In an increasingly competitive market, steelmakers face a
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1 STEELMAKING Sublances for BOF steelmaking The Danieli Corus sublance system including the static and dynamic steelmaking model offers significant reduction in tap-to-tap times and improved end point hit rate. These help increase productivity, enabling increased output of existing BOF plants and reduced capital expenditure for new ones. Additional benefits are cost savings through reduced consumption of hot metal, additives and converter refractories. Danieli Corus has sold over 55 sublance systems, including more than 25 in China in recent years. AUTHORS: Gert-Jan Apeldoorn and Peter Gootjes Danieli Corus In an increasingly competitive market, steelmakers face a continuous need to reduce costs. When striving for cost reduction in the BOF process, steelmakers need to extend converter life, reduce blowing times and tap-to-tap times, and reduce consumption of hot metal, fluxes, oxygen and energy. Besides improved logistics by pre-scheduled heats and steel qualities and improved charging strategies and preparation, dynamic process control tools are essential. The use of a sublance in conjunction with a Static-Dynamic Model (SDM) of the oxygen steelmaking process, has proven to be a very valuable tool for dynamic control. WHY USE SUBLANCES? Sublance equipment facilitates fully automated sample taking and measurements without tilting the vessel or interrupting the blow. Two cycles for sample taking and measuring are scheduled per heat: one during the main blow (typically after 90% of predicted oxygen has been blown), the other after the blow end. The in-blow measurement, using a TSC (Temperature, Sample, Carbon) type probe serves to update the required amounts of oxygen to be blown and additives such as coolants, in order to meet the carbon content and temperature endpoint requirements of the steel. These updated blow requirements are generated by the SDM on receipt of sample data. Oxygen flow rate is reduced slightly during measurement to improve reliability of the measurement. At the end of the corrected oxygen blow, steel bath temperature and free oxygen content are measured using a TSO (Temperature, Sample, Oxygen) type probe to determine the final carbon content and calculate the steel bath level. (Bath level is used to ensure the correct lance height is employed during blowing.) During both cycles, samples are recovered automatically from the spent probe and delivered in a probe collecting chute at control room elevation to be analysed for the projection of end point composition. Figure 1 illustrates the process control concept with respect to changes in temperature and carbon content. Figure 2 shows a typical screen ouput. Temperature B ath TSO Measurement - T bath - Sample Carbon content - Oxygen - Bath level 0.02% 8 C Bath Carbon Content Target window Range of aimed carbon content Range of aimed bath temperature TSC Measurement - T bath - T sol Carbon - Sample The black line indicates lance position, the red line shows the bath temperature and the blue line shows the solidification temperature. A typical sublance system layout is shown in Figure 3. The samples taken during both TSC and TSO O 2 Reblow Ore Addition r Fig.1 Static and Dynamic process control basic concept r Fig.2 TSC reading by sublance a 97
2 3.4 MS06-03 pp /6/06 6:44 pm Page 98 r Fig.3 Typical sublance layout measurements are used for analysis purposes and feedback into the control model. HISTORY OF SUBLANCE DEVELOPMENT Danieli Corus has designed, manufactured and developed the sublance system since After the first installation at the Corus IJmuiden site, and later on through the execution of sublance projects for clients all over the world, the design has improved and become a reliable and valuable tool in basic oxygen steelmaking. Today, with more than 55 sublance systems sold, Danieli Corus is very experienced in the implementation of the system in both existing and new BOF shops. SUBLANCE HARDWARE The sublance system consists of five main components: 98 r Fig.4 Automatic probe charger ` A slewing platform or side shift car equipped with a winch for raising and lowering the sublance body, which is attached to the platform or car ` An automatic probe charger with the probe storage chamber (see Figure 4), for automatic selection and attachment of probes to the sublance ` Probes of various types to suit local needs (see Figure 5) ` The equipment on or above the hood of the converter, such as a water cooled entrance port, a seal cap and a skull removing device (see Figure 6) ` Electrical and instrumentation equipment, such as the
3 3.4 MS06-03 pp /6/06 6:46 pm Page 99 STEELMAKING r Fig.6 Seal cap/skull remover r Fig.5 Various probe types developed over the years (courtesy Heraeus Electro-Nite) Digital Interpretation and Registration Computer (DIRC) for resgistering and interpreting the measurements, which is connected to a programmable logic controller serving as a connection means to the computer systems in the BOF control room (see Figure 7). The SDM, initially developed by Corus in 1958 and continuously improved since then, provides an accurate coverage of the steelmaking process from hot metal and scrap preparation to ladle alloying. The model is based on thermodynamic and metallurgical principles and is tuned continuously by means of statistical techniques. It has been designed to work with or without the sublance, bottom agitation and waste gas analysis. It also supports all common blowing control and tapping practices. A metallurgical model forms the heart of the SDM and all inputs and outputs are handled by a database system. All parameters and variables are defined within the database structure and are accessible through a user interface. The set points and actual values from the steel plant are also communicated through the database. The SDM system is client-server based, and is installed on standard Microsoft Windows-operated PC hardware. An Oracle database forms the heart of the system. Communication with common database architectures (ANSI SQL, ODBC) and control hardware (Siemens, Allen r Fig.7 DIRC-5 hardware Bradley/Rockwell, GE Fanuc) is supported (see Figures 8 and 9). A typical operator screen is shown in Figure 10. Based on hot metal samples and the required composition and temperature of the steel at the end of the process, the model performs the following calculations: ` Process aim ` Desulphurisation ` Ordering ` Blowing ` Dynamic control ` Second/re-blow ` End-of-blow verification ` Ladle alloying ` End of heat, model feedback calculation The following plant operations are performed simultaneously or in close relationship to these calculations: a THE STATIC DYNAMIC CONTROL MODEL (SDM) 99
4 Other BOF PLC s BOF Level 2 Process Control System r Fig.8 SDM-control equipment Plant Network Sublance PLC Connection to the External Network DIRC Office Network HMI Workstations in BOF Control Room DIRC PC improves converter productivity by up to 25% assuming that a sufficient amount of hot metal can be delivered to the BOF shop. For greenfield sites this can result in a capital expenditure reduction of up to 10% owing to the need for a smaller building, overhead cranes, vessels and ladles. For retrofitted plants an increase in output can be obtained. Under optimum circumstances, project execution times as short as months from contract award to acceptance test can be achieved. Such systems were implemented in operating shops without any noticeable interference to production. Improved process efficiency This is obtained through the following: BOF Level 2 Process Control System Client Workstations (OWS & PWS) SDM Server PC BOF PLC(s) r Fig.9 Typical sublance control system layout SUBLANCE PLC ` Ladle filling and hot metal desulphurisation ` Charging ` Blowing ` Measurements and sampling ` Addition of coolant and fluxes ` Tapping DIRC Application of the model results can either be performed automatically or through operator advice via the humanmachine interface. The model is comprehensive with respect to all aspects of the BOF process. BENEFITS OF THE SUBLANCE AND SDM Improved tap-to-tap time and productivity As the system eliminates the need for manual sampling and temperature measurement this saves time and reduces personnel requirement. A reduction in tap-to-tap time of over 15% is generated by the elimination of the need to tilt the converter for sampling and measurement and so ` Greater accuracy of end point temperature achievement ` Greater accuracy of end point carbon achievement ` Reduces the number of re-blows ` Decreases Fe content in slag ` Increases converter lining life ` Optimises scrap melting Improved working conditions Working conditions for steel plant crews are significantly improved by the elimination of the need for manual sampling. Samples are delivered automatically at the operator control room elevation, allowing the operator to keep away from the unpleasant and dangerous environment of a tilted converter. For normal operation, the sublance is operated from the main control room, however for maintenance purposes it can be operated manually from the automatic probe charger position, the maintenance position or from the winch platform (or side-shift car). The system, where physically possible, features a maintenance position which allows the sublance body to be lowered to the operating floor for easy maintenance on the probe holder. This feature significantly increases overall availability of the system. The automatic probe charger is positioned away from the converter hood in a more operator-friendly environment. Vital elements of the system are positioned such that they remain unexposed to circumstances jeopardising the integrity of the elements. Process cost reduction Through the application of the sublance and SDM, consumption of hot metal, fluxes, oxygen and energy is optimised. For well operated plants, 100
5 STEELMAKING Table 1 illustrates typical improvements. Consumable Change Hot metal Reduced by 10kg/t Scrap Increased by 10kg/t Oxygen Reduced by 1.0 standard m 3 /t Aluminium Reduced by 24kg/heat Ferro manganese Reduced by 60kg/heat Energy Equivalent to 20 C r Table 1 Raw material savings with sublance Converter lining life Process optimisation and the elimination of the tilting practice can increase in lining life by up to 40% without applying the slag splashing practice. Speed and accuracy Sublance measurement results are available approximately four seconds after the measuring probe enters the steel bath. Accuracy of the DIRC system handling the sublance measurements including analogue inputs, cold junction compensation, linearisation and evaluation is: ` < 0.2 C for bath temperature ` < 0.2 C for solidification temperature ` < 0.3mV for oxygen ` < 3cm for immersion depth Availability Good availability of all parts of a steel plant are essential, especially when linking with continuous casters and in-line rolling mills. The overall availability of the sublance system has proven to be very high and availabilities in excess of 98% have been met in the systems installed at various plants. (Availability of the sublance is expressed as the percentage of the probe immersions delivering measurements of a sufficient quality for the DIRC to be able to present solid results.) The high availability figures result from the continuous improvements made through extensive plant experience in many projects. HITTING RATES AND MODEL PERFORMANCE The hitting rate describes the performance of the model in terms of how many times the end-of-process bath temperature and carbon content are within a (low tolerance) window around the desired values (see Figure 1). The Danieli Corus SDM model in combination with the Danieli Corus sublance can perform at hitting rates over 90%, provided that the plant is well operated and the qualities of the hot metal, scrap and additives are within specifications. Model performance can be summarised through standard deviations of the essential end product parameters, based on the difference between the targeted or predicted and the actual values as illustrated in Table 2. r Fig.10 Typical operator screen Parameter Standard deviation Temperature 7 C Carbon content 0.018% Phosphorous prediction % Manganese prediction 0.015% r Table 2 SDM performance based on end point results CONCLUSIONS The sublance and SDM provide steelmakers with a proven tool for dynamic control of the BOF steelmaking process. Production will increase in existing plants and new BOF shops can be erected at reduced capital cost. Steel quality is improved and at a reduced overall cost per tonne. The implementation of the sublance and SDM will help meet increasingly stringent government restrictions with respect to emissions and help create a better working environment. The system is versatile and is proven around the world, especially in recent years in China, where steelmakers such as WISCO, BISCO, Meishan (Baosteel Group), Jigang, Xing Cheng, Xiangtan, Tonghua I&S, Tiantie I&S, Handan I&S, Maanshan I&S, Anyang I&S and Beitai I&S now rely on the superior sublances and SDM supplied by Danieli Corus. MS Gert Jan Apeldoorn is Manager Sales and Peter Gootjes is Project Manager, both at Danieli Corus, IJmuiden, The Netherlands CONTACT: Gert-Jan.Apeldoorn@danieli-corus.com 101
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