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Emerging Steelmaking Technologies: Energy Optimizing Furnace (EOF) and CONARC, Study notes of Metallurgy

Two emerging steelmaking technologies: energy optimizing furnace (eof) and conarc. Eof is a combination of three interconnected reactors - a furnace, preheater, and recuperator - that optimizes energy usage and scrap preheating. Conarc is a combined top and bottom blown steelmaking technology that utilizes the benefits of both electric arc furnace (eaf) and oxygen steelmaking. Both technologies aim to improve steelmaking processes by reducing energy consumption and increasing flexibility in raw material usage.

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Lecture 19: Emergi ng Steelmaking Techno logies
Contents:
Basis
Energy Opt imizing Furnace
CONARC
Key words: EOF, CONARC
Basis:
To develop ec ological balance techno logy. Such a techno logy wo uld re quire proc essing th e ra w
mate rials such th at liq uid pro ducts are discharged a t the e nvironmental tem perature and waste
products are discha rged in th eir harmless st a tes . Th is requires integrating t he c onc ep t of
recovery, reuse and recirculation with in the proces s envir onment .
To develop a process which is flexible to use varying proportion of metallic materials depe nding
on their availability. Con verter steelmaking is b ased on ho t meta l.
To develop te chnologies wh ich are n ot elec tric energy d ependent. E le c t r ic s t ee l m ak i n g i s
depe ndent of availab ility of cheap electric powe r, tho ugh dev elopments are made to use
chemical energy.
In t he abo ve conc ept, two tech nologies are wor thwhile to mention: Energy optimizing f urnace (EOF) and
CONARC (Co nverter + Arc furnace)
En ergy opt imizin g furn ace (E OF)
Figure 19.1 is a schematic sketch of an energy opt imizing furna ce (EO F). EOF is a comb ination of three
inde pendent, interco nnected react ors, n amely f urnace to pro duce steel, p reheater to heat the s crap and
a recuperator to rcover was te heat and to reus e by heating oxygen .
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Lecture 19: Emerging Steelmaking Technologies Contents: Basis Energy Optimizing Furnace CONARC Key words: EOF, CONARC Basis:

  • To develop ecological balance technology. Such a technology would require processing the raw materials such that liquid products are discharged at the environmental temperature and waste products are discharged in their harmless states. This requires integrating the concept of recovery, reuse and recirculation within the process environment.
  • To develop a process which is flexible to use varying proportion of metallic materials depending on their availability. Converter steelmaking is based on hot metal.
  • To develop technologies which are not electric energy dependent. Electric steelmaking is dependent of availability of cheap electric power, though developments are made to use chemical energy. In the above concept, two technologies are worthwhile to mention: Energy optimizing furnace (EOF) and CONARC (Converter + Arc furnace) Energy optimizing furnace (EOF) Figure 19.1 is a schematic sketch of an energy optimizing furnace (EOF). EOF is a combination of three independent, interconnected reactors, namely furnace to produce steel, preheater to heat the scrap and a recuperator to rcover waste heat and to reuse by heating oxygen.

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Figure19.1: Arrangement of furnace, scrap preheating chamber and a recuperator in an Energy optimizing Furnace Design of each reactor and their integration with each other is important such that furnace off gas exits the system at a low temperature to the extent possible and at the same time scrap is heated to the desired temperature and steel of required quality is tapped. Furnace The furnace is refractory lined and has a provision for injection of carbon and oxygen. Oxygen can be injected both at high speed to promote decarburization and at low speed to promote post combustion. Preheater A preheater is installed at the top of furnace to preheat the scrap by the waste gases flowing upward from the furnace. For scrap preheating residence time (R T) of the waste gas in the preheater R T = Diameter of the preheater flow velocity of exit gas =^0.^785 D^3 Q (1) should be maximum. D is diameter of preheater and Q is volume flow rate of furnace gases. Both D and Q are important. For a given Q, diameter of preheater must be such that furnace gases can cool within 700 ℃ to 800 ℃ from 1300 − 1350 ℃. The exit temperature of gas from the preheater is the inlet temperature of gas to the recuperator. Scrap size is also important to heat scrap to the desired temperature. Smaller size scrap can be preheated efficiently. Recuperator

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Basic Characteristics Standard capacities of EOF are available in capacities 30/40 t, 60/ 80 t and 100/ 120 t. Hearth surface is 6.6 to 22 square meters Shell diameter is around 5.3 to 7.5m Total height from working platform to top level =17 to 25 m No. of scrap-preheater staged 1to 2 Tilting tapping angle 80 Main equipments description

  1. Bottom car (2unit) is used for quick bottom exchange for a new campaign. One bottom car supports the EOF for operation and the other supports a second bottom for relining. Tilting is allowed at high speed hydraulic cylinders to allow slag free tapping.
  2. Gas cleaning plant is wet system.
  3. EOF has facilities for charging and weighing of bulk material and ferro-alloys. Advantages
  4. Flexibility to in terms of metallic charge
  5. No need of electric energy
  6. High productivity
  7. Low tramp elements
  8. Low inclusions due to slag free toppings Energy saving is due to A. Post combustion (95%) B. Scrap preheating ( 850 ℃) C. High operational of flexibility. Consumption of raw materials/ ton of liquid steel Hot metal and scrap+ pig iron are charged in 70% :30% proportion Lime 45 kg/t (depending on P content of HM) O 2 is consumed at 50 - 70 N cu.m./t Fuel consumption is 5 - 10 M cal/t Tapping- 1700 ℃ without ladle furnace and 1650 ℃ with ladle furnace.

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CONARC

In seventies there were discussions amongst scientists and technologies about the future of pure top blown and pure bottom blown steelmaking. These discussions resulted into a combined top and bottom blown steelmaking technology which has almost replaced pure top blown and pure bottom blown steel making. In recent years discussions are in progress about EAF and oxygen steelmaking with respect to use of energy and raw material. The objective is to develop a technology utilizing benefits of both EAF and top blown steelmaking. CONARC is the resultant of such discussions. What is CONARC? The CONARC steelmaking process has been developed by Mannesman Demag. It combines electrode arc melting with the oxygen steelmaking process. The process consists of two shells with one 3 phase electrode arm and one top blowing lance for hot metal treatment. This allows a high flexibility with respect to use of raw materials as well as energy source. Worldwide there are around 12 units in operation.

  • In India Ispat industries in Dolvi, Maharashtra has been integrated with Ispat’s converter and arc furnace. This combination has given flexibility of alternative choices of energy resources to use for steelmaking-be it coal, electricity or gas. In addition, choice of alterative metallic charge material is also available i.e. be it iron are, pellets, sponge iron, scrap or hot metal This plant will be equipped with compact strip production technology to produce high grade finished steel like hot rolled coils. Bhushan steel and strips limited have also installed CONARC.

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