PYREJETTM DESIGN AND INDUSTRIAL RESULTS

V. Shifrin, A. Popenov, L. Coudurier, M. Devaux Air Liquide

1 - INTRODUCTION

American Combustion, a division of Air Liquide, has developed PyreJet - a new

proprietary multi-functional burner/injection system for the Electric Arc Furnace (EAF).
The new PyreJet system combines the following operating capabilities:

Efficient oxy-fuel combustion for EAF operating conditions

Enhanced supersonic oxygen injection
Carbon fines injection
Useful post-combustion of CO

The results of several comparative installations show decisive advantages in the

following areas:

Reduction in electrical power consumption

Reduction in power-on-time
Increase in active power input
Increased oxygen efficiency
Reduction in injection carbon
Reduction of refractory wear

2 - PYREJET SYSTEM DESIGN AND OPERATING STRATEGY

2,1 PyreJet Design

The PyreJet system comprises multiple wall mounted injectors , which are installed in
several locations in the EAF to assist scrap melting and melt refining. The system can
combines Pyrejet multi-functional injectors and regular Pyrox burners (PyrOx and
PyreJet, US Patent Nos 4,622,007; 5,599,375; 5,788,921; 5,858,302).

. The PyreJet design gives not only the capability to melt and cut the scrap, but comprises
several additional features enabling this multi-functional tool to be used for the efficient
combined injection of carbon fines and supersonic oxygen to enhance slag foaming and
melt refining.

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The PyreJet utilizes water-cooled copper burner tiles, which have a deep combustion
chamber to control flame formation and flame shape. The combustion chamber also
protects the gas and oxygen discharge holes from plugging with splashed slag and steel.

The inner part of the Pyrejet can be quickly and easily disconnected and removed from
the combustor. This allows for on-the-fly burner change out, when necessary.

It is preferable that the PyreJet tool be installed in water-cooled copper panels. A typical
PyreJet installation is shown in Figure 1.

Figure 1 Typical PyreJet Installation

The PyreJet combustor is also equipped with a replaceable carbon injection pipe located
near the burner centerline. This allows carbon to be entrained and driven into the slag by
a highly inspirating supersonic oxygen stream.

2.2 Operating Mode

Each PyreJet burner / injector is engineered and designed to enhance the following
functions:

Oxy-fuel combustion
Supersonic oxygen lancing
Injection of carbon fines
Post-combustion of CO

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At the beginning of each charge, the PyreJet operate as regular oxy-fuel burners heating
the scrap located in the cold spots. After the scrap is preheated and partially melted in, the
fuel and oxygen flows are reduced and the central oxygen flow is increased to initiate soft
lancing in order to cut scrap in the more remote areas and get access to the melt. It is
essential that the burner reliably and consistently cleans the scrap from the adjacent area
so that supersonic lancing is possible without any danger of rebound from the remaining
scrap. The self-protecting design of the burners allows for a reliable, low maintenance
operation.

When a passage to the bath is clear the PyreJets begin to inject carbon for slag foaming
and oxygen for melt refining. The central supersonic flow is increased to achieve 2.1
Mach exit velocity while the jet is kept focused. A long, contained supersonic oxygen jet
then impacts the melt to begin the refining process. In the impact area the melt
temperature is raised from the exothermic oxidizing reaction and by the bath agitation
and homogenization. Carbon injection by the PyreJet burners begins to deoxidize the slag
and to maintain a thick foamy slag layer. The amount of oxygen and carbon introduced
by the PyreJet multi-functionnal tools is calculated on the basis of the scrap mix and the
desired melt carbon content. Carbon injection may be initiated simultaneously with
oxygen lancing to balance the slag temperature and chemistry in the jet impact area,
enhancing foamy slag formation. If the scrap mix contains a substantial amount of excess
carbon, the carbon fines injection can be delayed to allow oxygen to perform an initial
rapid reduction of the melt carbon.

The homogeneous and efficient foamy slag layer created by the PyreJet allows to
increase the active power input, specially during the refining period. The EAF voltage
can be increased with flat bath without negative effects of arc radiation on the water
cooled panels. Values up to +10 % are reachable, if the transformer capacity permits

A thick layer of foamy slag generated by the use of PyreJet burners not only improves
electrical efficiency and metallic yield but also protects the refractory from erosion. The
thick slag layer may help to capture some of the oxygen that may rebound from the metal
interface as well as droplets of metal that are inevitably generated during lancing. The
endothermic reaction of injected carbon with slag oxides reduces the temperature and
slows the chemical attack of slag before its basicity increases due to the lime dissolution.

The carbon/oxygen co-injection continues until the required chemistry of the melt is
achieved. A final melt carbon content as low as 0.02% can be accomplished by using
PyreJet technology. The PyreJet system control program is fully automated to ensure the
consistency of the EAF operation.

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3 - THEORETICAL ASPECTS

3.1 Flame Enhanced Oxygen Lancing

The length of a supersonic oxygen jet is greatly influenced by the condition of the
gaseous atmosphere surrounding the jet. The main reason for a conventional supersonic
lances jet normal disintegration is the interaction with surrounding atmospheric gases.
The high velocity supersonic jet inspirates the surrounding atmosphere. This increases the
mass of the jet stream and reduces its velocity.

Flame shrouding of a supersonic oxygen jet stream was first described and patented by
ACI in 1986 (US Patent No 4,622,007). The use of an oxy-fuel flame provides for high
temperature combustion gases accompanying the oxygen jet stream. High temperature
combustion gases have very low density as shown in Figure 2. This reduces the mass of
inspirated gases and keeps the oxygen jet stream focused much longer.

DENSITY OF FURNACE ATMOSPHERE VS. TEMPERATURE

GAS DENSITY * 1000, LB /

80
70
60
50 Range of furnace gas densities
Oxy-fuel flame
40
3

density
f

30
20
10
0
0 1000 2000 3000 4000 5000 6000
FURNACE GAS TEMPERATURE, F

Figure 2

3.2 Operating Philosophy

Recognizing that EAFs have different operating conditions, the PyreJet system has been
designed to optimize EAF performance by multi-point injection of auxiliary heat, oxygen
and carbon fines and post combustion. The main differences are due to a variation in
furnace design, electrical power, scrap mix and established melt shop operating practices.
Optimization of the PyreJet system in each case is carried out during burner system
design phase, installation and commissioning.

System Optimization includes the following:

Selection of appropriate number of burners and their positions

Estimated firing schedule
Oxygen lancing schedule
Layout of carbon fines injection points and carbon injection schedule

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The operation of PyreJet burners influences temperature, oxygen and carbon delivery in
areas adjacent to the burners. During supersonic lancing, a major portion of oxygen is
consumed by the oxidation of carbon and iron, and by dissolution into the melt. Carbon
oxidation is incomplete and is mainly oxidized to carbon monoxide.

Carbon content of the melt and melt temperature greatly influence the thermodynamic
equilibrium and the distribution of oxygen participating in oxidation of melt iron, carbon
and other alloying elements and the completion of the carbon oxidation. Due to
competition for oxygen, only a small portion of CO can be oxidized to CO2 at the melt
surface. For example, only ~ 0.5% of oxygen flow is used to oxidize CO to CO2 when
oxygen reacts with the melt having a carbon content of ~ 0.2%. However, the
contribution of oxygen to this reaction of CO oxidation increases to ~ 10 % when the
melt carbon content is reduced to 0.03%.

Quantitatively the oxygen content of metal can be approximated using the following C-O
equilibrium equation:

[C][O]=0.0025; @1620C (2950F), PCO=1

Therefore, assuming that melt temperature stays constant during refining, the variation in
the theoretical amount of oxygen dissolved in metal during decarburization from the melt
carbon content equal C1 to C2 can be approximated as follows:

d[O]=0.0025(1/C2-1/C1)

In practice, the oxygen content of metal is somewhat higher than the equilibrium
concentration but the difference is usually insignificant, although it may vary throughout
the refining period.

Similarly to the process of oxygen dissolution in the melt, the theoretical amount of
oxygen reported in the slag during decarburization process can be approximated using the
following equation:

d(FeO)=0.0163(1/C2-1/C1) at 1620C(2950F),
PCO=1)

Figure 3 shows the distribution of oxygen between reactions of melt carbon oxidation,
melt iron oxidation and oxygen dissolution in the melt during the refining period.
Obviously, in the beginning of the refining period, when the melt carbon content is
relatively high, nearly 90% of conveyed oxygen is consumed by the melt decarburization.
During the final stage of refining the oxidation of iron becomes predominant.

If extremely low tap carbon 0.02-0.03%) is required, as much as 90% of supplied oxygen
is going to form FeO.

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 D IS T R IB U T IO N O F S U P P L IE D O X Y G E N

100%

90%
DISTRIBUTION OF OXYGEN, %

80%

70%
O XG TO M ETAL
60%
O XG TO FeO
50%
D E C A R B U R IZ A T IO N O X G
40%

30%

20%

10%

.4 .3 .2 .1 5 .1 .0 5 .0 3 .0 2

BA TH C AR B ON , %

Figure 3

In the case of the intensive oxidation of iron, at the end of the steel making cycle not
being counterbalanced by an adequate foamy slag practice, a significant yield loss and
refractory erosion would be observed due to the high FeO content of high temperature
slag.

The removal of melt carbon is accomplished in two stages. During the first stage a film of
iron oxide is formed when gaseous oxygen contacts the melt surface and the droplets of
iron contained in the slag located in the lancing zone. Oxidation of Fe occurs via the
reaction:

Fe + 1/2O2 = FeO (+ 8.95 kWh/ Nm3 O2)

The film of iron oxide formed in the lancing zone is later partially reduced during the
second stage by the dissolved melt carbon via the reaction:

FeO + C = Fe + CO ( 6.31 kWh/.Nm3 O2)

The first reaction is exothermic and takes place at almost any time during the steel
making cycle when oxygen contacts melt iron. The second reaction is endothermic. At
lower melt temperature below 1565 C (2850 F) this reaction is controlled by the
diffusion rate of the carbon in the melt.

Based on the above the following practical rules are established for the PyreJet operation:

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 To avoid local slag over-oxidation, oxygen lancing is accompanied by simultaneous
carbon co-injection, especially if the final melt carbon content is below 0.1%
Aggressive oxygen lancing begins when both stages of carbon removal are kinetically
feasible to prevent slag over-oxidation

Oxygen utilization and the consistency of foamy slag practice can both be improved via
utilization of multiple points of oxygen/carbon co-injection in the EAF. Multi-point co-
injection also provides for better nitrogen control, lower refractory erosion and metallic
yield increase.

4 - INDUSTRIAL RESULTS

At the time of writing of this article there are 17 PyreJet systems in operation or pending
installation on EAFs worldwide. Below are some operating results of different EAFs,
where PyreJet technology was either used as a replacement for other oxygen injection
technologies or complemented them.

4.1 Kentucky Electric Steel (KES)

KES has two 50 ton AC EAFs equipped with 25 MVA transformers. The PyreJet systems
were installed in November of 1998. Each furnace has two PyreJet burners and one
PyrOx burner. The tap carbon varies from 0.05 to 0.50%. It is worth mentioning that the
logistics of the shop dictate strict control of power demand. Installation of the PyreJet
system has allowed power demand for the EAFs to be cut by 20%. Main operating data
before and after PyreJet system installation are summarized in Table 1.

Table 1. PyreJet Operating Results at KES

BEFORE AFTER CHANGE %

Electrical Consumption, kWh/tonne (kWh/ton) 530 (480) 440 (400) (17)

Natural Gas Consumption, Nm3/tonne (scf/ton) 0 8.0 (270) N/A

Oxygen Consumption, Nm3/tonne (scf/ton) 10 (330) 24 (800) 114

Power-on-time, min. 67 57 (15)
Furnace Brick Life, heats 400 1000 150
Gunning Material Consumption, kg/tonne (lbs/ton) 3.2 (7) 1.8 (4) (57)

4.2 Steel Dynamics, Inc. (SDI)

SDI, Butler, is a flat rolled product producer that operates two 150 tonne AC twin shell
EAFs equipped with 120 MVA transformers. The product mix necessitates tap carbon as
low as 0.025%. The scrap charge consists of busheling (15-20%), bundles (15-25%),
shredded (10-15%), pig iron (15-25%), with smaller amounts of P&S, #1HM, and other
high residual scrap. The first PyreJet system was installed in April 2000 with the

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second to follow in September 2000. Each system consists of three PyreJets of 2000
Nm3/hr (1200 scfm) oxygen capacity. Table 2 represents comparison of Shells #3
(PyreJet) and #4 (Burners & WC lance) for the first two months after PyreJet system
installation.

Table 2. PyreJet Performance at SDI (April-May 2000)

Shell #4 Shell #3
WC Lance, Burners PyreJet

Power-on-time, min. 48.5 44.2

Power Input, MW 84.0 88.4
Natural Gas Consumption, Nm3/tonne (scf/ton) 4.0 (150) 6.0 (230)
Oxygen Consumption, Nm3/tonne (scf/ton) 30 (1000) 28 (930)
Injection Carbon, kg/tonne (lbs/ton) 12 (24) 8 (16)

SDI also uses hot metal produced by the on-site Iron Dynamics plant. Typically they
substitute the second charge with 55 tonnes of hot metal. The hot metal supply is not very
consistent, therefore, it is not possible to make a proper statistical representation of the
results over a period of time. However, by SDIs estimate, production of hot metal heats
in the PyreJet shell showed 1.5 min power-on-time advantage and additional 10
kWh/tonne electrical savings. The much less violent bath behavior was also noted.

4.3 Trico Steel

Trico Steel has two twin cathode 155 tonne DC furnaces. Trico is a flat rolled product
producer 30% of continuously fed DRI/HBI is utilized in the scrap mix. Tap carbon
content is typically 0.02-0.25%. The PyreJet system, consisting of four 2400 Nm3/hr
(1500 scfm) PyreJet burners/injectors, was installed on the North furnace in July of 2000.
The results for the first three months of operation are presented in Table 3.

Table 3. PyreJet results at Trico Steel

South Furnace North Furnace

WC Lance, Burners PyreJet

Power-on-time, min. 50.0 48.3

HBI, % 30 30
Electrical Consumption, kWh/tonne (kWh/ton) 440 (400) 430 (390)
Oxygen Consumption, Nm3/tonne (scf/ton) 40 (1330) 35 (1170)
Injection Carbon, kg/tonne (lbs/ton) 9 (18) 6 (12)
.

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Oxygen Con

4.4 North Star Steel Texas

North Star Steel Texas (NSST) operates a 110 tonne AC EAF equipped with 65 MVA
transformer. The plant is primarily producing wire. For auxiliary equipment EAF has a
water cooled door lance, three sidewall and one EBT burner from American Combustion.
In an effort to increase production after conversion of the shop from two EAFs to one,
NSST installed one PyreJet in addition to existing auxiliary equipment. The operating
comparison before and after installation is presented in Table 5.

Table 5. Addition of one PyreJet at NSST

Before After
(November 2000) (December 2000)

Power-on-time, min 64.8 62.5

Electrical Consumption, kWh/tonne (kWh/ton) 415 (375) 400 (360)

Installation of the second PyreJet unit is currently pending.

5 - CONCLUSION

Air Liquide PyreJet Technology for EAF steelmaking has been successfully implemented
on a number of AC and DC EAFs. The results indicate improvements in the following
areas:

10-90 kWh/tonne electrical savings

Up to 10 min decrease in power on-time
Up to 5% increase in active power input
Increased oxygen efficiency
Up to 50% savings in injection carbon

A large number of new PyreJet installations are currently under way in North America,
South America , Europe and Asia.