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:
1.Foundation design
2.Chemical power only Multi point injection philosophy
3.HM tilting device
4.Innovative launder design
5.Miniconsteel module as a temperature regulator
6.Innovative roof design
7.Innovative lower shell design
8.Innovative lifting and swinging system design
9.Fume 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:
1.Electrical module to be implemented
2.Hydraulic unit module for electrode regulation to be implemented
3.Consteel as a continuous charging and preheating system
4.Consteel 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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SIDE VIEW

Thank you !!!