Capacity Enhancement at Emirates Steel ; Continuous Improvement in EAF Performance with HOT DRI Charge Capacity Enhancement at Emirates Steel ; Continuous Improvement in EAF Performance with HOT DRI Charge Capacity Enhancement at Emirates Steel ; Continuo

by D.Patrizio, P.Razza, A.Pesamosca

Publisher - Danieli & C. Officine Meccaniche S.p.A., Italy

Category - Engineering & IT

The performances of the two integrated plants supplied by Danieli in Mussafah Industrial Area – Abu Dhabi already exceeded expectations during first years after start-up (2009 and 2011 respectively). In order to meet Emirates Steel request for productivity increase, a revamping of DRP and Oxygen Plant was planned starting from integrated plant 2, new nominal productivity being 1.68 Mt/y (+ 0.28 Mt/y). Keeping fixed the original heat size of 150 ton and the charge mix (10% cold DRI and 90% Hot DRI), the target was to reduce the tap to tap time from 46 minutes to 38 minutes. The improvement of EAF operation was achieved reducing the power off time with dedicated tools and the chemical energy input was increased to shorten the power on time. Concurrently EAF slag was engineered to improve foaming consistency and increase the life of shell refractory, monitored with laser scan. Improvements at plant 2 are discussed in terms of productivity, such as new record beyond design target, 40 heats per day, only after 2 months from revamping. An overall analysis on EAF performances is described considering the influence of DRI characteristics on main process KPIs. Despite of the utilization of a specific electrical power input of 0.78 MW/ton, it was possible to reach 4 weeks of operation for the shell that considering the 100% flat bath operation represents an excellent result. The performances of the two integrated plants supplied by Danieli in Mussafah Industrial Area – Abu Dhabi already exceeded expectations during first years after start-up (2009 and 2011 respectively). In order to meet Emirates Steel request for productivity increase, a revamping of DRP and Oxygen Plant was planned starting from integrated plant 2, new nominal productivity being 1.68 Mt/y (+ 0.28 Mt/y). Keeping fixed the original heat size of 150 ton and the charge mix (10% cold DRI and 90% Hot DRI), the target was to reduce the tap to tap time from 46 minutes to 38 minutes. The improvement of EAF operation was achieved reducing the power off time with dedicated tools and the chemical energy input was increased to shorten the power on time. Concurrently EAF slag was engineered to improve foaming consistency and increase the life of shell refractory, monitored with laser scan. Improvements at plant 2 are discussed in terms of productivity, such as new record beyond design target, 40 heats per day, only after 2 months from revamping. An overall analysis on EAF performances is described considering the influence of DRI characteristics on main process KPIs. Despite of the utilization of a specific electrical power input of 0.78 MW/ton, it was possible to reach 4 weeks of operation for the shell that considering the 100% flat bath operation represents an excellent result. The performances of the two integrated plants supplied by Danieli in Mussafah Industrial Area – Abu Dhabi already exceeded expectations during first years after start-up (2009 and 2011 respectively). In order to meet Emirates Steel request for productivity increase, a revamping of DRP and Oxygen Plant was planned starting from integrated plant 2, new nominal productivity being 1.68 Mt/y (+ 0.28 Mt/y). Keeping fixed the original heat size of 150 ton and the charge mix (10% cold DRI and 90% Hot DRI), the target was to reduce the tap to tap time from 46 minutes to 38 minutes. The improvement of EAF operation was achieved reducing the power off time with dedicated tools and the chemical energy input was increased to shorten the power on time. Concurrently EAF slag was engineered to improve foaming consistency and increase the life of shell refractory, monitored with laser scan. Improvements at plant 2 are discussed in terms of productivity, such as new record beyond design target, 40 heats per day, only after 2 months from revamping. An overall analysis on EAF performances is described considering the influence of DRI characteristics on main process KPIs. Despite of the utilization of a specific electrical power input of 0.78 MW/ton, it was possible to reach 4 weeks of operation for the shell that considering the 100% flat bath operation represents an excellent result.

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