Paper 2 EOF

INTERNATIONAL SEMINAR ON START UP AND STAND UP INDIA FROM MINES TO STEEL
The Reliable Choice for Indian

Start-Up Steel Plants
Shailesh Burde
Yojana Engineering Solutions - MINITEC Representative
SOLUTIONS FOR MINI STEEL

PLANTS WORLDWIDE
EOF: The Reliable Choice for Indian Start-Up Steel Plants
The company - History

MINITEC is the successor of KTS KORF TECNOLOGIA
SIDERRGICA LTDA, which had a long track of successful
engineering and technological development from 1980 to
2000, in Brazil and abroad, especially in India.
MINITEC was founded in October 2002, having as major
goal to support Mini Steel Plants worldwide.
The company
MINITEC has proprietary technologies and develops design and
engineering of specific units, such as:
Mini Blast Furnaces
Oxygen Steel Furnaces (EOF)
Mini Sinter Plants
Integrated Mini Steel Plants
Conceptual and feasibility studies are part of MINITECs activities, as

well as technical and commercial support for procurement of equipment,
supervision of erection, commissioning and assisted operation. Your
plant will be delivered in full operation, after demonstration of the
guaranteed performance.
Furthermore, MINITEC supplies certain proprietary equipment.
Joint Ventures & Cooperation Agreements

Arabian and the
Near East countries
MSP, EOF and MBF
India
Sub-Saharan Africa
MSP
India
MSP
YOJANA
MBF and EOF
1. EOF - AN INTRODUCTION
Energy Optimizing Furnace was conceived to utilize the sensible heat of
small and medium sized steel converters in an effective way.
Oxygen is blown through two numbers of submerged tuyeres and one or
two numbers of supersonic lances.
Post-combustion of the emerging
gases above the steel bath is
done using four atmospheric
injectors supplying a part of the
heat to the metallic bath and rest
for scrap preheating.
EOF has the flexibility to operate
with up to 40 % scrap in the
charge or 15 % DRI.
PROCESS FLOW SHEET
The tap-hole and tilting

mechanism is designed for
efficient slag-free tapping.
Possibility of tilting of the
furnace, allowing continuous
extraction of slag through the
slag door, tapping at the very
moment
of
finishing
decarburizing, as well as the
instantaneous
release
of
scrap
from
the
scrap
preheater, allow tap-to-tap
times of less than 30 minutes.
2. The following are the main advantages offered by EOF:

i)
ii)
iii)
iv)
v)
Flexibility to a great extent, in terms of metallic charge;

High productivity and furnace availability;
Steel has very good metallurgical properties;
Low tramp elements;
Low inclusions due to continuous flushing of slag during
blowing, and slag free tapping;
vi) Electric energy consumption is required only for the
auxiliaries;
vii) Fast bottom exchange (in 4 hours),
Main advantages offered by the EOF

viii.Constructive features of the furnace allow quick and
efficient charging of hot metal and solid charge, as well as
fast and precise tapping.
ix. Very low noise level
x. Low investment and operating cost
xi. Detail design & Engineering, Equipment, Technical
Services from INDIA.
Hence EOF is the most suitable equipment for converting
the liquid hot metal, scrap and DRI to steel, especially for
heat sizes of 30 Ton to 80 Ton, or annual capacities of 0.3
to 0.8 million TPA.
3D image of the EOF.

Design in 3D is the
most updated
engineering tool,
which allows to
practically avoid
interferences in the
detail engineering,
fabrication and
erection stages,
eliminating rework
and corrections.
Complete Project in 3D
NEW SLAG DOOR CLOSING SYSTEM
FULLY MECHANIZED AND

AUTOMATED SYSTEM OF TAPPING
FINGERS MOVEMENT SIMULATION
3D simulation of the
EOF.
Design in 3D
provide the powerful
tool of movement
simulation and
dynamic tests.
BOTTON CAR TILTING SIMULATION
EOF.
Design in 3D
tool of movement
simulation and
dynamic tests.
SEALING SYSTEM MOVEMENT SIMULATION
EOF.
Design in 3D
tool of movements
simulation and
dynamic tests.
BOTTOM EXCHANGE SIMULATION
3D simulation of
the EOF.
Design in 3D
provide the
powerful tool of
movements
simulation and
dynamic tests.
MAIN FEATURES OF EOF

1. SCRAP PREHEATER
2. SEALING SYSTEM
3. FURNACE ROOF
4. FURNACE SHELL
5. FURNACE BOTTOM
6. BOTTOM CAR
7. SCRAP BUCKET
8. FINGERS
9. DOWN-COMER

2. RECENT PERFORMANCE DATA - EOF OPERATING FIGURES - 2013 AVERAGES
Hospet
Item
Unit
GERDAU
JSW Salem
Steels
Rated capacity (Liquid Steel)
t
43,5
52
45
65
Hot Metal
68
80.5
85
85
Scrap
18
12
15
15
%
Average charge
DRI
7.5
Pig Iron + Scrap Pig
Rated capacity
Production 2013 (Finish Steel)
14
570
538
600
504.6
650
460
Rebar
Quality
450
370
Rebar &
Quality
h/d
36,1
27.85
25
24
Nm3/t
LS
61
54
57
60
kg/t
LS
1,60
3,68 (2)
5,28
3.0
5.5
8.5
2.2
3.6
5.8
2.6
4.0
6.6
kWh/t
45
25
40
44
1.036(3)
650
850
800
ktpa
kt
Kind of steel
Average heats per day (365d/y)
365d/y)
Oxygen consumption
Refractory
consumption
Bricks
Gunning Mass
Total
Electric energy consumption (1)

Average heats per campaign
Quality
1. EOF proper (incl. Gas Cleaning, Cooling Water Systems, Alloy Addition, Overhead Cranes)
2. Includes launder repairs
3. Result of the improvement in tuyere design
3.
BENCH MARK RESULTS
i) Heats per shift :
16 heats in a shift at Hospet Steels Ltd, India.
ii) Heats per day :
41 heats In a day at Hospet Steels Ltd, India,

48 heats In a day at GERDAU Divinopolis, Brazil.
iii) Heats per year :
13,338 heats in a year (2005) at GERDAU, Brazil.
iv) Heats /campaign: 1,314 at GERDAU (Campaign Nr. 199 - July 2008)
a result of the improvement in tuyere design.
v) Electrical Energy : 24 units per Ton
vi) Phosphorous levels: 0.01 %
4.
DESIGN IMPROVEMENTS
I. Tuyere design optimized for longer life of refractory.

II. Supersonic lance: Optimum Injection speeds and Lance position for
effective results.
III. Scrap Preheater By-pass: A scrap preheater by-pass provision with
control damper is made to by-pass the hot flue gases to control the
scrap preheat temperature and to maintain suitable pressure in the
furnace. This addresses the problems faced, namely overheating
of scrap and positive pressure in the furnace during peak blow
period.
IV. Scrap pre-heater fingers are modified and improved for better cooling
and avoiding hot-spots.
V. SPH water cooled panels: Tubular construction replacing plate
construction for longer life.
VI. Gas Cleaning System (Wet): Stainless Steel construction of wetted
parts of GCP for increased life. Improved Venturi design.
DESIGN IMPROVEMENTS
vii. Improved cradle design for smooth quick tilt-back.
viii. Suitability to charge DRI continuously through weigh-feeders.
ix. Introduction of Coal injection, which will allow a higher proportion of
DRI in the charge.
x. Introduction of Lime Injection for better assimilation and reduce slag
quantity.
xi. Fully mechanized and automated system of tapping and tap-hole
closing
xii. New slag door closing system, allowing to work with higher slag level
in the furnace.
xiii. WHRS to utilize waste heat incase SPH is not opted.
5.
ECONOMICAL CONSIDERATIONS
5.1 Considerations on Operating Cost (OPEX)

a) High productivity optimizes fixed cost
b) Low energy consumption
c) Low cost of operating consumables
d) Low maintenance cost
e) Waste heat recovery options
5.2 Considerations on Capital expenditure (CAPEX)
a) Optimally sized to reduce the construction and equipment cost
b) High productivity in terms of number of heats reduces heat size
5.3 Operating Cost Comparison between EOF - BOF EAF

Done by Gerdau Group - Brazil
Year
EOF
BOF
Best EAF
2001
100,0
105,8
124,7
2002
100,0
121,5
129,9
2003
100,0
107,2
131,9
2004
100,0
105,1
143,7
2005
100,0
105,1
142,9
2006
100,0
100,3
139,1
Avge.
100,0
108,0
135,1
Table presents the

Operating Cost Index, in %, of the
EOF (GERDAU Divinopolis),
BOF (GERDAU Baro de Cocais)
and the best performing EAF of
the GERDAU Group in Brazil
(excluding raw materials).
Remarks:
(i) During the period covered by this survey, total operating cost (including maintenance)
of the BOF was 8 % higher than that of the EOF, while the cost of EAFs was much
higher - of course compensated by the lower raw material (scrap) cost.
(ii) The Divinopolis EOF is a 43,5 t unit (originally 35 t), while the Baro de Cocais BOF
is a 35 t unit (originally 28 t). Both operate with hot metal from charcoal blast furnaces,
while the BOF charges on average 16 % scrap, the EOF averages 36 % scrap.
6. CONCLUSIONS
EOF is proving itself to be the most suitable option for production

capacities up to 0.8 mtpa for converting hot metal and varying proportions
of scrap and DRI. The quality and productivity levels have been
appreciable and are still being enhanced by design improvements.
Operation and maintenance is much easier than in case of Converter or
EAF.
Today the EOF is a proven technology, competing with the classical steel
melting processes, with the advantage of producing the most critical
quality steels as a routine. Low investment cost (capex) and low
operating cost (opex), combined with great flexibility regarding
charge mix and low demand of electric energy render the EOF most
attractive for any new steel melt-shop. This is especially true in areas
where electric energy is scarce and expensive, and scrap is not available
- conditions which prevail in India these days.
CONCLUSIONS .
An integrated Mini Steel Plant based on mini blast furnaces and an EOF,
supported by ladle furnace and continuous casting machine, presents the
following advantages:
i. It warrants steel with highest purity.
ii. It does not depend on availability of a strong electric energy grid
iii. It presents high yield and productivity
iv. It demands less capital investment than a BOF plant of same capacity
v. It presents a lower operating cost than a plant based on any other
technology
vi. Environmental impact is lower than that of any other melt shop, due to
lower noise level and lower emissions.
vii. Detail design & Engineering, Equipment, Technical Services from
INDIA.
Though the number of installations are still few, the coming years will see
many installations coming up with new improvements making it an even
better option.
Worldwide Projects
Our main clients
THANK YOU!!
MINITEC Minitecnologias Ltda.
MINITEC Equipamentos Siderrgicos Ltda.
Rua Bananal, 405 - 5 andar - Bairro Santo Antnio
Rua Minas Gerais, 1.901 - Bairro Ipiranga
CEP: 35500-036 Divinpolis/MG Brazil
CEP: 35502.026 Divinpolis MG
Email: [email protected]
Website: www.minitec.eng.br
YO JANA ENGINEERING SOLUTIONS,

All India Representative For MBF and EOF
Hospet, Karnataka, India 583201
Phone : +91 88 6191 9988, +91 88 8456 7710.
email: [email protected]

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INTERNATIONAL SEMINAR ON START UP AND STAND UP INDIA FROM MINES TO STEEL

The Reliable Choice for Indian

INTERNATIONAL SEMINAR ON START UP AND STAND UP INDIA FROM MINES TO STEEL

SOLUTIONS FOR MINI STEEL

EOF: The Reliable Choice for Indian Start-Up Steel Plants

The company - History

EOF: The Reliable Choice for Indian Start-Up Steel Plants

Oxygen Steel Furnaces (EOF)

Mini Sinter Plants

Integrated Mini Steel Plants

Conceptual and feasibility studies are part of MINITECs activities, as

EOF: The Reliable Choice for Indian Start-Up Steel Plants

Joint Ventures & Cooperation Agreements

MSP, EOF and MBF

EOF: The Reliable Choice for Indian Start-Up Steel Plants

EOF: The Reliable Choice for Indian Start-Up Steel Plants

PROCESS FLOW SHEET

EOF: The Reliable Choice for Indian Start-Up Steel Plants

The tap-hole and tilting

EOF: The Reliable Choice for Indian Start-Up Steel Plants

2. The following are the main advantages offered by EOF:

Flexibility to a great extent, in terms of metallic charge;

EOF: The Reliable Choice for Indian Start-Up Steel Plants

Main advantages offered by the EOF

EOF: The Reliable Choice for Indian Start-Up Steel Plants

3D image of the EOF.

EOF: The Reliable Choice for Indian Start-Up Steel Plants

EOF: The Reliable Choice for Indian Start-Up Steel Plants

NEW SLAG DOOR CLOSING SYSTEM

EOF: The Reliable Choice for Indian Start-Up Steel Plants

FULLY MECHANIZED AND

EOF: The Reliable Choice for Indian Start-Up Steel Plants

FINGERS MOVEMENT SIMULATION

EOF: The Reliable Choice for Indian Start-Up Steel Plants

BOTTON CAR TILTING SIMULATION

EOF: The Reliable Choice for Indian Start-Up Steel Plants

SEALING SYSTEM MOVEMENT SIMULATION

EOF: The Reliable Choice for Indian Start-Up Steel Plants

BOTTOM EXCHANGE SIMULATION

EOF: The Reliable Choice for Indian Start-Up Steel Plants

MAIN FEATURES OF EOF

EOF: The Reliable Choice for Indian Start-Up Steel Plants

Electric energy consumption (1)

EOF: The Reliable Choice for Indian Start-Up Steel Plants

BENCH MARK RESULTS

i) Heats per shift :

16 heats in a shift at Hospet Steels Ltd, India.

ii) Heats per day :

41 heats In a day at Hospet Steels Ltd, India,

iii) Heats per year :

13,338 heats in a year (2005) at GERDAU, Brazil.

EOF: The Reliable Choice for Indian Start-Up Steel Plants

I. Tuyere design optimized for longer life of refractory.

EOF: The Reliable Choice for Indian Start-Up Steel Plants

EOF: The Reliable Choice for Indian Start-Up Steel Plants

5.1 Considerations on Operating Cost (OPEX)

EOF: The Reliable Choice for Indian Start-Up Steel Plants

5.3 Operating Cost Comparison between EOF - BOF EAF