IÇDA – TURKEYHigh quality steel bars and high alloy steels since 1970

PLANT INFORMATION

Annual production 1,800,000 t of good billets

Production mix Billets

Steel grades

150 mm sq., 180 mm sq., 200 mm sq.

Low and medium c-steel (rebar / SBQ grades)Raw material Charging ratio: 100% steel scrap

PROJECT INFORMATION

Customer IçDA

Location Turkey

Commissioning 2003

ThE bIggEsT sTEEL PRODUCER IN TURKEYHigh efficiency with ultra-high chemical power EAF

IçDA is the biggest steel producer in the private sector in Turkey based on production capacity. The company com-missioned its first steelwork in 2003. Overall, it achieves an average production of 1.65 million t per year. The steelwork incorporates the first UHCP (Ultra-High Chemical Power) electric arc furnace supplied by SMS Concast worldwide and has a ladle size of 180 t.

TOP qUALITY COMPONENTs MEET ThE

DEMANDs OF ThE PLANT OPERATOR

The technological equipment of this plant, e.g. scrap preheating, EAF, LF and CCM, was entirely supplied by SMS Concast. Various IçDA design suggestions were taken into consideration: the maximized rate of energy input and reduction of power-off times has been a key factor during the development of the plant. Furthermore, the single bay design and the controlled metallurgical operation by a superior automation system. A high efficiency of the plant is guaranteed by a continuous high yield. SMS Concast’s state-of-the-art technology is a success factor for plant operators in order to optimize cost control.

A wELL-CONNECTED PROCEss ChAIN

sAvEs REsOURCEs

Scrap for the steelwork is brought by ship and unloaded in the close by harbor. The ships are reloaded with good billets. Short transportation distances are positively influencing the overall performance of the plant. The well-connected pro-cess chain saves time, money and is more environmentally friendly.

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3

IÇDA 2 – 220 T EAF wITh UhCPExpansion of capacity and performance

sECOND sTEELwORK COMMIssIONED IN 2008

In September 2008 IçDA commissioned the second steelwork with an UHCP (Ultra-High Chemical Power) EAF at its Biga location. Supplied by SMS Concast, the UHCP furnace features a productivity of 320 t/h and stands for top performance. Special design measures ensure the high power input density of 230 MW. This makes it possible for IçDA to produce 2.2 million t of high-quality steel products per year.

The plant comprises a 220-t EAF, a ladle furnace and an eight-strand Convex® billet caster. With these facilities, IçDA turns liquid steel into square billets 150 mm x 150 mm or 180 mm x 180 mm in size.

The capacity and performance of electric steelworks shops have been drastically increased so that – with capacities over 220 t – these plants can hardly be called minimills anymore.

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wIThIN ThE FIRsT YEAR ThE MONThLY PRODUCTION CAPACITY INCREAsED

whEN AT ThE sAME TIME ELECTRICITY CONsUMPTION DECREAsED

During the start up phase the target of 1.5 mio t per year, e.g. 125,000 t per month, was achieved as shown in the diagram. Within four years of meltshop operation, a continuous optimi-

zation of the process technology allowed to achieve outstand-ing results. As a result of that, the production output in 2007 exceeded the original design capacity by 20 %.

140000

120000

100000

80000

60000

40000

20000

0

Dec

03

Jan

04

Feb

04

Mar

04

Apr

04

May

04

Jun

04

Jul 0

4

Aug

04

Sep

04

Oct

04

Nov

04

MONThLY PRODUCTION

IÇDAS ̧ – TurkeyMinimill designed by

SMS Concast

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PLANT LAYOUT AT IÇDAShort transportation distances are positively influencing the

overall performances

transport on rail

transport by over head crane

Material flow

480460440420400380360340320300

Dec

03

Jan

04

Feb

04

Mar

04

Apr

04

May

04

Jun

04

Jul 0

4

Aug

04

Sep

04

Oct

04

Nov

04

*GB: good billet, LS: liquid steel

(2003) Initial (2007) Actual

Electrode consumption EAF 1.3 kg/t GB* 0.92 kg/t GB*

Electrode consumption LF 0.22 kg/t GB* 0.15 kg/t GB*

Electrical energy EAF 380 kWh/t LS* 280 kWh/t GB*

Electrical energy LF 22 kWh/t LS* 20 kWh/t GB*

ELECTRICITY CONsUMPTION

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3

Electric arc furnace

Ladle furnaces

Vacuum degasser

Continuous casting machine

Fume dedusting plant

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5

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ELECTRIC ARC FURNACE

TypeHeat sizeHot heel

Shell diameterShell volume

Electrode armsElectrode diameter

Electrode regulationTransformer

Scrap chargesTap to tap timeConso injector

Power on

ElectricOxygen

Natural gasElectrode

Shell life timeRefractory life

TypeHeat sizeHot heel

Shell diameterShell volume

Electrode armsElectrode diameter

Electrode regulationTransformer

Scrap chargesTap to tap timeConso injector

Power on

ElectricOxygen

Natural gasElectrode

Shell life timeRefractory life

IçDA produces with the first UHCP EAF supplied by SMS Concast. The EBT-type furnace, with large tapped steel capacity, is also equipped with a CONSO-tech oxygen injection system and off-gas analysis using laser detectors.

AC full platform, EBT tapping180 t nominal20 t7.8m / 8.0 m200 m3

Conductive type (Cu)650 mmDigital hydraulic type168 MVA2 – 3 buckets43 – 47 minn Wall installation 4 x 4,500 Nm3/h / 6 MWn EBT installation 2 x 4.000 Nm3/h / 6 MW32 min (3 buckets)

< 300 kWh / t good billets48 Nm3 / t good billets5.2 Nm3 / t good billets0.9 kg / t good billets20 days (> 450 heats)> 600 heats / campaign

AC full platform, EBT tapping250 t nominal30 t8.3 m260 m3

Conductive type (Cu)750 mmDigital hydraulic type230 MVA2 buckets32 – 34 minn Wall installation with 8 CONSO

injectorn Each CONSO injector can work

as oxy-gas burner or oxygen lance.n The installed burner power will

be 7 MW per unit, corresponding to the natural gas flow rate of 730 Nm3/h and oxygen flow rate of 1.500 Nm3/h

34 min

< 42 kWh / t good billets41 Nm3 / t good billets4.9 Nm3 / t good billets1.3 kg / t good billets20 days (> 450 heats)> 600 heats / campaign

CONSUMPTION fIgURES

CONSUMPTION fIgURES with 100% non-preheated scrap

ELECTRIC ARC FURNACE

In its second steelworks IçDA uses a 250 t UHCP EAF with a 8.3 m shell diameter by SMS Concast.

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TypeNominal ladle capacity

Electrode armsElectrode diameterElectrode regulator

TransformerHeating rate

StirringLadle cars

ElectricElectrode

TypeRadius

Number of strandsStrand distance

Section rangeCast section size

Billet lengthLadle support type

Tundish car type

Tundish shapeTundish flow regulation

Mould typeElectro magnetic

stirringCasting speed

Dummy bar typeCutting device

DischargeCooling bed type

Product identification

LADLE FURNACE

The 175 t ladle furnace is equipped with a water cooled roof, conductive electrode arms, and an automatic tempera-ture and sampling device.

JIB Type CS 175175 t nominalConductive type (Cu)460 mmDigital hydraulic type25 MVA plus 20 %4.0 K / minDouble argon porous plugTwo cars with crane access on both sides of the ladle furnace

0.45 kWh / t and K0.010 kg / kW

CONVEX® 20-9 CCS9 m61,200 mm120 mm sq. to 200 mm sq.150 mm sq., 180 mm sq.,200 mm sq.6–18 mTurret with lifting / lowering and weighing systemFull overhead with lifting / lowering systemT-typeMechanical stopper mechanismCONVEX Technology®

Mould-EMS (adjustable height)2.8 – 4.4 m / minRigidTorch cuttingOverhead cross transferHydraulic turnoverBillet marking machines, one on each side of the turnover cooling bed

CONTINUOUs CAsTINg MAChINE

The high production 6-strand SBQ-Caster uses SMS Concast’s CONVEX® mould technology. The caster is equipped with a full range of supplementary features such as an automatic stopper control system, mould stirrers and a billet marking machine. The CCM can produce up to 1.8 mio t of good billets per year.

CONSUMPTION fIgURES

sMs Concast

Toedistrasse 9

8027 Zurich

Switzerland

Phone: +41 44 204 65 11

Fax: +41 44 202 81 22

sales@sms-concast.ch

www.sms-concast.ch B40

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MEETINg your EXPECTATIONs