANALYSIS % Fe Total 92.09 Fe Metallic 87.8 Metallization 95.

10 D.R.I. Quality CHEMICAL ANALYSIS % Fe Total Fe Metallic 87.8 Metallization Carbon 1.96 SiO Al2O CaO MgO 0.28 Sulfur Phosphorus 0.048

11 Process Impact of Carbon % on HDRI Temperature Sr no. Prodn Rate NG to Reactor Metn Carbon HDRI EAF Bins ton/h NM3/Mt % % DegC

12 CARBON % Vs HDRI TEMP HDRI TEMP vs CARBON Carbon : 1.81%, HDRI Temp.:541 DegC Carbon : 2.60,% HDRI Temp.:403 DegC

13 Hot DRI effect in Electric Arc Furnace Operation Date 12 th April 2014 No of Heats 40 Hot DRI Weight Cold DRI Weight Hot DRI Temp. Avg Tap to Tap Time Avg. Power on Time EAF Kwh Sp. Cons. O2 Sp. Cons. Productivity 6376 MT 582 MT 508 DegC min min 390 KwH/Ton Nm3/Mt Ton/Hr

14 Impact of DRI Temperature in EAF Power Consumption Study has been done to show the relation between Hot DRI temperature/ carbon content on EAF operation Effect of Hot DRI Temperature on EAF Power Consumption * Increase 100 ⁰C of Hot DRI Temp. will decrease power consumption 23 Kwh/t

15 Effect of Carbon on EAF Power Consumption * Increase Carbon content of Hot DRI 0.1% will decrease power consumption 11 Kwh/t

16 Questions?

17 THANK YOU THANK YOU

DRI in Use How is it being Utilized? Different Plants, Different Solutions. APPALA NAIDU POODI DRI Plants Manager

DRI in Use How is it being Utilized? Different Plants, Different Solutions APPALA NAIDU POODI DRI Plants Manager Emirates Steel is wholly owned by SENAAT, the UAE s largest industrial conglomerate and