Optimizing Production in the Steel Industry through ...

optimizing manufacturing in the steel industry December 2020 1

Optimizing Production in the Steel Industry

through Technology and Service Leadership

Process Optimization Environmental Performance Maximizing Productivity Plant Revamping / Upgrading



to optimize today’s performance and model next generation technology

Application of Best Practice ......

to minimize process-/product variation & down time and increase yield

to reduce consumption figures & conversion costs

to enhance product quality, improve equipment availability and perform operation with higher

reliability & consistency

to reduce the environmental impact of steelmaking – to remain sustainable & competitive


Why … ?


SCS – TECHNOLOGY

Who we are …

A private and medium sized

process engineering company

founded 1989

located in Linz/Austria


SCS – TECHNOLOGY

Our Activites …

Your

reliable, competent and focused

partner

for engineering tasks and complex projects

in defined technology fields e.g.

metallurgy, cement, graphite, pyrolysis, chemistry,…


SCS – TECHNOLOGY

Our Staff …

Highly educated and experienced engineers

combined with

a network of

independent national and international experts

including

good contacts with EU organizations


SCS – TECHNOLOGY

Our Services …

Feasibility Investigation

General Planning

Project Management

Process Engineering (Process Development,

Process Simulation, ……)

Basic and Detail Engineering

Engineering of Process Control Systems

Procurement

Supervision of Erection

Commissioning

Start-up

Process Optimization


Customer`s satisfaction is the ultimate measure of product and service

performance. SCS`s experts focus on customer’s needs and satisfaction.

SCS`s Technology engineers analyze customer applications and requirements – current

and future – to optimize today’s performance, model next generation technology and

improve environmental performance

Our process knowledge translates customer applications and requirements into raw

material, processing and testing Best Practices. This key Know-How ensures that

manufacturers would be able to apply state-of-the-art process technology

Best Practice procedures and targets minimize process and product variation through

extensive use of statistical process control and concurrently consumption figures &

conversion costs will be reduced

e.g. Customer Technical Service engineers provide electrode use Best Practices to assure

optimum graphite electrode performance

……

SCS is an independent, flexible and professional company with experts

along the entire process route of Steel making and Steel processing.

SCS`s knowledge and experience is your value added and business

advantage.

Technology and Service Leadership

Process Optimization, Environmental Performance


Europe’s efforts to go climate-neutral by 2050 could be undermined – risk of carbon leakage

(occurs when companies transfer production to countries that are less strict about emissions)

Steel products sold on the EU market, whether produced in the EU or imported from third countries,

should have similar CO2 cost

CBA mechanism would counteract this risk of carbon leakage by putting a carbon price on

imports of certain goods from outside the EU

CBA will be introduced in a way that the importer has on one side a comparable carbon cost

level to the EU industry and on the other side a sufficiently high incentive to decarbonize

CBA should at least cover direct and indirect emissions

Ukrainian Steel manufacturers have to assess, evaluate, and decide on a technologically

and economically viable way to optimize their energy consumption and productivity to

remain sustainable & competitive

SCS support you in setting these goals

EU Green Deal

Carbon Border Adjustment mechanism (CBA)


Steel manufacturers are increasingly facing a decarbonization challenge. This challenge is

driven by following main developments

Changing customer requirements and growing demand for low-carbon steel products (e.g. auto industry

wants to eliminate carbon emissions completely from their entire value chains (including their suppliers)

and taking on a full life cycle perspective.

Further tightening of carbon emission regulations. This is manifested in carbon dioxide reduction targets,

as well as rising carbon dioxide emission prices as outlined in the European Green Deal.

Growing investor and public interest in sustainability (e.g. institutional investors and global investment

firms confirming commitment to environmentally responsible business development and sustainable

investing)

SCS is able to support you to evaluate, and decide on a technologically and economically viable way

to decrease your carbon footprint (BF/BOF efficiency programs, Renewable Reducing Agents, Carbon

Capture & Usage, Optimization of DRI & EAF, ……)

EU Green Deal

Decarbonization – challenge for the Steel Industry


EU Green Deal



Optimization / Revamping / Upgrading - Examples

Existing EAFs

to increase tapping from e.g. 80 t to 95 t

to enhance electrode regulation system and

electric & automation

with the objective

to save consumption figures of energy & electrodes

to decrease tap to tap time & increase productivity

Increasing heat size up to 20%

Reduction energy consumption up to 12% (<405-415 kWh/t)

Increase productivity up to 20%

Measures: Split furnace shell design

Adaption of roof supporting, electrode lifting, titing mechanism,

water cooled roof and panels, hydraulic system

Design of new scrap basket

Upgrade of electrode regulation (loop for dynamic Set-point

Correction, nonlinear PI-controller to compensate varying

behaviour in lifting- and lowering movements, Melt Down

Automation, Foaming Slag Manager, Smart Measuring

Transducer, Heat Reporting, …)

Etc.


Environmental Performance - Examples

Optimization exhaust gas system

CFD - Simulation

to improve efficiency of primary- & secondary

suction system

to minimize emissions

to enhance environmental operation conditions

related to EAF production program

Increase capture efficieny of emissions up to 90%

Reduction of emissions up to 90%

Measures: On-site investigations applying measurment-technology

testing facilities

Engineering and CFD (Computational Fluid Dynamics) –

Simulation

Realizitation:

Optimizing of suction system (Canopy) and sealing

leakage points in steelworks building

Replacement of mixing chamber, exhaust gas line

system and installing spark catcher in primary exhaust

gas line

Installing new state of the art filterplant

Upgrade automation system

Etc.

CFD Simulation


The electrode control aims to keep the power consumption to

the furnace constant. By towering and lifting the electrodes,

ignition of the electric arc is achieved, the length of the arc and

the burn-up are controlled.

the more rarely the electric arc breaks-off, the more uniform the

power consumption of the furnace, and the shorter the

tap-to-tap – time is ……

the faster short circuits are compensated via the control, the fewer

the over current releases are triggered

Properties of high quality electrodes:

Low consumption rate thus homogeneity

High electrical conductivity

High thermal resistance and high thermal shock resistance

Mechanical resistivity against electrode breakage

Low ash and sulfur content

Resistance against oxidation in air

Reduce power-off time up to 20%

Reduce electrode consumption up to 25% Development of Electrode Consumption Over the Last Years

Maximizing Productivity - Examples

Electrode control – key to improve performance



References

voestalpine Stahl GmbH Austria

Integrated Steel Mill Process Engineering along the entire Production Route

Energy and Environmental Optimization Projects

Dust Reference Project (impact of voestalpine emissions to the city of Linz)

Process and CFD Simulation

MCR Holding AG Switzerland

Metallurgical Car Recycling Process Engineering and Plant Design


Process Simulation Recycling Plant

Lech-Stahlwerke Gmbh Germany

EAF Steel Mill Process Engineering along the entire Production Route



Stahl und Walzwerk Marienhütte GmbH Austria

EAF Steel Mill Energy and Environmental Assessments

Process and Waste Gas Measuring's



OAM Ózdi Acémüvek Kft. Hungary

EAF Steel Mill Process Engineering along the entire Production Route



Acroni d.o.o. Slovenia

EAF Steel Mill Process and Waste Gas Measuring

Mass and Energy Balance EAF Process Line


Dofasco Inc. Canada

Integrated Steel Mill Energy and Environmental Assessments

Process and Waste Gas Measuring BOF Plant

Mass and Energy Balance BOF Plant

Třincké Železárny a.s Czech Republic





References


EGE Celik Endüstrisi Sanayi Ve Ticaret a.s. Turkey

EAF Steel Mill Process Optimization



Posco South Korea




Böhler Edelstahl GmbH & Co KG. Austria

High Grade Steel Mill Energy and Environmental Assessments

Process and Waste Gas Measuring

Mass and Energy Balance

Saudi Iron and Steel Company Saudi Arabia

EAF Steel Mill Process and Waste Gas Measuring



Khouzestan Steel Company Iran

EAF Steel Mill Master Plan Production Expansion

Master Plan Environmental Improvement


References


SCS-TECHNOLOGY Verfahrenstechnik GmbH

Jägerstraße 18

4040 Linz / Austria

Phone +43 732 736601-0

Fax +43 732 736601-3

[email protected]

www.scs-technology.at

mailto:[email protected]



through Technology and Service Leadership


BACKUP


EU Green Deal



Reducing the environmental impact of steelmaking through providing plant managers and

technicians with a consolidated and understandable metric to quantify and monitor the

overall environmental impact of the production cycle.

SCS`s experts design sustainable solutions ……

Data inventory for the steelmaking route based on historical industrial data bases

collection, available on-line specific plant database and data of dedicated campaigns

Define Key Performance Indicators – KPI`s based on data inventory to asses in a

quantitative manner the environmental impact to monitor metric evolution during time

Set-up of a process modelling tool which uses the data inventory as input for an

integrated modelling of the energy and mass flow, allowing to investigate different

scenarios for potential reduction of the environmental impact of the production cycle

Develop the basis of decision making (process modelling + KPI`s) to access and

track the environmental impact of the present process, to evaluate the potential effect

of alterations/modifications of process parameters and of the equipment on the

environmental footprint

Assess the effectiveness and the reliability of alterations/modifications during time

……

„There is no planet B, so stick to plan A – be ecological.“

CFD Simulation of Charging EAF

Emission / Immission Prognosis


Environmental Performance


SCS provides global technical service leadership through innovative state-of-the-art programs

and value added services. Our expertise in analyzing furnace and electrode performance helps

steelmakers to maximize their productivity......

Arc Furnace Optimization:

high speed measurements enables advanced electrode regulation system

diagnostics. With SCS`s expertise, arc furnace electrical operation will be optimized.

Optimization of Electrode Performance

Electrode Handling can have a significant impact on the performance

Time Utilization: savings of crucial minutes of power-off time that will not only reduce

electrode consumption but also aid production.

Chemical Energy: Efficiently used chemical energy produces reaction and energy

transfer where required in the furnace. Inefficient energy use reacts with electrode and

heats up the fume system.

Electrode Spray Cooling: electrodes spray cooling reduce consumption up to 10%.

Power Program and Electrodes Regulation: Optimization have the effect of increasing

average MW and reducing power-on time, thus minimizing tip consumption.

Foaming Slag Practice: good foaming slag practice minimizes electrode consumption by

stabilizing electrical operation and giving beneficial furnace atmosphere conditions.

Product Selection: Selecting the correct grade and size of electrodes to suit the application

will also minimize consumption.

UHP - electrodes UHP electric arc furnace

Arc Furnace Analyser


Maximizing Productivity


In the course of revamping / upgrading many elements have to be considered for a project to

improve (e.g. reduce the amount of charges, promote highest possible chemical energy

utilization, allow best optimization on existing transformer power, modification on Drop Out box

and Water Cooled Duct, Hydraulic System for EAF, Scrap Bucket design to fit to new EAF with

existing loading and transport system, Automation System Review and Upgrade) as well as

limitations of the existing installation (limited space, lifting capacity building and cranes and the

required solutions for fast shell and roof exchange).

SCS`s experts provide proven and reliable concepts......

Innovative technologies, comprehensive experience – SCS provides upgrade systems

reduce tap-to-tap time, reduce consumption figures, reduce conversion costs, reduce down

time, enhance product quality, improve equipment availability, perform operation with higher

reliability & consistency, ……

Training, comprehensive experience and Know How – on site training and Show How

set up of continuous improvement programs, introduction of new practices (maintenance,

operation, organization, management), ……

EAF modernization technologies

current conducting arms steel-Cu plated, electrode spray cooling, columns and rollers,

hydraulic, electrode modernization/regulation, high current system, upgrading with a new

transformer, EAF control, visualization, electrics & automation, foaming slag manager,

meltdown control, power input optimization, ……

.


Plant Revamping / Upgrading

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