Benchmark Study of EAF Plants Using the KT Injection System

I
n the last five years, the amount of oxygen used in electric arc furnaces (EAFs) has increased a great deal, especially for those plants that do not require high-quality steel grades, such as carbon steel as rebar and other common grades. In some countries, the increased use of oxygen chemical energy depends on the cost of electrical energy, considered are the production figures for liquid steel for long products worldwide.

Background
A benchmark study for the steel industry is always a difficult task. Comparing EAFs is probably even more difficult, considering the number of variables that can affect EAF operation. One approach to accomplishing this kind of study is the standardization of some parameters in order to make as equal a comparison as possible. In this case, the study compares EAF plants using the KT Injection System the multipoint oxygen and carbon injection system by Techint with other plants that are in the same market section and have comparable production facilities. This benchmark study has been divided in two parts. The first part compares EAF furnaces producing carbon steel for long products. Approximately 40 plants have been taken into account, with EAF heat size ranging from 20 to 160 metric tons. The second part compares EAF furnaces charging continuously from the roof more than 40 percent of DRI and producing at least 400,000 tons/year. Ten plants have been taken into account for this second part. All plant data used in this benchmark study was collected during 2002 and 2003. This article is not meant to provide general conclusions regarding average energy consumption or average productivity for a typical EAF. Nearly everyone in the steel industry, and particularly in the EAF field, knows how difficult it can be to determine absolutes for the best energy consumption or productivity. This is because so many direct factors (including scrap type, furnace design and manpower) as well as indirect factors (plant efficiency and market conditions) influence liquid steel production. Apart from this general consideration, this benchmark study can be used as am overview of the different operational figures in many

New injection technologies have increased the efficiency of thermal and chemical input into the EAF. A benchmark study compares the performance data of three plants using Techints multipoint oxygen and carbon injection system with 40 other EAFs.

but in general this increase can be explained by the development of new injection technologies, which have increased the efficiency of thermal and chemical input into the EAF. In addition, the multipoint injection of supersonic oxygen and powder carbon around the EAF has created the possibility of automating the melting and refining operations, so that nowadays furnace operators can simply supervise the melting and refining processes. There is no longer any risk of human errors for instance, overoxidation with manually operated lances. The KT Injection System, a product of Techint for multipoint oxygen and carbon injection, has undergone development over the last two years, with more than 20 projects started up worldwide. It is now the chemical package with the highest level of technology. This article presents a benchmark study detailing the performance of three plants producing carbon steel for long products where the KT Injection System has been installed. These three plants are compared with 40 other furnaces with the same kind of productivity. Also

Authors
Francesco Memoli, technology service manager, and Per Lckhoff, senior process engineer, Techint SpA, Italy 1

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Figure 1 plants. For the sake of confidentiality, the names and locations of the plants, other than the plants using the KT Injection System, are not disclosed. A KT oxygen lance is pictured in A KT oxygen lance, a product of Techint. Figure 1, while the typical locations of both lances and KT carbon injectors are show in Figure 2. Figure 2

EAFs Producing Carbon Steel for Long Products

Geographic Distribution Forty furnaces were considered for this benchmark study. They are located in seven different countries and produce an average of 500,000 metric tons/year (total production is approximately 20 million of tons). The majority of these plants produce carbon steel with no special quality requirements, and all of them are in the long products market. Figure 3 shows the locations of the plants considered in this study. There is no particular reason for this distribution besides the availability of consistent statistics about the EAFs. This geographic distribution does not reflect global carbon steel production. In fact, fact China represents only 7 percent of this study, and some larger markets (i.e., Russia) are not included. Since the European and North American continents together represent 75 percent of the data considered, one could say that this study focuses on these two continents, with some influence coming from the rest of the world. EAF Statistics Table 1 summarizes the data considered for the benchmark study. The figures have been selected as monthly averages of consecutive months in 2002 or 2003; therefore, they can be considered as representative of each one of the 40 plants studied. For each of the itemized figures, the table indicates the minimum value registered, the maximum value registered, the average value (calculated by weighing each plant on the basis of its yearly production of liquid steel) and the standard deviation of the 40 plants, just to give a summary indication of the group of plants considered and thus maintaining discretion. It is important to note that the high value of standard deviation is clear evidence that there is not uniformity of performance for this kind of steel production worldwide. The average consumption figures in Table 1 represent a yearly production of about 20 million tons of liquid steel. The electrical energy consumption is 433 kWh/metric ton. Even if some plants in this group consume only 318 kWh/t, the global average is much higher; the trend is to go below 400 kWh/t, but for the

Typical locations of KT oxygen lances and KT carbon injectors in an electric arc furnace.

Figure 3

Locations of the plants considered in the benchmark study.

July 2004

Table 1
Summary of Benchmark Data (Monthly Averages of Consecutive Months in 2002 or 2003)
Item Intl. Total charge Heat size Yield Power-on time Power-off time Tap-to-tap time Average active power Electrical energy consumption O2 consumption CH4 consumption Total carbon consumption FeO in slag content Electrode consumption Tapping temperature kg/ton C kWh/ton Nm3/ton Nm3/ton kg/ton % lb/short ton F 1.97 1,640 metric ton metric ton % minutes minutes minutes MW kWh/short ton scft scft lb/short ton 433 32 5 13 34 3.9 2,984 Unit* U.S. short ton short ton Average Intl. 101 87 U.S. 111.8 95.8 0.86 52 20 72 46 393 1,023 146 26 41 40 4 43 53 40 41 15 29 72 44 25 21 2 1.0 1,600 Standard deviation (%) Minimum Intl. 24.2 21.3 0.78 15.2 6.0 43.0 12.3 318 18.0 0.0 4.0 28.0 1.8 2,912 3.1 1,720 288 416 0.0 8.0 525 50.0 13.0 31.0 46.0 6.4 3,128 U.S. 26.7 23.5 Maximum Intl. 196.5 160.0 U.S. 216.6 176.4

0.937 160.0 46.0 203.0 95.8 521 1,601 416.5 62.0

*Heat size and specific consumptions are referred to metric or short tons of tapped liquid steel.

moment this target has not yet been reached for the majority of the plants. The same consideration can be made for electrode consumption: this value is decreasing in Europe, and sometimes in the U.S., to below 2 kg/ton, due in part to improvements in electrode quality. However, even in other countries, with no first-suppliers consumption figures, this value is decreasing, due to the introduction of foamy slag practice. At any rate, even if there are some plants consuming 0.9 or 1.0 kg/ton in AC furnaces, there are still plants that have electrode consumptions of more than 3 kg/ton. This high value likely stems from the age of the equipment used in such furnaces. Another consideration must be made regarding tapping temperature. In the group of plants considered, some depend on a ladle furnace (LF) for steel treatment before casting, and others have no LF, so they have to tap at high temperatures to prevent low temperatures during casting. In fact, even if a LF is very common equipment nowadays, there are still plants working without it, yet maintaining good production performance. This analysis indicates once more that it is quite difficult to come to general conclusions by looking only at these data. Of course, the figures for some plants are clearly different from the others, but there was no good reason to exclude those plants from the study. The
3

majority of the plants considered have some strange but consistent figure; therefore, in order to come to general conclusions, a different approach must be taken.

Benchmark of the EAFs

All data were adjusted to reflect the same tapping temperature of 1,640C, which is the average tapping temperature of all the plants (on the basis of 0.4 kWh/C). Two parameters were then considered: the total energy consumption and the specific productivity. Total energy consumption (kWh/ton) is the sum of electrical energy consumption and thermochemical energy consumption. To calculate the second factor, standard efficiencies have been given to natural gas (9.6 kWh/Nm3) and oxygen (3.2 kWh/Nm3) Specific productivity is the furnace net productivity tons of liquid steel produced in the power-on time divided by the total furnace power (electrical and chemical power, considering the same rates as before). Specific productivity indicates tons produced per hour per MW installed. These two parameters constitute the y-axes of the graphs in Figures 4 and 5, while the xaxes indicate heat size. Grey dots are the results of the calculation for each plant, while

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Figure 4 dark dots denote the three EAFs using the KT Injection System and matching the requirements for this benchmark. Those three plants are IRO and Profilati Nave in Italy and Davsteel in South Africa, which have been using the KT system for at least two years, producing carbon steel for long products. The result of the parameter adjustment and the following calculation indicates that: Average total energy consumption is 550.1 kWh/metric ton. The graph indicates a trend line, representing a minimum value of approximately 100 tons and 537 kWh/ton. Average specific productivity is 1.317 metric tons/hour/MW. The graph indicates a trend line, representing a maximum value of approximately 90 tons and 1.362 tons/hour/MW. In general, Techint experience over the past several years has shown the following: If an EAF is below the average curve of specific productivity, it can jump over that curve by at least 0.25 tons/ hour/MW after the KT system is introduced. If an EAF is above the average curve of total energy consumption, introducing KT can cause it to jump below that curve by about 75 kWh/ton liquid steel (tls). This reflects four years of developing multipoint injection systems for oxygen and carbon powder all over the world.
Specific Productivity Vs Heat size, the jump of some plants after KT Installation

Total Energy Consumption Vs Heat size, the jump of some plants after KT Installation

Figure 5

Benchmark of the Plants Charging a High Percentage of DRI

Ten furnaces were considered for this second benchmark. They are located in seven different countries, produce at least 400,000 tons/year in each furnace (total production is about 7 million tons) and use at least 50 percent of DRI charged continuously from the roof into the furnace. The plants officially approved all data shown in Table 2. While the names of those plants are not disclosed here, many of them are considered as reference plants for the DRI melting process worldwide. Perwaja Steel Sdn Bhd, Malaysia, is the only one named, as this plant uses the KT Injection System. As shown in Table 2, Perwaja is among the group of plants with the best performance levels. Perwaja has the lowest electrical consumption with the highest rate of DRI percentage in charge and the highest DRI feeding rate specific on active power, which is a very good parameter to compare different furnaces. For an even better comparison, Table 2 was recalculated, with tapping temperature adjust-

ed to 1,645C and DRI in charge adjusted to 71 percent for all furnaces. Table 3 shows the recalculation, which was done by giving standard values to the ratios kWh/C (0.35) and kWh/%DRI (1.69); these standard values are the average of the values considered in each one of the 10 plants for such conditions of DRI in charge. It is then possible to calculate the total energy input (by giving a standard value to O2 of 3.2 kWh/Nm3, average of values considered in each one of the plants), and net productivity during power-on time, as seen in Table 4.

Conclusion
As it turns out, Perwaja has the lowest energy consumption and the second highest net productivity. Plant D has the second lowest consumption, still below 600 kWh/ton liquid steel. Plant H has higher net productivity but very high energy consumption. Plants D and H have a lower specific power per tons charged, which is good and can be easily explained with a lower ratio between bath surface and steel volume. (Because of crane and
July 2004

Table 2
Plants Charging a High Percentage of DRI
Perwaja Total Charge DRI Heat size Yield Power On Time Avg. Active Power EE consumption O2 consumption C consumption FeO slag content Tapping Temp DRI metallization Total Iron in DRI DRI Car. content DRI Feeding Rate DRI Charging time ton % tls % min. MW kWh/tls Nm3/tls kg/tls % C % % % A 84.7 87.7 75.2 88.8 36 57.9 462.9 45.6 27.8 29.6 1610 96.3 90.9 2.18 B 87 72 79.7 91.6 45 62.7 590 20 6 31 1650 94.4 91.5 2.1 38.8 37 D 87 58 79.4 91.3 36 68.8 520 30 6 32 1650 94.4 91.5 2.1 27 27 E 116 65 105 90.5 47 69.7 520 19 14 29 1662 95 93 2.1 27.2 35 F 137 75 117 85.4 70 55.5 553 25.6 12 33 1640 92.3 91.4 2.8 30.9 63 G 173 46 150 86.7 87 69.3 670 27 24 23 1650 91.7 90.6 0.14 29.4 77 H 190 75 160 84.2 87 71.7 650 20 25 32 1660 93 90.8 2.1 15 79 I 230 79 190 82.6 84.1 88 649 26.3 12.8 35 1643 93 91 2.1 25.1 78 220 82 190 86.4 106 66.1 615 18 12 28 1640 92 89.11 1.8 26.5 110 24.8

kg/min./MW min. 33

Table 3

Perwaja Power On Time Avg. Active Power EE consumption O2 consumption C consumption FeO slag content DRI Feeding Rate min. MW kWh/tls Nm3/tls kg/tls %

A 33.9 57.9 435.1 45.6 27.8 29.6

B 44.9 62.7 588.2 20.0 6.0 31.0 38.8

D 37.4 68.8 540.7 30.0 6.0 32.0 27.0

E 47.9 69.7 529.5 19.0 14.0 29.0 27.2

F 69.1 55.5 545.9 25.6 12.0 33.0 30.9

G 91.6 69.3 705.4 27.0 24.0 23.0 29.4

H 86.0 71.7 642.8 20.0 25.0 32.0 16.2

I 82.2 88.0 634.5 26.3 12.8 35.0 25.1 106.0 66.1 615.0 18.0 12.0 28.0 26.5 24.8

kg/min./MW

Table 4

Perwaja Net Productivity Total Consumption Specific Power t/h kWh/t MW/ton

A 133.1 581 0.68

B 106.5 652 0.72

D 127.3 637 0.79

E 131.6 590 0.60

F 101.6 628 0.40

G 98.3 792 0.40

H 111.6 707 0.38

I 138.7 719 0.38 107.5 673 0.30

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Figure 7

KT oxygen lances on pilot flame mode: EBT side (left) and slag door side (right).

building structure restrictions, Perwaja cannot increase its heat size.) Figures 79 illustrate the KT Injection System installed and in use. Table 5 provides a list of KT system installations worldwide. This benchmark study confirms that by using the KT Injection System, thereby improving oxygen injection efficiency and foamy slag practice for DRI furnaces, it is possible to reach high levels of productivity without compromising the furnace conditions Figure 8

(FeO in the slag and yield). This spells big benefits in terms of variable cost reduction. References
1. High DRI Feeding Rate for an EAF-DC Using a Multipoint Oxygen and Carbon Injection, 14th Steelmaking Seminar & 4th ISS Argentina Section Meeting, Buenos Aires, Oct.13, 2003. 2. New Electrical and Chemical Technologies Implemented in the Dalmine Steel Plant, MPT International, Oct. 2002.

View of a KT natural gas valve stand and a KT oxygen valve stand.

Figure 9

The pneumatic carbon injection system (left) and one of the lances installed in the slag line (right).

July 2004

Table 5
Plants With KT Injection Systems
Start-up Feb. 2005 (under work) May 2004 (under work) Apr. 2004 (under work) Feb. 2004 (under work) Feb. 2004 (under work) Dec. 2003 (under work) Nov. 2003 (under work) Nov. 2003 (under work) Nov. 2003 (under work) Oct. 2003 (under work) Oct. 2003 (under work) 2003 (under work) 2003 (under work) 2003 (under work) Sept. 2003 Aug. 2003 July 2003 June 2003 Mar. 2003 Jan. 2003 Dec. 2002 Sept. 2002 Aug. 2002 Aug. 2002 Jan. 2002 Aug. 2001 Aug. 2001 Plant Wheeling-Pittsburgh, Pittsburgh, Pa. Heng Li, Ningxia Province CISCO, Cape Town Wuxi Xuefeng Iron & Steel Co. Ltd., Wuxi, Xuefeng Province Perwaja Steel SDN BHD, Kemaman Acciaierie di catania, Catania CHIMET, Arezzo TAMSA, Veracruz Gerdau Cosigua, Rio de Janeiro OJI, Gunma Tokio MSC, Mobarakeh Ferriera Valsabbia SpA, Odolo (Brescia) Wei Chih, Kaohsiung Kouzestan Steel Corp. KSC, Ahwaz Profilati Nave SpA, Montirone (Brescia) Davsteel, division of Cape Gate Pty Ltd, Vanderbijlpark MARIENHTTE, Graz SIDOR (Long Products), Puerto Ordaz Gerdau AmeriSteel, Knoxville Perwaja Steel SDN BHD, Kemaman Ferriere Nord SpA, Osoppo, Udine Industrie Riunite Odolesi SpA (IRO), Odolo (Brescia) Riva Acciaio SpA, Verona Riva Acciaio SpA, Verona EWK Edelsthal Witten Krefeld GmbH TENARIS Dalmine, Dalmine (Bergamo) Makstil A.D. Duferco Group, Skopie Country United States China South Africa China Malaysia Italy Italy Mexico Brazil Japan Iran Italy Taiwan R.O.C. Iran Italy South Africa Austria Venezuela United States Malaysia Italy Italy Italy Italy Germany Italy Macedonia EAF type EAF AC, 225 ton, Consteel system EAF AC, 75 ton, Consteel system EAF AC, 45 ton, 100% scrap EAF AC, 75 ton, Consteel system EAF DC No.5, 75 ton, 90% DRI EAF AC, 70 ton, 100% scrap SAF (Cu-Ar-Au), 3 ton, 100% powder EAF AC, 150 ton, 20% DRI EAF AC, 100 ton, 100% scrap EAF AC, 80 ton, 100% scrap EAF No. 8, 182 ton, 100% DRI EAF AC, 80 ton, 100% scrap EAF AC, 100 ton, Consteel system EAF AC, 185 ton, 80% DRI EAF AC, 70 ton, 100% scrap EAF AC, 75 ton, 15% DRI EAF AC, 45 ton, 100% scrap EAF No.1, 150 ton, 80% DRI EAF AC, 55 ton, Consteel system EAF DC No.4, 75 ton, 90% DRI EAF AC, 100 ton, 100% scrap EAF AC, 70 ton, 100% scrap EAF AC No.2, 76 ton, 100% scrap EAF AC No.1, 76 ton, 100% scrap EAF AC, 130 ton, Stainless steel EAF AC, 97 ton, 100% scrap EAF AC, 110 ton, 100% scrap KT system Complete system: 5 KT oxygen lances, 4 KT carbon injectors, TDR-H Complete system: 3 KT oxygen lances, 3 KT carbon injectors, TDR-H Complete system: 2 KT oxygen lances, 2 KT carbon injectors, TDR-H Complete system: 3 KT oxygen lances, 3 KT carbon injectors, TDR-H Complete system: 4 KT oxygen lances, 2 KT carbon injectors Complete system: 3 KT oxygen lances, 3 KT carbon injectors 2 KT oxygen lances, KT cooling blocks Complete system: 4 KT oxygen lances, 3 KT burner/carbon injectors Furnace improvement: 1 KT oxygen lance, 1 KT carbon injector Complete system: 4 KT oxygen lances, 2 KT burner/carbon injectors Complete system: 3 KT oxygen lances, 3 KT carbon injectors, TDR-H Furnace improvement : 1 KT oxygen lance, 1 KT carbon injector, TDR-H Complete system: 3 KT oxygen lances, 3 KT carbon injectors, TDR-H Complete system, 3 KT oxygen lances, 3 KT carbon injectors System improvement: 4 KT oxygen lances, 2 KT carbon injectors, TDR-H System improvement: 4 KT oxygen lances, 3 KT carbon injectors, TDR-H Complete system: 3 KT oxygen lances, 3 KT carbon injectors Complete system: 3 KT oxygen lances, 1 KT carbon injector Furnace improvement: 1 KT carbon injector Complete system: 4 KT oxygen lances, 2 KT carbon injectors System improvement: 2 KT LF-slag injectors, TDR-H System improvement: 4 KT oxygen lances, 2 KT carbon injectors Furnace improvement: 3 KT burn/ C/CaO injectors, TDR-H Furnace improvement: 3 KT burn/ C/CaO injectors, TDR-H Complete system: 2 KT oxygen lances, 2 KT carbon injectors Complete system: 2 KT oxygen lances, 2 KT carbon injectors, TDR-H Complete system: 3 KT oxygen lances, 3 KT carbon injectors

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Table 5
Plants With KT Injection Systems (contd)
Start-up June 2001 May 2001 Plant Siderurgica Sevillana SA Riva Group, Sevilla Tianjin Pipe Corp. TPCO, Tianjin Ferriere Nord SpA, Osoppo, Udine Davsteel, division of Cape Gate Pty Ltd, Vanderbijlpark IRO Industrie Riunite Odolesi SpA, Odolo (Brescia) George Fischer, Mettmann (Dsseldorf) Profilati Nave S.p.A., Montirone (Brescia) Sidenor Steel Co. SA, Thessalloniki M.M.Z. Country Spain China EAF type EAF AC, 75 ton, 100% scrap EAF AC, 150 ton, 50% DRI EAF AC, 100 ton, 100% scrap EAF AC, 75 ton, 15% DRI EAF AC, 70 ton, 100% scrap Cupola Furnace, 70 tons/hour EAF AC, 70 ton, 100% scrap EAF AC, 75 ton, 100% scrap EAF AC, 120 ton, 100% scrap KT system Furnace improvement 2 KT carbon injectors Complete system: 3 KT oxygen lances, 2 KT carbon injectors, 1 KT DRI-fines injector Furnace improvement: 2 KT lime injectors Complete system: 3 KT oxygen lances, 3 KT carbon injectors, TDR-H Complete system: 2 KT oxygen lances, 2 KT carbon injectors New development: KT spout cooling element Complete system: 2 KT oxygen lances, 2 KT carbon injectors Furnace improvement: 1 KT carbon injector Furnace improvement: 1 KT carbon injector

Mar. 2001 Jan. 2001 Jan. 2001 Dec. 2000 Oct. 2000 Aug. 1999 Sept. 1999

Italy South Africa Italy Germany Italy Greece Moldova

3. Increase of Productivity in Dalmine Steel Plant Through the Application of Innovative Electrical and Chemical Technologies, 7th European Electric Steelmaking Conference, Venice, May 2629 2002. 4. Operational Improvements Achieved in Davsteel (division of Cape Gate Pty. Ltd., South Africa) Utilizing the New Techint KT Injection System and TDR Digital Regulation: A Case Study, Electric Furnace Conference, Phoenix, Ariz., Nov. 1114, 2001. 5. Aplicaciones y resultados de la tecnologa KT Injection System en los hornos de arco elctrico, 13th Steelmaking Seminar & 3rd ISS Argentina Section Meeting, Buenos Aires, Oct. 29Nov. 1, 2001. 6. The Advanced KT Injection System for Electrical Arc Furnace With High Productivity, AISE 2001 Iron

& Steel Exposition and Annual Convention, Cleveland, Ohio, Sept. 2326, 2001. 7. La solucin para incrementar la productividad de un EAF: nueva regulacin digital integrada con un sistema de inyeccin oxgeno/carbn avanzado, VII Congreso Metalrgico Cubano, La Habana, July 1619, 2001. 8. KT Injection System: State of the Art and Results Achieved in the New Applications, Current Electric Arc Furnace Injection Technology, AIM Seminar, Milan, July 4, 2001. 9. KT Injection System: The Key for Chemical Energy in High-performance Electric Arc Furnace, Millennium Steel, 2001.

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When faced with the threat of potentially devastating wildfires, 85 percent of consumers say they would prefer a steel roof on their homes, a new survey finds. The results indicate that steel, with its fire-retardant qualities, could become the new material of choice for residential roofing, particularly in the wildfire-prone Western states. The survey, conducted by the global research firm Wirthlin Worldwide, also found that among the group wielding primary influence on home improvement purchases women ages 1854 an even greater 93 percent said they favor a steel roof. Asked whether they would favor a mandate to change local building codes to require that roofs in fire-prone areas be constructed of fire-retardant materials like steel, two of three said they support such a requirement. The American Iron and Steel Institute sponsored the metal roofingrelated survey. To locate a roofing contractor in your area or to find detailed information about steel roofing, visit www.metalroofing.com.

July 2004

Company Index 045July Techint 1 Davsteel 4 Perwaja Steel 4 Profilati Nave 7 Company Index 045JulyFiller Wirthlin Worldwide 8 American Iron and Steel Institute 8

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