#207 - Tenova Goodfellow to optimize twin shell EAFs at Steel Dynamics Inc.

Mississauga, 17 February 2015: Tenova Goodfellow receives PO for two (2) EFSOP holistic optimization® systems including water detection for both twin shell EAFs at Steel Dynamics Inc. Butler, IN.

In Post #205, we discussed the basic operation of an electric arc furnace (EAF). One of type EAF is known as ‘twin shell’. From Wikipedia:

The scrap basket is then taken to the melt shop, the roof is swung off the furnace, and the furnace is charged with scrap from the basket. Charging is one of the more dangerous operations for the EAF operators…In some twin-shell furnaces, the scrap is charged into the second shell while the first is being melted down, and pre-heated with off-gas from the active shell…After charging, the roof is swung back over the furnace and meltdown commences. The electrodes are lowered onto the scrap, an arc is struck and the electrodes are then set to bore into the layer of shred at the top of the furnace. Lower voltages are selected for this first part of the operation to protect the roof and walls from excessive heat and damage from the arcs. Once the electrodes have reached the heavy melt at the base of the furnace and the arcs are shielded by the scrap, the voltage can be increased and the electrodes raised slightly, lengthening the arcs and increasing power to the melt. This enables a molten pool to form more rapidly, reducing tap-to-tap times.

Tenova Goodfellow has significant expertise in making this and other types of EAF operate more efficiently and effectively.

Steel Dynamics Inc., has confirmed an order with Tenova Goodfellow for the supply and purchase of two (2) EFSOP holistic optimization® systems for both EAF batteries at their SDI, Butler, IN steelmaking facility. Tenova’s innovative technology and value proposition will provide full spectrum evaluation via upstream and downstream offgas analysis and water detection technology for all 4 EAF shells. The scope of supply will also include newly developed optical sensors for the measuring of off-gas velocity and temperature.

The order which was received in December 2014, included project work that was scheduled to begin immediately with the manufacturing of hardware & sensors at TGI’s Hamilton, ON production facility, Nova Analytical Systems. Installation and commissioning of the systems is scheduled to take place by April 2015.

About SDI Steel Dynamics, Inc. - one of the largest domestic steel producers and metals recyclers in the United States based on estimated annual steelmaking and metals recycling capability, with annual sales of $7.4 billion in 2013, over 7,400 employees, and manufacturing facilities primarily located throughout the United States (including six steel mills, six steel processing facilities, two iron production facilities, over 90 metals recycling locations and six steel fabrication plants).

About Tenova Goodfellow - part of the Metals Division of Tenova and is a leader in the design and supply of process control technology for the EAF and BOF markets. Tenova is a worldwide supplier of advanced technologies, products and engineering services for the iron & steel and mining industries providing innovative, integrated solutions for complete process areas. Tenova's network companies operate in 26 countries on 5 continents with more than 4,900 people.

For more information on EAF optimization, please contact:

Tenova Goodfellow Inc.

6711 Mississauga Road, Suite 200

Mississauga, ON

L5N 2W3 - Canada

Phone +1 905 567 3030

Fax +1 905 567 3899

goodfellow@ca.tenovagroup.com

#205 - What is iEAF?

In Post #194, we asked the question - What is iBOF? In this post we will discuss iEAF.

To begin, it will be helpful to describe EAF. The acronym stands for Electric Arc Furnace and is used to describe a method of steelmaking that heats the charged material using a powerful electric arc originating from large graphite electrodes.

From Wikipedia: 

An electric arc furnace used for steelmaking consists of a refractory-lined vessel, usually water-cooled in larger sizes, covered with a retractable roof, and through which one or more graphite electrodes enter the furnace. The furnace is primarily split into three sections:

• the shell, which consists of the sidewalls and lower steel "bowl";
• the hearth, which consists of the refractory that lines the lower bowl;
• the roof, which may be refractory-lined or water-cooled, and can be shaped as a section of a sphere, or as a frustum (conical section). The roof also supports the refractory delta in its centre, through which one or more graphite electrodes enter.

The hearth may be hemispherical in shape, or in an eccentric bottom tapping furnace, the hearth has the shape of a halved egg. In modern meltshops, the furnace is often raised off the ground floor, so that ladles and slag pots can easily be maneuvered under either end of the furnace. Separate from the furnace structure is the electrode support and electrical system, and the tilting platform on which the furnace rests. Two configurations are possible: the electrode supports and the roof tilt with the furnace, or are fixed to the raised platform.

iEAF stands for “intelligent Electric Arc Furnace” and is a trademark of Tenova Goodfellow Inc. The iEAF system is a progressive, modular technology package designed to provide sustainable long-term cost savings to steelmakers. The system uses dynamic control and holistic optimization of the EAF process.

iEAF® enabling technology can be applied to all variations of the EAF process including: 

• top charge melting furnaces (bucket and/or shaft) using scrap, DRI and/or pig iron;
• the Consteel® process (iConsteel®) with or without hot metal;
• continuous DRI fed furnaces (iDRI®).

While the basic structure remains constant, the automation hardware, software and communication modules can be customized according to the individual customer’s existing automation system and network.

The iEAF technology package is comprised of well-defined modules which each focus on a specific aspect of the EAF process. 

• MODULE 1 - Dynamic Chemical Energy Control & Optimization (EFSOP)
• MODULE 2 - Dynamic Melting Control
• MODULE 3 - Dynamic End-Point Control

While the iEAF® can be easily integrated with any existing automation and process control system, the cornerstone and necessary first step in the iEAF® technology program is EFSOP® off-gas analysis; other off-gas analysis methods which cannot provide complete analysis of CO, CO2, H2 and O2 lack a necessary prerequisite for determining an online Mass & Energy Balance which is critical for efficient energy utilization and effective dynamic control of the melting and refining processes.

MAIN BENEFITS

• Dynamic Control & Optimization of the Melting & Refining Process

• Electrical Energy Savings

• Fuel Savings

• Reduced Power-On Time

• Increased Yield

• Reduced Tap Additions

• Electrode, Delta & Refractory Savings

• Reduced Tap-to-Tap Time

• Reduced Emissions

There are other add-on technologies that are available under the iEAF umbrella. We’ll elaborate on those in a future post.

For more information, contact:

Tenova Goodfellow Inc.

6711 Mississauga Road, Suite 200

Mississauga, ON

L5N 2W3 - Canada

Phone +1 905 567 3030

Fax +1 905 567 3899

goodfellow@ca.tenovagroup.com

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