Improving EAF productivity by PasekTap EBT Sand Customized size distribution Laboratory testing & industrial application
Index: PASEK Introduction PasekTap optimization model for EBT Sand: Lab test for product adjustment Product development for each customer Industrial scale CONCLUSIONS
Spanish company founded in 1971. Working from the beginning in the Steel Industry. Continuously adapting to the steel plants necessities: In the refractory sector In the fluxing industry
+ 500 employees REFRACTORIES
(%) MgO 37.2 SiO 2 40.7 Fe 2 O 3 8.3 Al 2 O 3 2.4 CaO 1.8 One of the largest Magnesium Silicate deposits in Europe. Mine concession for 90 years, started operations in 1972. Na 2 O + K 2 O < 0.2 PPC 9.2 Very close to the harbor (8Km). 1 Mton / year production; reserves over 600 Mton. Over 26 Mton of Dunit@ already extracted.
Pasek MineraleS product portfolio Pasek MINERALES Product Portfolio Industry Application Product Market Grain Size Big Market Sinter/ BF/BOF Flux Dunite Spain Lumps (> 10mm) EAF TapHole sand Dunite Calcined EU MiniLumps (<10mm) Rockwool Raw material Silica North America Fines (<3mm) Distribution Refractory Sand Dolomite South America EBT (>1, <6mm) Fertilizer CO2 capture Limestone Russia/Eastern EU AFAs(micron) Fluidized bed Middle East/Africa Rock (>80mm) Foundry Asia / India Customized Ceramics Sandblast
Pasek MineraleS customer portfolio US & Canada ArcelorMittal BlueScope Nucor (7 plants) SDI (2 plants) Gerdau (1 plants) Republic Steel NLMK EU & Russia ArcelorMittal (13 plants) Tata Ijmuiden Salzgitter Thyssenkrupp-HKM Rogesa-Dillinger Hütte Saint-Gobain PAM Arvedi Celsa ( 5 plants) Ilva Taranto Megasa ( 3 plants) Beltrame( 3 plants) Salzgitter Peine, Feralpi, Lsw, Thuringen RIVA, Pittini, Ovako, Metalloinvest, OMZ, Yartsevo ASIA GUNUNG GARUDA REFRASERVICE Central & South America ArcelorMittal (2 plants) Ternium Gerdau (3 plants) Andec Arequipa Simec MENA ArcelorMittal ( 1 plant) Maghreb Steel Ezz Steel Emirates Qatar ( Sabic ( in development) 17
Index: PASEK Introduction PasekTap optimization model for EBT Sand: Lab test for product adjustment Product development for each customer Industrial scale CONCLUSIONS
EBT sand operation principle
EBT SAND TARGETS 3 main objectives Excelent free opening No slag/steel leaks Large lifespan of the tap hole
EBT SAND TARGETS Sand: 3 main objectives Excelent free opening No slag/steel leaks Large lifespan of the tap hole Grain size customized Quality control Material Hardness Process: Filling method Quantity of sand used Tap Hole lifespan
EBT SAND TARGETS Sand: 3 main objectives Excelent free opening No slag/steel leaks Large lifespan of the tap hole Dry Angulosity of the material Grain size Process: Tap hole cleaning Gap sliding gate/tap hole Tap Hole lifespan
LAB TEST: PRODUCTS 3 main objectives Excelent free opening No slag/steel leaks Large lifespan of the tap hole Sand: Chemical Grain size Process: Dimensions of the Tap Hole
LAB TEST: TECHNICAL DATA INVOLVED IN GRAIN SIZE RECOMMENDATION EAF PARAMETERS 1 6 mm 3 6 mm Calcined 2 6 mm Furnace temperature > 1650 º < 1650 º >1600 º Variations of the temperature >7 % < 7 % > 3 % Inclination of the furnace > 5 % < 5 % > 3% Furnace capacity > 120 mt < 120 mt > 80 mt Tap to tap > 45 min < 45 min > 38 min Variations of the tap to tap > 15 % < 15% > 10 % Soaking plane > 40 min < 40 min > 25 min Tap hole diameter > 200 mm < 200 mm > 180 mm Tap hole filling method Manual Hopper/neumatic/silo Hopper/neumatic/silo Number of heats of the tap hole before > 120 < 120 > 80 reparation/substitution Tap hole cleaning frequency < 1 per day > 1 per day > 1 per day Separation between tap hole and sliding gate < 10 mm > 10 mm > 10 mm
LAB TEST: PRODUCTS 1-6 mm 3-6 mm Calcined 2-6 mm 45 % market share 50 % market share 5 % market share
LAB TEST: SIMEBT Tap hole simulation PREHEATING EVOLUTION
LAB TEST: GLASSY PHASE A) B) C)
Temperature measurements LAB TEST: SIMEBT 2500 Temperature progress 2000 T ºF 1500 1000 T1 T2 T3 T4 500 0 1 11 21 31 41 51 61 71 81 91 101 111 121 131 141 151 161
Industrial scale trial Controlled industrial test Technical assistance during the initial tests of the product After-Sales Service: Technical and delivery support Continuous improvement process support > 300.000 heats in 2016 with > 97 % free opening
Ladle sand Started in 2107 Customized per customer 70 % of spanish market in 7 months Cr, Si and C blend Supervision of customer procedure 2
Customized ladle sand Acería 1 Acería 2 Acería 3 Acería 4 Acería 5 Acería 6 Acería 7 Ø Buza 45 mm 45mm 55 mm 55 mm 80 mm 45 mm 55 mm L Buza 650 mm 220mm 380 mm 270 mm 320 mm 270mm 220 mm Cantidad Acero 98 t 110t 130 150 t 130 t 300t 122 t 135 t Calidad acero princial S355 JR Cantidad Arena 10 kg 40 60kg 20 30 Kg 15 kg 40 kg 10 kg 30 40 Kg Ø Tronco cono 140mm L Tronco cono 300mm No tiene No tiene No tiene No tiene Temp. precalentamiento NO SI (1200ºC) SI (900ºC) Vesuvius SI/ Sokao NO 1100 ºC NO Temp. Proceso 1540 1585ºC 1690ºC 1540 1670ºC 1640 ºC 1570 ºC 1620 1640ºC 1595 1615ºC Tiempo medio proceso 60' 180' 60 90' 50' 120' máx 40' 45 50' Material buza Al2O3 + C Al2O3 + C Al2O3 + C MgO + C FO (%) 99% 97 98% Proveedor 1: Comp. Arena 1 (%) Granulometría arena 1 (mm) SiO2 25,06 19,93 11,4 16,37 20,63 arena 66% 42,38 Cr2O3 34,89 36,75 37,37 38,65 37,42 arena 30% 26,3 C 0,44 0,32 0,47 0,42 0,19 arena 4% 0,53 1 2,4 0,7 3,4 0 5,6 0 1,9 0,8 1 1,4 7,5 6,9 3,7 1,5 >0,5mm 3% max 9,6 0,4 08 21,9 29,7 15,7 11,3 31,7 0,2 0,5 mm 30 35% 0,1 0,2mm 55 60% 40,2 0,18 0,4 63,7 50,1 60,4 68,4 59,6 <0,1 mm 2% max 42,9 <0,18 12,4 9,4 17 11 7,2 5,4 Average free opening 99 %
Thank you PASEK Dunit@ Value in Use improve evacuation ban Ruisanchez ban.ruisanchez@pasek.es k@pasek.es 648793878