FMF Flexible Modular Furnace
Flexible Steelmaking with FMF
Tommaso M. Sarpietro
START UP AND STAND UP INDIA FROM MINES TO STEEL
30th January 2016, Ranchi
CONTENTS
Introduction
Market Scenario (India China)
Global Scenario
FMF
Base Module Mechanical Equipment
Add On Module Mechanical Equipment
Base Module Process Philosophy
Conclusions
INTRODUCTION
SIDE VIEW
FMF (Flexible Modular Furnace) was born from Tenova experience on EAF
and Hot Metal steelmaking practices in China.
The combination of the two experiences guided Tenova toward a unique
flexible steelmaking technology
MARKET SCENARIO (INDIA CHINA)
In the market the usage of hot metal in EAF is a common practice in order
to be competitive in the current scenario (A)
Steelmaking is clearly moving toward more environmentally friendly and
less energy intensive processes (B)
Raw material and energy variability will remain a
major condition in the medium term (C)
Starting from 2025 scrap availability will increase
together with the share of EAF based production (D)
MARKET SCENARIO (INDIA CHINA)
A
TODAY THE MARKET NEEDS A TECHNOLOGY
THAT CAN WORK EFFICIENTLY AS A
CONVERTER
B+C+D
IN THE FUTURE MARKET WILL LIKELY SEE A
SUBSTANTIAL SHIFT TO A FLEXIBLE TECHNOLOGY
READY TO WORK FROM 100% HM, TO 100% SCRAP,
TO 100% DRI
MARKET SCENARIO (INDIA CHINA)
A+B+C+D
THE MARKET NEEDS A FLEXIBLE TECHNOLOGY
THAT:
IN THE SHORT TERM CAN EFFICIENTLY WORK WITH
HIGH PERCENTAGE OF HOT METAL
IN THE LONG TERM CAN EFFICIENTLY WORK WITH
DIFFERENT RAW MATERIALS
INTRODUCTION GLOBAL SCENARIO
Raw material price volatility and steel market saturation are the main
conditions to be faced by steel makers worldwide in the medium term.
In this scenario Tenova FMF works efficiently with full a range of raw
material:
0-90% Hot Metal
0-100% Scrap or DRI
90%
Hot Metal
FMF
100%
DRI
100%
Scrap
FMF - FLEXIBLE MODULAR FURNACE
MODULAR DESIGN
Base Module
Converter
Mode
CHEMICAL
POWER ONLY
HM TILTING DEVICE
WITH WEIGHING
SYSTEM
INNOVATIVE
LAUNDER
DESIGN
CORE
EQUIPMENT
Add on
Modules
BASE FURNACE
MINICONSTEEL (Option Scrap)
INNOVATIVE ROOF (Option DRI)
INNOVATIVE LOWER SHELL
INNOVATIVE LIFT AND SWING
SYSTEM
FUME ANALYZER
Scrap Mode
DRI Mode
ELECTRICAL
POWER MODULE
TDR+HRR ELECTRODES
AUTOMATION MODULE
CONSTEEL
EXTENSION MODULE
(Option Scrap)
FMF - FLEXIBLE MODULAR FURNACE
HIGH EFFICIENCY MODULES
Add on Modules
HIGH EFFICIENCY
Temperature and Sampling Device
EBT Restoring Module
Electrode Automatic Changing device
Process Efficiency
&
Safety
iEAF - iSTEEL
Door cleaning Module
Add on Modules
ENERGY
Heat recovery system
iRecovery
220 kg/tls
FMF BASE MODULE MECHANICAL EQUIPMENT
KEY FACTORS:
[Link] design
[Link] power only Multi point injection philosophy
[Link] tilting device
[Link] launder design
[Link] module as a temperature regulator
[Link] roof design
[Link] lower shell design
[Link] lifting and swinging system design
[Link] analyzer
FMF BASE MODULE MECHANICAL EQUIPMENT
SIDE VIEW
FMF BASE MODULE MECHANICAL EQUIPMENT
MULTY POINT INJECTION SYSTEM
O2 Injector
+
C Injector
O2 Injector
+
C Injector
Continous Scrap Feeding
Consteel
Continuous
DRI Feeding
O2 Injector
+
C Injector
LOWER SHELL
NEW DESIGN
Continuous
Hot Metal
Feeding
SIDE VIEW
FMF BASE MODULE MECHANICAL EQUIPMENT
MULTY POINT INJECTION SYSTEM
TENOVA KT oxygen injectors shrouding flame technology.
The supersonic oxygen stream is protected by a low-energy annular flame that
greatly reduces drag on the supersonic jet and allows greater effective SIDE
lancing
VIEW
distances (about 65 times the exit diameter of the nozzle, compared with about
20 times achievable with standard convergent-divergent nozzles without
shrouding flame).
Exit speed of the oxygen jet exceeds MACH 2.
Oxygen injectors having higher rated flows generate longer and more effective
jets, this means get better efficiency and generate stronger stirring for the steel
bath
FMF BASE MODULE MECHANICAL EQUIPMENT
HOT METAL TILTING DEVICE
SIDE VIEW
FMF BASE MODULE MECHANICAL EQUIPMENT
INNOVATIVE LAUNDER SYSTEM
SIDE VIEW
FMF BASE MODULE MECHANICAL EQUIPMENT
MINICONSTEEL AND NEW ROOF DESIGN
MiniConsteel
as
Temperature
Regulator
New Roof
design
SIDE VIEW
FMF ADD ON MODULE MECHANICAL EQUIPMENT
SIDE VIEW
KEY FACTORS:
[Link] module to be implemented
[Link] unit module for electrode regulation to be implemented
[Link] as a continuous charging and preheating system
[Link] hood as a standard Tenova scrap preheating system
FMF MECHANICAL EQUIPMENT
INNOVATIVE LIFTING AND SWINGING SYSTEM
SIDE VIEW
FMF MECHANICAL EQUIPMENT
INNOVATIVE LIFTING AND SWINGING SYSTEM
SIDE VIEW
FMF BASE MODULE PROCESS PHILOSOPHY
CONTINUOUS RAW MATERIAL FEEDING:
Process control in FMF converter mode is based on continuous material feeding
as main process control philosophy. In this way it is possible to control theSIDE
typical
VIEW
issues that occur with high Hot Metal Processes (jamming, splashing, etc..)
HOT METAL TILTING DEVICE :
The continuous charge of HM into the furnace give the possibility to better control the bath reactivity that
Is one of the main concern for this kind of process (by reducing temperature gradients, chemical
gradients, etc.)
MINI-CONSTEEL /DRI FEEDING:
Continuous scrap/DRI charge into the furnace gives another tool to control the
bath temperature and the process reactivity.
DEPHOSPHORIZATION:
As we said it is possible to control and continuously tune the bath
temperature. Thanks to a typical EAF slag door de-slagging during process
time is a kind of standard practice in this condition.
Considering the above mentioned practices it is possible to minimize the P
reversal to the slag and so improving the dephosphorization practice.
FMF BASE MODULE PROCESS PHILOSOPHY
Effect on Bath Temperature and Carbon
Tilter charging reduces amplitude of bath Carbon and
Temperature trends allowing a more stable and quicker
process
Temperature
Carbon
21
Workshop Session EAF Heat Recovery System
FMF BASE MODULE BASE MODULE PROCESS PHILOSOPHY
REFERENCE PLANTS
SIDE VIEW
High HM feeding plants supplied
By Tenova
250 t Wheeling Pit USA - 2004
160 t Vallourec Sumitomo Brazil
4 x 100 t Bhushan India
100 t Shaoguan China
70 t Echeng China
75 t Hengli China
75 t Xining Special Steel China
60 t Xining Special Steel China
2 x 100 t TPCO China
65 t Tonghua China
100 Raighar India
FMF BASE MODULE BASE MODULE PROCESS PHILOSOPHY
REFERENCE PLANTS
SIDE VIEW
Reference 4
Reference 1
Reference 2
Reference 3
Tapping size
100t
75t
60t
100t
Hot Metal %
86
90
90
87
Scrap %
14
10
10
DRI %
13
O2 Capacity
3 x 3800
3x3200 +
1x3000
2x3200 +
1x1000
4x3200
Average TTT
38 min
48 min
53 min
40 min
Yield
92.5%
92%
90%
88%
Year
2009
2013
2014
2015
JSPL RAIGARH
- Capacity: 100 T tap, 130 T total
- Furnace Diameter: 5.5 M, EBT
- HM Charge: 85%, Coal based DRI 15%
-Oxygen lance: 4 x 3000 Nm3/h Wall
- Heats per day: 32~34, record 42 heats in a day.
-Transformer rating: 100 MVA
-Average O2 consumption: 55-60 Nm3/tls
- Tap to Tap time: 42~45 (no electric) -Yield : 88%
Workshop Session EAF Heat Recovery System
JSPL RAIGARH
Conversion cost reduction: 1200 Rs/tls
Annual saving: 120 Cr per year
Refractory life: 900+ heats
Workshop Session EAF Heat Recovery System
JSPL RAIGARH
Conversion cost reduction: 1200 Rs/tls
Annual saving: 120 Cr per year
Refractory life: 900+ heats
42 heats record
Workshop Session EAF Heat Recovery System
FMF BASE MODULE BASE MODULE PROCESS PHILOSOPHY
PRODUCTIVITY FIGURES
SIDE VIEW
CONCLUSION
FMF (Flexible Modular Furnace) is a flexible solution able to adapt to
SIDE VIEW
different and volatile scenarios (HM scenario, Scrap scenario, DRI
scenario) by adding and/or removing the different modules.
FMF Base Module is a solution developed starting from Chinese
experiences and now ready to face the transition from Oxygen Steel
making to EAF steel making
FMF Base module can be a low investment
revamping solution for steelmakers that invested in EAF
technology to face a scrap (or DRI) scenario that now
must change to HM scenario.
Tenova Group
Tenova is a worldwide supplier of advanced
technologies, products and engineering services
for the metals and mining & minerals industries
providing innovative, integrated solutions for complete
process areas
Being part of an industrial group Techint Group
shapes our mindset to understand the needs of a
customer better than others
29
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Techint
Engineering &
Construction
11%
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5%
Humanitas
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42%
Annual Revenue
Over US$ 26 billion
Permanent Employees
59,000
Total Employees
87,000
Ternium
32%
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SIDE VIEW
Thank you !!!
