FMF – Flexible Modular FurnaceFlexible Steelmaking with FMF

FMF – Flexible Modular Furnace

Tommaso M. Sarpietro

“START UP” AND STAND UP” INDIA FROM MINES TO STEEL

30th January 2016, Ranchi

CONTENTS

Introduction

� Market Scenario (India – China)� Market Scenario (India – China)

� Global Scenario

FMF

� Base Module Mechanical Equipment

� Add On Module Mechanical Equipment

� Base Module Process Philosophy

Conclusions

SIDE VIEW

INTRODUCTION

FMF (Flexible Modular Furnace) was born from Tenova experience on EAF

and Hot Metal steelmaking practices in China.

The combination of the two experiences guided Tenova toward a unique

flexible steelmaking technology

In the market the usage of hot metal in EAF is a common practice in order

to be competitive in the current scenario (A)

Steelmaking is clearly moving toward more environmentally friendly and

less energy intensive processes (B)

MARKET SCENARIO (INDIA – CHINA)

less energy intensive processes (B)

Raw material and energy variability will remain a

major condition in the medium term (C)

Starting from 2025 scrap availability will increase

together with the share of EAF based production (D)

TODAY THE MARKET NEEDS A TECHNOLOGY

THAT CAN WORK EFFICIENTLY AS A

“CONVERTER”

A

MARKET SCENARIO (INDIA – CHINA)

IN THE FUTURE MARKET WILL LIKELY SEE A

SUBSTANTIAL SHIFT TO A FLEXIBLE TECHNOLOGY

READY TO WORK FROM 100% HM, TO 100% SCRAP,

TO 100% DRI

B + C + D

A + B + C + D

MARKET SCENARIO (INDIA – CHINA)

THE MARKET NEEDS A FLEXIBLE TECHNOLOGY

THAT:

�IN THE SHORT TERM CAN EFFICIENTLY WORK WITH

HIGH PERCENTAGE OF HOT METAL

�IN THE LONG TERM CAN EFFICIENTLY WORK WITH

DIFFERENT RAW MATERIALS

INTRODUCTION – GLOBAL SCENARIO

Raw material price volatility and steel market saturation are the main

conditions to be faced by steel makers worldwide in the medium term.

In this scenario Tenova FMF works efficiently with full a range of raw

material:

�0-90% Hot Metal�0-90% Hot Metal

�0-100% Scrap or DRI

90%

Hot Metal

100%

Scrap

100%

DRI

FMF

FMF - FLEXIBLE MODULAR FURNACE

BASE FURNACE

MINICONSTEEL (Option Scrap)

Base Module

CHEMICAL

POWER ONLY

Add on

ModulesConverter

Mode Scrap Mode

DRI Mode

CORE

EQUIPMENT

MODULAR DESIGN

INNOVATIVE ROOF (Option DRI)

INNOVATIVE LOWER SHELL

INNOVATIVE LIFT AND SWING

SYSTEM

FUME ANALYZER CONSTEEL

EXTENSION MODULE

(Option Scrap)

POWER ONLY

HM TILTING DEVICE

WITH WEIGHING

SYSTEM

INNOVATIVE

LAUNDER

DESIGN

ELECTRICAL

POWER MODULE

TDR+HRR ELECTRODES

AUTOMATION MODULE

FMF - FLEXIBLE MODULAR FURNACE

iEAF® - iSTEEL®

Temperature and Sampling Device

Electrode Automatic Changing device

Add on Modules

HIGH EFFICIENCY EBT Restoring ModuleProcess Efficiency

&Safety

HIGH EFFICIENCY MODULES

Door cleaning Module

Add on Modules

ENERGY

Heat recovery system

iRecovery

220 kg/tls

FMF BASE MODULE – MECHANICAL EQUIPMENT

KEY FACTORS:

1.Foundation design

2.Chemical power only – Multi point injection philosophy

3.HM tilting device

4.Innovative launder design

5.Miniconsteel module as a temperature regulator

6.Innovative roof design

7.Innovative lower shell design

8.Innovative lifting and swinging system design

9.Fume analyzer

FMF BASE MODULE – MECHANICAL EQUIPMENT

SIDE VIEW

SIDE VIEW

FMF BASE MODULE – MECHANICAL EQUIPMENTMULTY POINT INJECTION SYSTEM

O2 Injector

+

C Injector

O2 Injector

+

C Injector

Continous Scrap Feeding

Consteel ©

Continuous

DRI Feeding

LOWER SHELL

NEW DESIGNO2 Injector

+

C Injector Continuous

Hot Metal

Feeding

Consteel © DRI Feeding

SIDE VIEW

FMF BASE MODULE – MECHANICAL EQUIPMENTMULTY POINT INJECTION SYSTEM

TENOVA KT oxygen injectors shrouding flame technology.

•The supersonic oxygen stream is protected by a low-energy annular flame that

greatly reduces drag on the supersonic jet and allows greater effective lancing

distances (about 65 times the exit diameter of the nozzle, compared with about 20 times achievable with standard convergent-divergent nozzles without

shrouding flame). •Exit speed of the oxygen jet exceeds MACH 2.

•Oxygen injectors having higher rated flows generate longer and more effective jets, this means get better efficiency and generate stronger stirring for the steel jets, this means get better efficiency and generate stronger stirring for the steel bath

SIDE VIEW

FMF BASE MODULE – MECHANICAL EQUIPMENTHOT METAL TILTING DEVICE

SIDE VIEW

FMF BASE MODULE – MECHANICAL EQUIPMENTINNOVATIVE LAUNDER SYSTEM

SIDE VIEW

FMF BASE MODULE – MECHANICAL EQUIPMENTMINICONSTEEL® AND NEW ROOF DESIGN

MiniConsteel ®

as

Temperature

Regulator

New Roof

design

FMF ADD ON MODULE – MECHANICAL EQUIPMENT

SIDE VIEW

KEY FACTORS:1.Electrical module to be implemented2.Hydraulic unit module for electrode regulation to be implemented3.Consteel ® as a continuous charging and preheating system4.Consteel ® hood as a “standard” Tenova scrap preheating system

SIDE VIEW

FMF – MECHANICAL EQUIPMENTINNOVATIVE LIFTING AND SWINGING SYSTEM

SIDE VIEW

FMF – MECHANICAL EQUIPMENTINNOVATIVE LIFTING AND SWINGING SYSTEM

SIDE VIEW

FMF – BASE MODULE PROCESS PHILOSOPHY

CONTINUOUS RAW MATERIAL FEEDING:

Process control in FMF converter mode is based on continuous material feeding

as main process control philosophy. In this way it is possible to control the typical

issues that occur with high Hot Metal Processes (jamming, splashing, etc..)

HOT METAL TILTING DEVICE :

The continuous charge of HM into the furnace give the possibility to better control the bath reactivity that

Is one of the main concern for this kind of process (by reducing temperature gradients, chemicalIs one of the main concern for this kind of process (by reducing temperature gradients, chemical

gradients, etc.)

MINI-CONSTEEL® /DRI FEEDING:

Continuous scrap/DRI charge into the furnace gives another tool to control the

bath temperature and the process reactivity.

DEPHOSPHORIZATION:

As we said it is possible to control and continuously tune the bath

temperature. Thanks to a typical EAF slag door de-slagging during process

time is a kind of standard practice in this condition.

Considering the above mentioned practices it is possible to minimize the P

reversal to the slag and so improving the dephosphorization practice.

FMF – BASE MODULE PROCESS PHILOSOPHY

Effect on Bath Temperature and Carbon

Tilter charging reduces amplitude of bath Carbon and

Temperature trends allowing a more stable and quicker

process

Temperature Carbon

Workshop Session – EAF Heat Recovery System

21

SIDE VIEW

FMF BASE MODULE – BASE MODULE PROCESS PHILOSOPHY

REFERENCE PLANTS

High HM feeding plants supplied

By Tenova

• 250 t Wheeling Pit USA - 2004• 160 t Vallourec Sumitomo Brazil• 4 x 100 t Bhushan India• 100 t Shaoguan China• 100 t Shaoguan China• 70 t Echeng China• 75 t Hengli China• 75 t Xining Special Steel China• 60 t Xining Special Steel China• 2 x 100 t TPCO China • 65 t Tonghua China• 100 Raighar India

SIDE VIEW

FMF BASE MODULE – BASE MODULE PROCESS PHILOSOPHY

REFERENCE PLANTS

Reference 1 Reference 2 Reference 3 Reference 4

Tapping size 100t 75t 60t 100t

Hot Metal % 86 90 90 87

Scrap % 14 10 10Scrap % 14 10 10

DRI % 13

O2 Capacity 3 x 38003x3200 +

1x3000

2x3200 +

1x10004x3200

Average TTT 38 min 48 min 53 min 40 min

Yield 92.5% 92% 90% 88%

Year 2009 2013 2014 2015

- Capacity: 100 T tap, 130 T total

- Furnace Diameter: 5.5 M, EBT

- HM Charge: 85%, Coal based DRI – 15%

-Oxygen lance: 4 x 3000 Nm3/h Wall

-Transformer rating: 100 MVA

- Tap to Tap time: 42~45 (no electric)

JSPL RAIGARH

- Heats per day: 32~34, record 42 heats in a day.

-Average O2 consumption: 55-60 Nm3/tls

-Yield : 88%

Workshop Session – EAF Heat Recovery System

JSPL RAIGARH

Conversion cost reduction: 1200 Rs/tlsAnnual saving: 120 Cr per yearRefractory life: 900+ heats

Workshop Session – EAF Heat Recovery System

JSPL RAIGARH

Conversion cost reduction: 1200 Rs/tlsAnnual saving: 120 Cr per yearRefractory life: 900+ heats

42 heats record

Workshop Session – EAF Heat Recovery System

SIDE VIEW

FMF BASE MODULE – BASE MODULE PROCESS PHILOSOPHY

PRODUCTIVITY FIGURES

SIDE VIEW

CONCLUSION

� FMF (Flexible Modular Furnace) is a flexible solution able to adapt to

different and volatile scenarios (HM scenario, Scrap scenario, DRI

scenario) by adding and/or removing the different modules.

� FMF Base Module is a solution developed starting from Chinese

experiences and now ready to face the transition from Oxygen Steelexperiences and now ready to face the transition from Oxygen Steel

making to EAF steel making

� FMF Base module can be a “low investment”

revamping solution for steelmakers that invested in EAF

technology to face a scrap (or DRI) scenario that now

must change to HM scenario.

� Tenova is a worldwide supplier of advanced

technologies, products and engineering services

for the metals and mining & minerals industries

providing innovative, integrated solutions for complete

process areas

� Being part of an industrial group – Techint Group –

shapes our mindset to understand the needs of a

customer better than others

Tenova Group

29

Techint Group

Six main companies operating worldwide

• Annual Revenue

Over US$ 26 billion

• Permanent Employees

Tenaris

42%

Techint

Engineering &

Tenova

7%

Tecpetrol

5%

Humanitas

3%

Techint Group Presentation 30

• Permanent Employees

59,000

• Total Employees

87,000

Ternium

32%

Engineering &

Construction

11%

SIDE VIEW

Thank you !!!Thank you !!!