Abu Dhabi, United Arab Emirates Capacity Enhancements and new Developments at Emirates Steel Appala Naidu Poodi Manager- Direct Reduction Plants
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 2009. 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 2012. 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 Plants 3.8 Million TPA HYL Technology Pneumatic Transfer of hot DRI@ 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 5.5-16 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
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.
D.R. Plants Capacity Enhancement & Modifications Installed Higher Capacity Pneumatic Transport Compressor. Operating Capacity Operating Pressure 22500 Nm3/Hr 7.18 Barg Installed Higher Capacity Cooling Gas Compressor. Operating Capacity Operating Pressure 210000 Nm3/Hr 6.06 Barg Installed additional Oxygen lances to increase Oxygen flow. Operating Capacity Operating Pressure 4500 Nm3/Hr 13.0 Barg
DRI PRODUCTION Year 2009 2010 2011 2012 2013 DRI Production in Metric Tons 143,535 1,104,250 2,166,976 2,717,520 3,074,013 3500000 DRI PRODUCTION (MT) 3000000 2500000 2000000 1500000 1000000 2009 2010 2011 2012 2013 500000 0 2009 2010 2011 2012 2013
DRI Plants Performance Highest Yearly Production : 1602000 MT (Phase-2, FY 2013) Highest Monthly Production : 156473 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 : 4500 Nm3/Hr Reactor I/L Temp. : 1010 Deg C Bed Temps : 920-930 Deg C Feed Mix : SAMARCO: 50 %, VALE : 30 %, LKAB : 20 %
Hot DRI EAF HDRI Temp @ EAF : 534 Deg C Quality : Metallization : 95.34 % Carbon : 1.96 %
D.R.I. Quality CHEMICAL ANALYSIS % Fe Total 92.09 Fe Metallic 87.8 Metallization 95.34 Carbon 1.96 SiO2 1.58 Al2O3 0.72 CaO 0.915 MgO 0.28 Sulfur 0.005 Phosphorus 0.048
Process Impact of Carbon % on HDRI Temperature Sr no. Prodn Rate NG to Reactor Metn Carbon HDRI temp @ EAF Bins ton/h NM3/Mt % % DegC 1 265 73 94.54 2.60 403 2 255 68 95.64 2.56 445 3 255 62 95.18 2.26 465 4 255 55 94.78 1.93 488 5 255 57 94.94 2.04 496 6 255 59 94.49 2.04 498 7 255 61 92.86 1.89 489 8 255 61 93.67 1.97 489 9 255 57 95.51 2.03 505 10 250 55 95.41 1.98 527 11 250 57 95.92 1.91 527 12 250 57 95.08 1.77 533 13 255 61 94.66 1.81 541
CARBON % Vs HDRI TEMP. 600 550 HDRI TEMP vs CARBON Carbon : 1.81%, HDRI Temp.:541 DegC 500 450 400 350 Carbon : 2.60,% HDRI Temp.:403 DegC 300 250 2.60 2.56 2.26 1.93 2.04 2.04 1.89 1.97 2.03 1.98 1.91 1.77 1.81
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 36.81 min 31.69 min 390 KwH/Ton 36.87 Nm3/Mt 246.89 Ton/Hr
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
Effect of Carbon on EAF Power Consumption * Increase Carbon content of Hot DRI 0.1% will decrease power consumption 11 Kwh/t
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