The Safe Use of High Power in a DC Arc Furnace

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1 The Safe Use of High Power in a DC Arc Furnace Mark Trapp and Tony Gurley Nucor Steel, Berkeley PO Box 2259 Mount Pleasant, SC Telephone: Helmut G Oltmann LWB Refractories PO Box 1189 York, PA Telephone: Key Words: Power, DC Furnace, RTD, Slag Foaming INTRODUCTION Through the course of the last two years, average power used for melting, at Nucor- Berkeley, has been raised from 80 MW to above 120 MW, with peak power reaching levels as high as 154 MW. Difficulties encountered while running higher power included water-cooled shell (roof and sidewall) damage as well as decreased anode life. Through the use of an array of Resistance Temperature Detectors (RTD s) strategically located in the cooling system, visual observations and slag analysis coupled with mass balances, the occurrence of shell damage has decreased and the anode life has improved. Melting is accomplished using two, 160 MVA, DC furnaces supplied by Mannesmann GmbH. One furnace is equipped with two conventional water-cooled oxygen lances (3,500 scfm each), and the other furnace uses four, Praxair, CoJet lances (2,300 scfm each). DIFFICULTIES During the month of September 2000, the two furnaces shut down a combined 26 times to repair holes in either the sidewall or roof. The obvious safety concerns due to the water leaking into the furnace, plus the extensive downtime, warranted extensive study into the problem. Also, at this time, our anode life was averaging heats, well below industry standards. Roof and sidewall holes were often not discovered until melting was completed. Determination of when the holes occurred was nearly impossible. The holes varied in size from inches in diameter to several feet across. The damage seemed to appear more frequently toward the tap-hole side of the furnace, but was not limited to that area alone. Distinguishing between arc damage and oxygen lance damage was sometimes subjective, depending on who was running the furnace at the time and who did the repair. The installation of the RTD monitoring system was a major key in the troubleshooting process.

2 When average power began increasing, anode life dropped nearly in half. Typically, during a furnace change-out, the slag line would be replaced. Now, one slag line lasted for two anode replacements. Sister plants, Hickman and Darlington, were achieving anode life over 1,000 heats, with identical anode arrangements. The RTD s PROBLEM SOLVING TOOLS The RTD s were placed in the roof itself, as well as in the roof and sidewall water return lines. The tip of the RTD s in the roof extended downward into the depth created by the water cascading down the slope of the roof, toward the outer edge. The water collected here and was evacuated through several drain lines. Roof RTD s were appropriately named by their respective clock positions (Fig.1). T-5 and T-7 were located directly above each of the two, water-cooled lances. T-10 is above a burner on EAF #1. T-2, T-5, T-7 and T-10 are presently located above each of the four, CoJet burners on EAF #2. The difference between the outgoing and incoming water temperature was referred to as the delta T ( T). All temperatures and T s refer to degrees Fahrenheit. Trendlines of RTD behavior were used to develop warnings and alarms. An alarm will shut down the power and lances to the furnace. A warning was set to occur at a T of 10 degrees less than the alarm point. This allowed the operator time to react appropriately, by shutting 2

3 off a lance or burner corresponding to that particular alarm. Eventually, these corrective actions were incorporated into the furnace control logic. While the roof RTD s provided instant information regarding conditions in the furnace, the return line RTD s provided information of a different sort. Using the return line flow rate and T, an overall power loss number was calculated. When plotted over an eighthour time scale, the energy losses to the water-cooling provided the best indication of slag foaming and overall efficiency of operations. Visual Observations One of the greatest tools during any of the investigations and experiments was simply opening the roof of the furnace and observing what was happening at the time. This was true for both the shell holes and the anode problems. Occasionally, when a roof alarm persisted, a better determination of its cause could be made by opening the roof and inserting the lance, or by increasing the flow to a burner. Often this would reveal the offending power source. When this did not work, the furnace could be run with the roof slightly raised, revealing an arc-flaring problem. Any time there was damage to the roof or sidewall, operators sketched the damage in a book made up of blank drawings of the shell and roof. This helped identify patterns in the damage. One of the keys to determining when anode damage was occurring was by making observations of the scrap mound in the furnace at different times during melting. For example, changes were made in the scrap layering heat to heat. The roof was opened during each heat at 15,000 kwh and the melt pool was observed. This technique was also used to optimize bore-in power profiles. Slag Analysis and Mass Balances It is well known that proper slag chemistry and slag foaming are paramount to efficient operation of an electric arc furnace. When running at long arc lengths and high power levels, any breakdown in slag protection will result in damage to the roof and walls. The RTD system pointed out times during melting when we were not protected from the damage of the arc. Frequent analysis of the final slag taken prior to tapping provided a false sense of security. Only when looking at the slag during the entire melting process, did it become apparent that a dynamic slag model was needed as well as a dynamic flux addition system. The scrap mix at Berkeley consisted of nearly 50% pig iron and hot briquetted iron (HBI). The silicon/silica content of the HBI used was very consistent, however, the silicon content of the pig iron varied substantially from shipment to shipment. The flux usage hinged on the silicon content of the particular pile of pig iron being used that day. This change in fluxes associated with the pig iron chemistry directly affected the total amount of slag created each heat, therefore affecting arc coverage and water-cooled 3

4 energy losses. Also, the creation of slag directly impacted furnace yields. Large volumes of slag provided better arc coverage, but adversely impacted yields. A mass and energy balance was used to investigate possible reasons for anode damage. By evaluating the melt-pool size compared to the power-input rate, the maximum heel temperature achieved during the initial stages of melting could be determined. By not having an adequate liquid pool, extreme superheating of the steel in contact with the anode was possible. Scrap Layering SOLUTIONS Using a one-bucket scrap charge has advantages and disadvantages. Scrap layering was found to be extremely important. Not only was the layering in the scrap bucket critical, the dropping of the charge and how the layers fall and mix, during charging, can become an issue. In order to protect the roof, voltage, hence arc length, is calculated as a function of borein distance. The arc length and power increase only when the distance of bore-in reaches a safe value. As a result, the quickest way to increase power was to put a layer of busheling at the top of the scrap charge. Busheling is fluffy in density and can be quickly melted. When a deep bore-in was achieved quickly, power also increased quickly and this contributed to an increase in average power input. When dense scrap, such as pig iron or HBI, contacted the water-cooled sidewalls, it would form a large agglomeration, or skull. These skulls caused tremendous problems with, heel-size control, taphole free opening, burner and lance damage and scrap caveins. Visual observations concluded that it was necessary to keep these dense commodities as low in the charge bucket as possible, placing them below the watercooled shell and down into the liquid heel upon charging. The one extreme of layering light material at the top and dense material at the bottom created a different type of skulling. The arc energy was quickly focused low in the furnace, causing the upper portion of the furnace to become a cold spot. Plots of energy versus bore-in distance revealed how this was occurring. Figure 2 shows the plot of a charge that would typically exhibit skulling. Notice that most of the energy was inputted low in the furnace. Figure 3 shows the profile of the same scrap mix with a different layering scheme. Some of the busheling layer was broken up with some commodities of higher density. Notice the larger portion of energy higher in the furnace. 4

5 Slag Inventory RTD data proved that, while scrap protected the furnace from arc damage early and great foaming slag during flat bath offered protection at the end of melting, the furnace was vulnerable to damage in between these portions of melting. The solution was found to be twofold. The slag chemistry was critical as well as the total slag volume in the furnace. At the time, fluxes were added in the charge bucket using a surge hopper. The slag in the furnace was poured off completely prior to tapping. A mass balance revealed that the 5

6 slag was extremely basic early in the melting stage. Only at the end of the heat, when the silicon in the pig iron was melted in and oxidized and the iron oxide levels in the slag were higher, could we achieve slag foaming. Figure 4 shows an isostability diagram clearly demonstrating the extreme basicity of the initial furnace slag. The established practice was to pour off the slag completely before tapping (metal) and fluxes were all added to the charge bucket using a surge hopper. The initial slag is thus highly basic and would not foam well (See ISD in Figure 4). Through the course of the heat as more SiO 2 and FeO formed the slag became more fluid and at the end of the heat when the acidic and basic oxides were balanced the slag foaming would be good (Figure 5). Not only the overall slag balance is thus important, but also the transient changes in slag composition throughout the heat. The solution was to install a system that would feed the fluxes into the furnace at a rate proportional to the rate silica and iron oxide were being generated in the furnace. The goal was to keep the slag chemistry as consistent as possible during the entire melting operation. % MgO Slag as formed Slag+FeO %FeO+%MnO Figure 4: Iso-Stability Diagram for the slag formed B3=2.6 at an intermediate stage with an assumed oxide contribution of 40% of the total charge and 70% of the total flux. Slag formed will not foam or requires increase in FeO to 50% to reach foaming region. 6

7 % MgO Ideal final slag %FeO+%MnO Figure 5: Ideal foaming slag after all fluxes and oxides from charge are molten (B3=1.8) Plots of water-cooled energy losses still showed a pattern of increased energy loss during the initial portion of the heat. By experimenting and observing these plots it was determined that slag chemistry was not the only issue. Slag volume was also a problem. In a related effort to improve yields, pig iron silicon levels were lowered. This lowered the amount of slag being created each heat. With a clean slag-off every heat, the total slag in the furnace went from 50,000 pounds while running higher silicon pig iron, to levels as low as 28,000 pounds when running lower silicon pig iron. Yields were improved, but it was nearly impossible to run with high voltage. The answer was to carry-over slag from heat to heat. As long as the same fluxes were used, the steel quality was not affected. By performing a mass balance based on the lime addition, the total slag created each heat can be estimated. If it is assumed that the ideal slag volume in the furnace is 50,000 pounds, the difference can be made up with carryover slag. The carry-over slag acts both as a foaming slag early in the heat and a buffer to reduce variation in slag chemistry. Figure 5b shows that increasing the slag carry over (25000lb versus 5000lb) for the same dissolution rate of charge and flux, results in less deviation from ideal foaming composition. An example of a water-cooled energy loss versus time plot of two heats, one with a complete slag off and one with slag carryover can be seen in Figure 6. 7

8 % MgO Slag as formed Slag+FeO %FeO+%MnO Figure 5b: ISD of intermediate slag of B3=2.1 (40% charge and 70% flux) with lb of carry over slag reduced deviation from foaming region. Heel Size The major contributing factor to anode damage was determined to be superheating of the melt pool. At high power levels, with a one-bucket scrap charge, scrap must continually cave-in in order to prevent the melt pool from becoming too hot. With a small heel being carried from heat to heat, anything preventing scrap caving will make the pool susceptible to absorbing too much heat and reaching extremely high temperatures. Keeping a larger heel will act as an energy/heat buffer, to provide more even heat distribution without superheating and destroying the refractory. If high power is being used and the scrap is not being melted, due to bridging, all of the energy is going into the heel. This will allow the heel temperature to increase proportionally to the power being used. Then, a scrap cave will chill the heel back down as it melts into the bath. Figure 7 shows the effect of running on a heel and having a late scrap cave. It can be seen that the larger heel will prevent out of control superheating. Running with a larger heel has proven effective, increasing average anode life above 850 heats. CONCLUSIONS The use of RTD s, visual observations, slag analysis and mass/energy balances have been instrumental in learning the effects of high power levels on the EAF. The instances of damage have been significantly reduced, anode life has increased and energy losses have been reduced. Improvements in flux additions, scrap layering, and carryover of proper amounts of steel and slag have made the operation safer and more efficient. 8

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