Metals Technologies SIMETAL EAF FAST DRI The future of DRI melting www.siemens-vai.com
Local solutions for global demands 80 70 70.7 Mt 60 0 40 0 20 10 0 1970 1980 1990 2000 2010 HDR HBI CDRI Latin America Middle East/North Africa Asia/Oceania Rest of the world 14.0 Mt 10.1 Mt 8.8 Mt 6.0 Mt 8.9 Mt Increasing world DRI production Middle East, Latin America, and Asia are the leading DRI producers. Your challenge The world needs steel. Particularly in newly industrialized countries, the demand for structural steel is growing at a tremendous rate and these countries want to replace costly steel imports with local steel production. Regions that have easy access to gas are predestined for steel production using DRI, in either cold or hot conditions. The Middle East region is perfectly suited for DRI production, because abundant gas resources along with comparably low gas prices are the cornerstone of successful DRI-based EAF steelmaking. Other regions around the world also have a growing DRI-based EAF steel production: DRI can also be produced in a coal-based process. Today s market requirements: Growing demand for steel High gas resources in regions like the Middle East resulting in easy DRI-based steelmaking Weak power grids requiring the highest flicker compensation to ensure best power quality The need for sustainable steel production Use of local iron-ore resources To decrease conversion costs and receive an attractive ROI, the challenges are: Easy DRI access Reduced operational expenditures High productivity and efficiency Totally integrated automation Better steel quality 26 7 9 1 11 6 64 117 Cumulative production In trillion m³: Resources 1 16 16 7 2 Reserves 8 9 7 Reserves: 191.9 trillion m³ (=247.9 Gt SKE) Production:.0 trillion m³ (=.9 Gt SKE) World gas resources 2
Highly productive and low-cost DRI-based EAF steelmaking Increases productivity by 10% Our solution SIMETAL EAF FAST DRI provides a continuous DRI melting process. There is no need to stop electric power input or the DRI feeding during tapping: Tapping and tap-hole refilling are performed under power-on conditions. This achievement is possible thanks to a revolutionary mode of shell movement combined with FAST, a slag-free tapping system. Siemens VAI developed its new SIMETAL EAF FAST DRI as an improved DRI-based EAF process that can meet the growing demands of DRI-based steelmaking. Due to its improved shell design and extensive liquid heel operation, the DRI melting process is much more efficient. In addition, slag carryover is reduced to an absolute minimum as a result of its siphon-type tapping channel design. Thanks to its sophisticated modernization concept, even existing furnaces can benefit from the major improvements of the FAST DRI system. To boost productivity even more, it is possible to use hot DRI with the FAST DRI system. Therefore, the hot link our own development feeds the DRI at a temperature of 600 C to the EAF. The development of the SIMETAL EAF FAST DRI is the outcome of our extensive experience and expertise with the DRI process, and confirms Siemens VAI as the world s leaders in DRI EAF technology. Advantages of SIMETAL EAF FAST DRI, based on cold DRI: 10% shorter tap-to-tap times Virtually no power-off times thanks to FAST tapping Non-stop DRI feeding Tapping and taphole refilling during power-on 20 kwh/t less energy consumption 10% less electrode consumption 10% higher productivity with a 10-ton EAF Slag-free tapping for better steel quality Lower consumption of ladle additions and refractory Higher alloy yield and better desulfurization Reduced temperature loss Lower tapping temperature
Boost your profits with FAST as a new solution or modernization FAST in working position FAST in tilting position FAST in new installation The SIMETAL EAF FAST DRI enables DRI melting in a large hot heel, which results in a pure flatbath operation. The process is characterized by continuous DRI feeding, efficient and process-related oxygen and coal injection, foaming slag control by means of roof lances, and eliminates the need for the installation of additional burner power. In combination with the furnace advanced slag-free tapping system (FAST) with a siphon design for slag-free tapping, the new furnace concept permits feeding, tapping, and taphole refilling during power-on continuous DRI. In addition, the continuous input of electrical energy not only improves productivity, it is also important for the energy infrastructure with respect to flicker problems in the region s power grids. The nearly constant heat load extends refractory durability and minimizes equipment wear through reduced thermal stress. All of the advanced technologies just described for Siemens VAI s new SIMETAL EAF FAST DRI will result in lower capital and operational expenditures for your plant. FAST for your existing EAF Increase the efficiency and productivity of your existing EAF. Due to an EAF modernization which is replacing the existing lower shell, you can get the opportunity of the furnace advanced slag-free tapping system (FAST). It is not necessary to replace components like the roof, electrode-supporting arms, and dedusting system. With a new lower shell and FAST, the furnace can achieve higher productivity levels with a similar input of energy. Another option is to reduce energy input and still obtain similar productivity and improved efficiency. If you modernize your existing EAF with Siemens VAI s new technology, not only will your productivity and efficiency grow, your overall capital and operating expenditures will be reduced accordingly. 4
Competence in DRI melting ELECTRICAL POWER INPUT DRI Feeding (kg/min.mw) MW 100 1 heat OXYGEN INPUT Nm³/h,000 80 4,000 60,000 40 2,000 20 1,000 0-10 - 0 10 1 20 2 0 40 4 0 60 TIME (min) Elec. Energy DRI O₂ Lance 0 Feeding, tapping, and taphole refilling under power-on conditions Leading position in DRI-EAF technology 1 2 4 6 10 8 9 = EAF DRI = EAF 11 7 1 2 4 6 7 8 9 Rocky Mountain Steel, Pueblo, U.S. Altos Hornos de Mexico S.A. (AHMSA), Monclova, Mexico HYLSA, Monterrey, Mexico HYLSA, Puebla, Mexico Egyptian Sponge Iron & Steel Company ESISCO, Sadat City, Egypt Suez Steel, Suez, Egypt Scaw Metals, Johannesburg, South Africa National Steel Company Ltd./NASCO, Dammam, Saudi Arabia Qatar Steel, Mesaieed, Qatar 10 11 Saudi Iron & Steel Company EAF 1, Al Jubail, Saudi Arabia Saudi Iron & Steel Company EAF 2, Al Jubail, Saudi Arabia Saudi Iron & Steel Company EAF, Al Jubail, Saudi Arabia Saudi Iron & Steel Company EAF 4, Al Jubail, Saudi Arabia Saudi Iron & Steel Company EAF, Al Jubail, Saudi Arabia Krakatau EAF, Cilegon, Indonesia Krakatau EAF 6, Cilegon, Indonesia Krakatau EAF 7, Cilegon, Indonesia
Competence Center: Siemens VAI Metals Technologies GmbH Reithallenstr. 1 7771 Willstätt-Legelshurst, Germany Phone: +49 782 4100 Fax: +44 782 41141 E-mail: electricsteelmaking.metals@siemens.com Headquarters: Siemens VAI Metals Technologies GmbH P.O. Box 4, Turmstr. 44 401 Linz, Austria Phone: +4 72 692-0 Fax: +4 72 6980-0 E-mail: contact.metals@siemens.com www.siemens-vai.com Order No. E10001-M-A14-V1-7600 Dispo No.: 21661 K-No.: 2810 Printed in Germany GB 111112 PP 11111. 11.2011, Siemens AG The information provided in this brochure contains merely general descriptions or characteristics of performance which in actual case of use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. All rights reserved. Subject to change without prior notice. SIROLL and SIMETAL are trademarks of Siemens AG.