Improving EAF productivity by PasekTap EBT Sand -...
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Improving EAF productivity by PasekTap EBT Sand Customized size distribution Laboratory testing & industrial application
Transcript of Improving EAF productivity by PasekTap EBT Sand -...
Improving EAF productivity byPasekTap EBT SandCustomized size distribution
Laboratory testing & industrial application
Index:
PASEK Introduction
PasekTap optimization model for EBT Sand:
– Lab test for product adjustment
– Product development for each customer
– Industrial scale
CONCLUSIONS
Spanish company founded in 1971.
Working from the beginning in the Steel Industry.
Continuously adapting to the steel plants necessities:
In the refractory sector
In the fluxing industry
+ 500 employees
REFRACTORIES
One of the largest Magnesium Silicate deposits in Europe.
Mine concession for 90 years, started operations in 1972.
Very close to the harbor (8Km).
1 Mton / year production; reserves over 600 Mton.
Over 26 Mton of Dunit@ already extracted.
(%)
MgO 37.2
SiO2 40.7
Fe2O3 8.3
Al2O3 2.4
CaO 1.8
Na2O +
K2O< 0.2
PPC 9.2
Pasek MineraleSproduct portfolio
Application Product Market Grain Size
Big Market Sinter/ BF/BOF Flux Dunite Spain Lumps (> 10mm)
EAF TapHole sand Dunite Calcined EU MiniLumps (<10mm)
Rockwool Raw material Silica North America Fines (<3mm)
Refractory Sand Dolomite South America EBT (>1, <6mm)
Fertilizer CO2 capture Limestone Russia/Eastern EU AFAs(micron)
Fluidized bed Middle East/Africa Rock (>80mm)
Foundry Asia / India CustomizedCeramicsSandblast
Distribution
Industry
Pasek MINERALES Product Portfolio
ArcelorMittal (2 plants)TerniumGerdau (3 plants)AndecArequipaSimec
Central &
South America
ArcelorMittalBlueScopeNucor (7 plants)SDI (2 plants)Gerdau (1 plants)Republic SteelNLMK
US &
Canada
ArcelorMittal ( 1 plant)Maghreb Steel Ezz SteelEmirates Qatar (Sabic ( in development)
MENA
ArcelorMittal (13 plants)Tata IjmuidenSalzgitterThyssenkrupp-HKMRogesa-Dillinger HütteSaint-Gobain PAMArvediCelsa ( 5 plants)Ilva TarantoMegasa ( 3 plants)Beltrame( 3 plants)Salzgitter Peine, Feralpi, Lsw, ThuringenRIVA, Pittini, Ovako, Metalloinvest, OMZ, Yartsevo
EU &
Russia ASIAGUNUNG GARUDAREFRASERVICE
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Pasek MineraleScustomer portfolio
Index:
PASEK Introduction
PasekTap optimization model for EBT Sand:
– Lab test for product adjustment
– Product development for each customer
– Industrial scale
CONCLUSIONS
EBT sand operation principle
• 3 main objectives
– Excelent free opening
– No slag/steel leaks
– Large lifespan of the tap hole
EBT SAND TARGETS
• 3 main objectives
– Excelent free opening
– No slag/steel leaks
– Large lifespan of the tap hole
Sand:
‐ Grain size customized‐ Quality control‐ Material Hardness
Process:
‐ Filling method‐ Quantity of sand used‐ Tap Hole lifespan
EBT SAND TARGETS
• 3 main objectives
– Excelent free opening
– No slag/steel leaks
– Large lifespan of the tap hole
Sand:
‐ Dry‐ Angulosity of the material‐ Grain size
Process:
‐ Tap hole cleaning‐ Gap sliding gate/tap hole‐ Tap Hole lifespan
EBT SAND TARGETS
• 3 main objectives
– Excelent free opening
– No slag/steel leaks
– Large lifespan of the tap hole
LAB TEST: PRODUCTS
Sand:
‐ Chemical‐ Grain size
Process:
‐ Dimensions of the Tap Hole
LAB TEST: TECHNICAL DATA INVOLVED IN GRAIN SIZE RECOMMENDATION
EAF PARAMETERS 1‐6 mm 3‐6 mm Calcined 2‐6 mmFurnace temperature > 1650 º < 1650 º >1600 ºVariations of the temperature >7 % < 7 % > 3 %Inclination of the furnace > 5 % < 5 % > 3%Furnace capacity > 120 mt < 120 mt > 80 mtTap to tap > 45 min < 45 min > 38 minVariations of the tap to tap > 15 % < 15% > 10 %Soaking plane > 40 min < 40 min > 25 minTap hole diameter > 200 mm < 200 mm > 180 mm
Tap hole filling method Manual Hopper/neumatic/silo Hopper/neumatic/silo
Number of heats of the tap hole before reparation/substitution
> 120 < 120 > 80
Tap hole cleaning frequency < 1 per day > 1 per day > 1 per daySeparation between tap hole and sliding gate
< 10 mm > 10 mm > 10 mm
3-6 mm
LAB TEST: PRODUCTS
Calcined 2-6 mm
45 % market share 50 % market share 5 % market share
1-6 mm
PREHEATING EVOLUTION
Tap holesimulation
LAB TEST: SIMEBT
A)
B)
C)
LAB TEST: GLASSY PHASE
Temperature measurements
LAB TEST: SIMEBT
0
500
1000
1500
2000
2500
1 11 21 31 41 51 61 71 81 91 101 111 121 131 141 151 161
T ºF
Temperature progress
T1T2T3T4
• Controlled industrial test Technical assistance during the initial tests of the product
Industrial scale trial
• After-Sales Service: Technical and delivery support
Continuous improvement process support
> 300.000 heats in 2016 with > 97 % free opening
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Ladle sand Started in 2107 Customized per customer 70 % of spanish market in 7 months Cr, Si and C blend Supervision of customer procedure
Acería 1 Acería 2 Acería 3 Acería 4 Acería 5 Acería 6 Acería 7
Ø Buza 45 mm 45mm 55 mm 55 mm 80 mm 45 mm 55 mm
L Buza 650 mm 220mm 380 mm 270 mm 320 mm 270mm 220 mm
Cantidad Acero 98 t 110t 130‐150 t 130 t 300t 122 t 135 t
Calidad acero princial S355‐JR
Cantidad Arena 10 kg 40‐60kg 20‐30 Kg 15 kg 40 kg 10 kg 30‐40 Kg
Ø Tronco‐cono 140mmNo tiene No tiene No tiene No tiene
L Tronco‐cono 300mm
Temp. precalentamiento NO SI (1200ºC) SI (900ºC) Vesuvius SI/Sokao NO 1100 ºC NO
Temp. Proceso 1540‐1585ºC 1690ºC 1540‐1670ºC 1640 ºC 1570 ºC 1620‐1640ºC 1595‐1615ºC
Tiempo medio proceso 60' 180' 60‐90' 50' 120' máx 40' 45‐50'
Material buza ‐‐ Al2O3 + C Al2O3 + C Al2O3 + C MgO + C ‐‐ ‐‐
FO (%) 99% 97‐98%
Proveedor 1:
Comp. Arena 1(%)
SiO2 25,06 19,93 11,4 16,37 20,63 arena 66% 42,38
Cr2O3 34,89 36,75 37,37 38,65 37,42 arena 30% 26,3
C 0,44 0,32 0,47 0,42 0,19 arena 4% 0,53
Granulometría arena 1(mm)
1‐2,4 0,7 3,4 0 5,6 0
>0,5mm ‐ 3% max0,2‐0,5 mm ‐ 30‐35%0,1‐0,2mm ‐ 55‐60%<0,1 mm ‐ 2% max
1,9
0,8‐1 1,4 7,5 6,9 3,7 1,5 9,6
0,4‐08 21,9 29,7 15,7 11,3 31,7 40,2
0,18‐0,4 63,7 50,1 60,4 68,4 59,6 42,9
<0,18 12,4 9,4 17 11 7,2 5,4
Customized ladle sand
Average free opening 99 %
