Special EAF/LF Competences

Layout of Electric Arc Furnaces with nom. Tap weights from 5 – 140 to 

 

  • General Layout Calculations on EAF Volume – and Dimensioning, Energy requirements, in respect to considered plant performance

  • Calculations on EAF AC – and CD - Transformer Performance, established by means of a transformer specific circle diagram withdrawn from transformer nameplate and reactor layout data, and evaluations on respective operational working points, and by the Layout of a fossil Energy Concept (Oxygen/Gas Burners, Oxygen coherent Jets, water cooled Oxygen Lances),

  • Evaluation on potential thresholds related to EAF working diameter compared to installed transformer power, evaluation on critical arc radiation (Arc Radiation RI) as criteria for the expected refractory wear in critical EAF side wall sections

  • Evaluations on threshold values in respect to permissible Offgas values and permissible gas concentrations (i.e. CO – concentrations)

  • Assessment on the total AC – and DC - EAF Performance in terms of process times, consumption figures, by considering the various electrical- and fossil energy sources in use, for different raw material charges and charge mixes (Scrap, Scrap/DRI, Scrap/HBI, Hot Metal, Scrap / Hot Metal Charge) and for different DRI / HBI Chemistries

  • Determination of permissible Feeding Rates for DRI / HBI charge materials according to the energy available during material feeding

  • Quantitative Determination of slag forming materials such as lime and dolomite lime, according to process related requirements (Gangue contents and chemistry of DRI or HBI, Hot Metal), addition times and addition quantities

  • Assessment on requirements of various injection Systems for Carbon Lime and dolomite lime, by evaluation of Injection rates / time sequence

  • Layout and Dimensioning of Offgas / Dedusting System, by means of the EAF / LF exiting Offgas Volumes / Offgas Chemistry / Offgas Temperatures, Assessment on Duct- and Canopy sizing/ Offgas velocities, Assessment on required Cooling Volume, Filter surface according to Filter Loads

  • Requirements on Scrap Yard layouts, Scrap transport and Loading Equipment, Scrap Yard Logistics

  • Time Studies

  • EAF Process – Simulations for AC – and DC – Electric Arc Furnaces

    • For all kinds of charge mixes

      • Pure Scrap Charge

      • Scrap / DRI or HBI – Charge (also by considering different DRI / HBI chemistries & - properties)

      • Scrap / Hot Metal Charge

    • Evaluations of Transformer – Performance and related operational working points, compilation of circle diagram established by EVA – Simulation

    • Process data calculation  – Determination by means of EXCEL based process simulation program

    • Threshold considerations in respect to 

      • Suitability of installed transformer power

      • Limitations on oxygen usage by oxy Jets

      • Permissible feeding rates of DRI / HBI

  • Determination of Flux Requirements for the respected charge / charge mix

  • Development of the specific melting technology for a regarded process, considering the designated charge materials, furnace layout, available energy sources and time requirements of downstream processes

  • Assessments on Process Performance, plant throughput, process Times and related Consumption Figures for the examined melting process

  • Preparation of related Process Diagrams as bar charts, with process mean data for each process step

Layout of Ladle Furnaces from  25 – 140 t according to Production Requirements

  • Calculations on LF Transformer Performance, established by means of a transformer specific circle diagram withdrawn from transformer nameplate, and evaluations on respective operational working points

  • Determination of operational working points

  • Determination of Heating Rate and Radiation Load on Ladle Slag Line Refractory (RI – Factor) per Working Point

  • Quality related Requirements on Equipment of Ladle Furnaces, depending on Steel Quality to produce (Wire Injection machines, Injection of powder materials by means of ceramic lances)

  • Calibration of Alloy Addition Systems for medium - und high alloyed steel qualities at LF stations

 

Process Technology of Ladle Furnaces

  • LF Process – Simulations by means of

    • Process Simulation for a regarded production specification, process calculation by means of an EXCEL based process simulation program

      • Threshold considerations for an existing LF, when substantial changes (heat size, transformer power) have been made

  • Suggestions on Process Guiding, in respect to treatment requirements, to promote and support i.e. Deoxidation, Desulphurization and alloying technics in respect to steel qualities to be produced 

  • Suggestions on Special Process measurements within the LF Process to increase steel cleanliness

  • Development of the specific treatment technology for a regarded process, considering the designated analysis requirements for the steel quality to produce, the type and chemistry of alloying materials and time requirements of downstream processes

  • Preparation of related Process Diagrams as bar charts, with process mean data for each process step

  • Suggestions on Purging Technics 

  • Deoxidation Practice & Alloying

  • Development of Al – deoxidized steel qualities with ultra – low Sulphur specification ( < 0,0008 % S) by means of Ca – Injection Technology

  • Process Technology for the production of Ca - treated free cutting steel grades, by controlled Re – Sulphurization by means of Sulphur containing wires