19338-Technical Specification - R1 (001-250)

Complete Steel Melting Plant
ArcelorMittal Jubail - Saudi Arabia
Technical specification n° 19338

Revision 1
11/08/2022
Eduardo Egaña
File name: 0-Cover and foreword-19338-R1 Page 0 of 4

Confidential document, not disclosable and not reproducible without written SARRALLE authorization.
Technical specification content

Chapter 1 Introduction √
Chapter 2 Process √
Chapter 3 Technological equipment √
Chapter 4 Auxiliaries √
Chapter 5 Civil and buildings √
Chapter 6 Electrical and automation √
Chapter 7 Options and alternatives -
Chapter 8 Engineering √
Chapter 9 Advisory service √
Chapter 10 Training √
Chapter 11 Supply √
Chapter 12 Project time schedule √
Chapter 13 Vendors √
Chapter 14 Performance and guarantees -
Chapter 15 Drawings √-
Chapter 16 Documentation -
Date: 11/08/2022 Technical specification n° 19338 Revision 1

Revisions
Revision Description Text indication
0 Budgetary Proposal 2021 Black
1 Budgetary Proposal 15/08/2022 Black
2 Green
3 Blue
4 Highlighted yellow
Note: latest proposal revision overhauls all previous ones.
Confidentiality
The document contains know-how and confidential information and is intended only for the
indicated Customer and only for the purposes of the present project.
The Customer undertakes to treat this document, and all other information received during the
project development, as proprietary information and to not distribute, copy or disclose all or any
part to any third parties.
Terminology
Supplier Means Sarralle Steel Melting Plant S.L. or any of its branches
Customer Means ArcelorMittal Jubail
Technical specification Means this document, including all chapters and units reported as
per table of content
Plant Means the equipment described in this technical specification
relatives chapters and supplied as indicate in the scope of supply
and time schedule tables
Services Means the advisory service of erection and commissioning, training
and erection (where included)

Parties information
Sarralle data
Seller name Grupo Sarralle
Division Steel Melting Plant
Address Bº Landeta, C/Orendaundi nº 7, Apdo. P.O.BOX 1, 20730 AZPEITIA
(Gipuzkoa) SPAIN
Phone +34 943 15 70 88
e-mail sarralle@sarralle.com
Web site www.sarralle.com
Customer data
Customer name ArcelorMittal Jubail
Address Al Jubail 35738, Arabia Saudí

Phone +966 13 510 7300

Sarralle project team

Vincent Lye *
Job position Sales Area manager
e-mail and Teams call vlye@sarralle.com
Mobile +34 682043 162
Aitor Odriozola*
Job position Proposal Department Manager
e-mail and Teams call aodriozola@sarralle.com
Mobile + 34 652 70 03 96
Eduardo Egaña*
Job position Proposal department
e-mail and Teams call eegana@sarralle.com
Mobile + 34 697 30 41 05
Edurne Guinea*
Job position UAE Director
e-mail and Teams call ezubiaga@dusartrading.com
Mobile 00 971 52 980 1728
Lorenzo Ippoliti
Job position E&A Proposal Department
e-mail and Teams call lippoliti@sarralle.com
Mobile + 34 943 15 70 88

Chapter 1 – Introduction
Chapter 1
Introduction

File name: 1-Introduction-19338-R1 Page 0 of 1
Chapter 1 – Introduction
1 Project overview
ArcelorMittal Jubail is planning to install a new Steel Melting Plant to produce steel billets in Al
Jubayl, Saudi Arabia.
The equipment proposed is based on Sarralle state of the art technology of meltshops,
engineered following the philosophy of heavy duty equipment, maximizing the efficiency and
availability and minimizing the maintenance operation.
The following technical specification describes the process description and the scope of supply.
The SMP plant is designed with the following main units:
1 x Scrap yard
1 x 120 t - Electric Arc Furnace;
1 x 120 t – Twin Ladle Furnace;
1 x 120 t – Twin Vacuum Degasser;
1 x Material Handling Plant;
1 x Fumes Extraction System;
1 x 4 Strands Continuous Casting Machine;
1 x Electrical and automation Process Equipment
Auxiliary equipment

File name: 1-Introduction-19338-R1 Page 1 of 1
Chapter 2 – Process
Chapter 2
Process
Date: 05/08/2022 Technical Specification n°19338 Revision 1

File name: 2-Process-19338 -R1 Page 1 of 115
Confidential document, not disclosable and not reproducible without written SARRALLE authorization
Content
1 Meltshop Process .......................................... 6

1.1 Meltshop Preliminary Design Data ................................... 6
1.1.1 Main Facility Description ............................................................................................7
1.1.2 Steel Grades ...............................................................................................................8
1.1.3 CCM Cast Products .....................................................................................................8
1.1.4 Process Routes ...........................................................................................................8
1.1.5 Raw Materials (estimated analysis)............................................................................9
1.1.6 Productivity Data (estimated) ..................................................................................10
1.2 Scrap Yard........................................................................ 11

1.3 EAF Main Features .......................................................... 12
1.3.1 EAF Productivity .......................................................................................................12
1.3.2 EAF Design................................................................................................................13
1.3.3 EAF Shell Geometry..................................................................................................15
1.3.4 Scrap Charging Bucket .............................................................................................16
1.3.5 Chemical Energy Package – Injection Technology ...................................................17
1.3.6 EAF Auxiliaries ..........................................................................................................20
1.4 LADLE Main Features ...................................................... 21

1.4.1 LADLE Design............................................................................................................21
1.4.2 Ladle Refractory Lining .............................................................................................23
1.4.3 Number of Ladles .....................................................................................................24
1.4.4 LADLE Stirring ...........................................................................................................25
1.4.5 Automatic Argon Coupling .......................................................................................26
1.5 Ladle Furnace- Twin LF Main Features ........................... 27

1.5.1 Main Twin LF Features .............................................................................................28
1.5.2 Twin LF Design .........................................................................................................29
1.5.3 LF Process Technology .............................................................................................30
1.5.4 LF Transformer and Steel Heating Set Points ...........................................................31
1.5.5 LF Auxiliaries.............................................................................................................32
1.6 Vacuum Degasser – VD Main Features ........................... 33

1.6.1 VD Design .................................................................................................................34

1.6.2 VD Equipment Configuration ...................................................................................35

1.6.3 VD Equipment dimensioning....................................................................................36
1.6.4 Minimun Freeboard Requirement ...........................................................................37
1.6.5 Vacuum Tank Cover .................................................................................................38
1.6.6 Suction Line Ducts ....................................................................................................40
1.6.7 Vacuum Switch .........................................................................................................40
1.6.8 Cyclone - Filter .........................................................................................................41
1.6.9 Main Shut-off valve ..................................................................................................43
1.6.10 Vacuum Pumps ........................................................................................................44
1.6.11 Auxiliary Systems......................................................................................................47
1.7 Material Handling System - MHS .................................... 50

1.7.1 MHS Main Features..................................................................................................50
1.7.2 MHS bins dimensioning............................................................................................51
1.8 Fumes Exhaust System – FES .......................................... 53

1.8.1 FES Design ................................................................................................................53
1.8.2 Main FES Features....................................................................................................54
1.8.3 Main FES flow rates and main data ..........................................................................55
1.8.4 MHS FES Features ....................................................................................................57
1.9 EAF Process Calculations ................................................. 58

1.9.1 70% CDRI - 30% SCRAP (Base Case) .........................................................................58
1.9.2 100% CDRI (Option 1)...............................................................................................62
1.9.3 90% CDRI – 10% SCRAP (Option 2)...........................................................................66
1.9.4 80% CDRI – 20% SCRAP (Option 3)...........................................................................70
1.9.5 Scenarios Comparative ............................................................................................74
1.10 LF + VD Process Calculations ........................................... 75

1.10.1 VD Material Balance .................................................................................................76
1.10.2 Hydrogen Removal ...................................................................................................77
1.10.3 Nitrogen Removal ....................................................................................................78
2 Billet caster process ..................................... 79

2.1 Project requirements ...................................................... 79
2.1.1 Casting machine .......................................................................................................80
2.1.2 Steel grades classification and casting speed ...........................................................82
2.1.3 Production calculation .............................................................................................85

2.1.4 Casting speed ...........................................................................................................86
2.1.5 Strain Calculation .....................................................................................................86
2.1.6 Oscillation.................................................................................................................89
2.1.7 Electro Magnetic Stirring .........................................................................................90
2.1.8 Secondary cooling ....................................................................................................91
2.2 CCM Design ..................................................................... 92

2.2.1 Ladle Turret ..............................................................................................................92
2.2.2 Tundish.....................................................................................................................93
2.2.3 Tundish Cars .............................................................................................................94
2.2.4 Casting Technique ....................................................................................................95
2.2.5 Automatic start of the hot strands ...........................................................................95
2.2.6 Mould level detection system ..................................................................................96
2.2.7 Mould .......................................................................................................................97
2.2.8 Mould and Primary cooling ......................................................................................98
2.2.9 Mould Electromagnetic Stirring (M-EMS) ................................................................99
2.2.10 Foot Rolls and Containment ...................................................................................100
2.2.11 Oscillation...............................................................................................................101
2.2.12 Spray Cooling System .............................................................................................102
2.2.13 Strand Guide ..........................................................................................................104
2.2.14 Final Electromagnetic Stirrer (F-EMS) ....................................................................104
2.2.15 Withdrawal and straightening unit modular type ..................................................105
2.2.16 Chain dummy bar and storage unit ........................................................................106
2.2.17 Torch Cutting Machine...........................................................................................106
2.2.18 Discharge Equipment .............................................................................................107
2.2.19 Turn over cooling bed (TOCB) ................................................................................107
2.2.20 Controlled Tertiary Cooling (slow cooling) .............................................................108
2.3 CCM specific consumption figures ................................ 109

3 Technical Requirements ............................ 110
3.1 Electrical Power .............................................................110
3.2 Compressed Air .............................................................111
3.3 Cooling Water ...............................................................112
3.4 Oxygen...........................................................................114
3.5 Natural Gas ....................................................................114
3.6 Inert Gas ........................................................................115

1 Meltshop Process
1.1 Meltshop Preliminary Design Data
The present technical specification has been prepared taking into consideration required
technical parameters of process equipment and information received by the customer.
The plant is designed with the following main units:

1.1.1 Main Facility Description

MAIN DATA CAPACITY
SCRAP YARD autonomy:
Available scrap volume: 97500m3
approx. 60 days
Available area: 19500m2
(30% scrap use)
AC / EAF / 6900 approx.

EBT/ 120 t / 150 MVA 120-135 t/h Liquid Steel
No. of Units: 1
Tap-to-tap: 53 - 60 min
Charge mix: 30% Scrap – 70% CDRI
100% CDRI
10% Scrap – 90% CDRI
20% Scrap – 80% CDRI
TWIN Ladle Furnace - LF / 120 approx.
120 t / 25 MVA 888.000 tpy ls
No. of Units: 2 based on customer’s
Heating Rate: 4 °C/min steel grades
Treatment time LF approx. 44 min.
Vacuum Degasser-– VD / 120 155.000 m3/h pumping

120 t capacity
No. of Tanks: 2
Quantity of covers: 1
Average treatment time: approx. 30-35 min.
Material Handling System – M H S Total No. of bins:

Bins for lime, coal, alloying materials and DRI 13 for EAF + tapping
Conveyors
Weighing control 8 for LF ferroalloys
Fumes Extraction System – FES maximum capacity:

2.400.000 m3/h
Fans capacity: 3 (+1) x 2400kW for EAF
1x 132kW for TWIN LF
1x 22kW for VD
1x132kW for MHS (DRI bins) 57.000m3/h

Continuous Casting Machine – approx.

Billet Caster: 750.000 tpy gb
No. of strands: 4/ (5)
Cast sections: Ø200 mm, Ø280 mm, Ø350 mm
1.1.2 Steel Grades

ASTM A108 -133-301-305-313
ASTM 350-108/131-108/133-320A.1
AMJ02-AMJ09-AMJ11-AMJ21D-AMJ21E-AMJ21C-AMJ21D-AMJ22-AMJ23-AMJ25-AMJ35B
1.1.3 CCM Cast Products

Round billet/bloom:
- Ø200 mm
- Ø280 mm
- Ø350 mm
1.1.4 Process Routes
EAF LF VD CCM
This figure route is the most common route by far. A route with VD station before LF station
offers better temperature control but it suffers from risk for reoxidation, nitrogen and hydrogen
pick up after degassing.

1.1.5 Raw Materials (estimated analysis)

Lime:
Chemical Analysis:
[%] 1,0
Fe2O3
CaO [%] 90,0
MgO [%] 1,5
SiO2 [%] 2,0

Al2O3 [%] -
p [%] 0,02
CaF2 [%] -
LOI [%] 2,88
Others [%] 0,53
Bulk Density kg/m³ 1.600
Grain Size mm 20-50
Carbon:
F.C. S P V.M. Ash Moisture Size
Antracite >80% <0.7% <0.2% <0.7% <10% <1% 0.2/2mm>90%
Coke >86% <0.6% <0.7% <0.035% <12% <1% 0.2/2mm>90%
Graphite >97% <0.7% <0.7% <0.2% <2% <0.3% 0.2/2mm>90%
Ferro alloys & other additives:
Regular quality for production of considered steel qualities.

CDRI:
PARAMETERS
Fe (met) (%) > 84,0
Metallization (%) 94,0
Carbon (%) 2,0

1.1.6 Productivity Data (estimated)

EAF productivity is considered to be the base for a definition of the productivity of the complete
melt shop. EAF charge mix is defined by the customer as follows:
30% SCRAP - 70% CDRI (BASE CASE)

100% CDRI (OPTION CASE 1)
10% SCRAP - 90% CDRI (OPTION CASE 2)
20% SCRAP - 80% CDRI (OPTION CASE 3)
Available Working Time:

The new melt shop is foreseen to operate 365 days/year with 24-hours continuous operation
divided into 3 shifts; available working time has been defined as follows:
Net available working hours h 7.200

Net available working days day 300,0
EAF Production Target:

Considering the average tapping weight and Tap-to-Tap time, the respective liquid steel
production has been defined as below:
EAF average tapping weight (t) 120

Main EAF charge structure 30%SCRAP – 70% CDRI (base case)
Assumed average EAF tap-to-tap time (min) 53
Productivity [t/hour] 135,8

Annual Liquid Steel production [t/year] 888.063

1.2 Scrap Yard

One short term scrap yard is foreseen for scrap storage. There should be two EOT cranes
provided with grabs and/or magnets for bucket filling. Two rails and two bucket cars for scrap
handling will be there to supply scrap to the EAF. External access will be provided for unloading
of trucks delivering charge materials from open storage areas.
In the same area can be storage the return scrap and considered an area for scrap preparation
equipped with NG/O2 piping for heavy scrap cutting. Tentative dimensions shall be 195x100 with
an average scrap storage capacity of 5m high. Regarding the lay out area the calculation results
of the scrap yard autonomy are shown below.
The area is direct accessible to the domestic scrap truck and the internal scrap truck used to
transfer the collected scrap from the Steel melt shop and Rolling Mill areas.
The position of the car is monitored and displayed in the HMI screen. The positions are
separated into Melt shop, car ready for loading outside MS (Take over for crane) and at scrap
yard and the area is equipped with bins that add ferroalloys into the bucket.
Available area m2 19.500

Average scrap pile height m 5
Available scrap volume m3 97.500
Scrap density t/m3 0,7
Stored scrap weight t 68.250
Scrap weight for single heat t 41,3
Scrap volume for single heat m3 59,0
Daily melt shop production heats/day 27,2
Resulting scrap yard autonomy days 60,8

1.3 EAF Main Features

1.3.1 EAF Productivity
The results of the EAF productivity calculation based on the available networking time and
according to selected furnace capacity are shown below:
Base Case Option 1 Option 2 Option 3

70% CDRI – 100% CDRI 90% CDRI - 80% CDRI –
30% SCRAP 10% SCRAP 20% SCRAP
Number of furnace(s) in operation 1
Furnace capacity t 180
Max Hot heel t 60
Furnace average tapping capacity t 120
Net Available hours h/year 7200
Required Scrap per heat t 41,3 - 13,8 27,6

Required DRl per heat t 96,3 138,7 124,6 110,5
Assumed Tap-to-Tap time min 53 60 58 56
Resulting number of daily heats 27,2 24,0 24,8 25,7
Resulting daily liquid steel production t 3.260 2.880 2,979 3.086
Resulting productivity t/h 135,8 120,0 124,1 128,6
Annual liquid steel production t/y 888.063 784.456 811.506 840.488

1.3.2 EAF Design

The main features of the proposed EAF are as follows:
Furnace type AC / 6900

Liquid steel capacity t 180
Hot heel size t 60
Average tap weight t 120
Transformer power MVA 160
Electrode diameter mm / ” 610 / 24
Shell design EBT type
Oxy-fuel Injectors 4x1800Nm3/h Wall
Carbon Injectors 3x50kg/min Wall
Lime / Dololime injectors 2x100kg/min Wall
Electrode Regulation System SARRALLE – SarCON
The EAF will be designed and supplied with the following main components:
• Tilting frame full platform design.
• EBT type lower shells design made of copper.
• Upper shell with modular water-cooled panels (EBT horizontal panel in copper) and
feeding window.
• Water-cooled steel roof panels attached to cage type structure.
• Swivelling type single point roof lift system for roof movement.
• Sarralle advanced copper conducting electrode arms.
• Digital electrode regulation system SARRALLE - SarCON
• Oxy-gas, Carbon and Lime /Dololime injectors as a chemical energy input package.
• Hydraulic unit
• Hydraulic cylinders
• Electrical & Automation package

EAF – Typical for Reference only

1.3.3 EAF Shell Geometry

The EAF preliminary shell dimensioning has been carried out considering the following main
aspects:
EAF SHELL VOLUME: selected in function of charging practice and available charge density with
a sufficient safety factor preventing shell overfilling during charging.
o 30% Scrap charge
o 0,7t/m3 density
o 1 bucket charge practice
o 15% furnace overfilling volume
SHEEL DESIGN ASPECTS: the design and the geometry (diameter and height) are decided in
consideration of expected electrical power input and allowed wear refractory index (RWI) as
well as chemical energy sources (injectors) and their distribution on the shell perimeter.
The table below indicates the basic preliminary EAF shell dimensions:
A Upper shell diameter 6900 mm
B Upper shell height 2500 mm
C Liquid steel height (at the deepest point) 1170 mm
D Lower shell height 2460 mm
E Bottom refractory thickness 750 mm
F Wall refractory thickness 475 mm
G Lower shell diameter 6800 mm
EAF calculated total volume (approx) 135,0 m3
Refractory overall weight (approx)
149,0 Ton
The above data have to be considered as preliminary

1.3.4 Scrap Charging Bucket

As per 100% scrap charging and results of charge volume calculations related to the bucket
utilization are as follows, considering a 5% safety margin charge capacity:
A Internal diameter 5700 mm

C Bottom part height 1300 mm
E Total height 5100 mm
Bottom part volume 23 m3
Cylindrical part volume 97 m3
Total volume 120 m3
The scrap bucket size is optimized in order to spread the scrap in the furnace at its best and ease
an efficient melting.

1.3.5 Chemical Energy Package – Injection Technology

The furnace will be equipped with a combination of coherent flame combined burner/oxygen
injectors supplying additional chemical energy required for EAF charge melting.
The chemical energy package is complete with the carbon + lime /dololime injection system
through the furnace shell walls.
The preliminary technical data of coherent injectors and carbon injectors are described below:
Number of Injectors (Coherent
4
Type)
Nominal Power in BURNER
3,0 MW
MODE
Natural Gas Flow in FULL
310 Nm3/h
POWER BURNER MODE
O2 Flow in FULL POWER
636 Nm3/h
BURNER MODE
Min. O2 Flow in PRELANCE
100 Nm3/h
MODE
Max. O2 Flow in PRELANCE
200 Nm3/h
MODE
Min. O2 Flow in SUPERSONIC
1800 Nm3/h
LANCE MODE
Max. O2 Flow in SUPERSONIC
1800 Nm3/h
LANCE MODE
Carbon Injection Nozzles 3
Nominal Carbon Flow per

50 kg/min
Nozzle
Lime/dololime injection Nozzles 2
Nominal lime/dololime Flow per

100 Kg/min
Nozzle
The coherent injectors are designed and manufactured by SARRALLE. The design is always
optimized for the expected operational conditions and nominal flow ranges of natural gas and
oxygen.

All injectors are installed around the furnace upper shell perimeter using specially designed High
Speed panels with optimized cooling flow pattern for operation with high thermal loads resulting
from a specific injector locations (distance between pane from and the steel bath level is
typically about 1.2 - 1.6 m).
High Speed Injector Panels - For Reference Only
The positioning of the individual wall-mounted injectors ensures optimum thermal balance
during melting and reduces the difference among hot and cold spots. It is a key point to achieve
the following design criteria:
- Balanced ratio of installed chemical power vs EAF perimeter [MW/m]
- Specific ratio of installed chemical power vs bath surface area [MW/m2]
- Shell height/diameter ratio related to residence time inside the furnace of the hot
gases generated by the injection system.
The melting process take places in two directions:

- From the shell centre to the walls be means of electric arcs.
- From the shell walls to the centre by means of the coherent injectors.
Melting of the furnace charge is very uniform without any sudden scrap caving or power supply
interruptions. Carbon injectors coupled with oxygen lance allow for early start of carbon
injection (after about 50% of the total melting time) greatly improving the arc stability, energy
transfer and reducing the thermal load on the furnace walls.

1.3.5.1 Carbon injection module

The whole system will be based on three (3) storage main silos, three (3) carbon dispensers and
three (3) injection lines.
Carbon injection points are distributed strategically to create and spread a good foaming slag
along the liquid bath surface. They are well assembled in parallel with oxygen injectors in order
to optimize carbon efficiency and ease a quick reaction as soon as it is reached the steel-slag
interface. This parallel disposition together with the oxygen injector guarantees the reaching of
the steel because of the non-existing scrap or stacked slag around.
- Carbon injection lances are coupled with combined burners / lances
- Start of injection is possible at any moment of the melting time
The ideal carbon injection rate is determined through mass balance calculation (total 10-
30kg/min for this EAF) and controllable carbon injection through four injection points, so carbon
is always available at locations where high oxygen potential can develop. To achieve control of
the FeO in the slag, the carbon injection system is controlled automatically and the system
should have the ability to inject carbon at variable rates.
Carbon injection must begin at, or shortly after beginning of supersonic oxygen injection into
the bath and it must be continued for the entire duration of the refining process.
Installation reference scheme

1.3.5.2 Lime/Dololime injection module

The whole system could be based on one (1) storage main silo (lime+dololime), two (2)
lime/dololime dispensers and two (2) injection lines (lime/dololime). Lime/dololime injection
point is fixed following the same criteria of carbon injection and foaming slag practice.
Lime/dololime injectors are assembled on the upper shell panel in parallel with oxygen injectors
in order to optimize lime/dololime efficiency and ease a quick reaction as soon as it is reached
the steel-slag interface. This parallel disposition together with the oxygen injector guarantees
the reaching of the steel because of the non-existing scrap or stacked slag around.
Lime injection rates provides control on the following process main items:
• Slag viscosity and consequently it´s basicity index.
• Steel dephosphorization during refining phase.
As a result, it provides a fast and effective way of managing foaming slag quality.
The amount of lime to be injected is mainly defined by:
• The foaming slag practice
• Slag basicity and its saturation in MgO for refractory lifetime optimization
• Lime yield and injection efficiency
In these terms it is estimated that the amount of injected lime will be 100% of the total lime
addition to one single heat.
Installation for reference
1.3.6 EAF Auxiliaries

Please, refer to scope of supply to check auxiliary equipment.

1.4 LADLE Main Features

1.4.1 LADLE Design
The ladles must be properly designed for the actual refining requirements:
• The freeboard must be enough for safe operation during the refining and vacuum
treatment conditions required for the actual grade specifications.
• The D/h, bath diameter to liquid height, must be correct considering the stirring and
heating conditions and risk for dead zones at the furnace bottom.
• The bath area must be sufficient for slag – metal reactions such as de-S.
The preliminary dimensions of a ladle, which fulfils the above requirements, are included below:
Ladle shape Straight
Liquid steel Capacity t 120
Freeboard (new) FB mm 795
Outside ladle upper shell diameter C mm 3500
Outside ladle lower shell diameter D mm 3500
Ladle Shell Heigth J mm 3700
Liquid steel Height mm 2568
Liquid Bath Area m2 6,73
Refractory thickness Wall R1 mm 262
Refractory thickness Botton R2 mm 380
Ladle botton Shell Thickness P mm 40
Ladle wall Shell Thickness O mm 24
Distance Between lifting axis A mm 4800
Ladle Structure weight t 24,5
Refractory Weight t 33,8
Total Weight (+ steel) t 178

The 120ton capacity ladles will be dimensioned considering a minimum freeboard with new
refractory lining around 800 mm. This freeboard value is required for ladle refining and vacuum
operations.
Figure below shows the freeboard situation for new and worn-out ladles:
1600 New lining

1400 Worn lining
1200
FreeBoard, mm
1000
800
600
400
200
0
110 115 120 125 130
Heat Size, Tn
Ladle - For Reference Only

1.4.2 Ladle Refractory Lining

The final selection of the ladle refractory shall be in cooperation with a locally available
recognized refractory supplier. The following information shall only be used as major guidelines.
The ladle refractory must be selected for the actual refining situation:
• Ladle slag composition
• Refining temperature
• Variations in refractory temperature
• Contamination of impurities from the refractory such as Al, H, C and Ti
• Risk for reoxidation
• Reasonable lining life to minimize the refractory cost
• Thermal insulation good enough to avoid damage of the ladle steel
structure
The refractory concept is subject for continuous improvement and the final “best” refractory
concept cannot be defined.
There are 4 principal concepts:
• High alumina with magnesia in the slag line
• Complete magnesia lining
• Dolomite lining
• Chrommagnesia
The lining type should be High Alumina, Magnesite or Dolomite.
For the start-up period, the High Alumina lining is to be preferred, being less sensitive to
temperature fluctuations, while for continuous production, a Dolomite or Magnesite lining can
be advantageous, giving lower oxygen and sulphur contents. Particular attention will be paid
to the choice of refractory for steels with very low C content in order that the C pick-up from
refractory remains acceptable.

1.4.3 Number of Ladles

For a given ladle size, 2 porous plugs per each ladle is recommended to ensure optimum stirring
pattern for LF (heating and alloying) as well as for efficient inclusion, flotation and future VD
operations.
In order to ensure uninterrupted melt shop operation, a sufficient number of casting ladles
should be ensured. According to SARRALLE experience, the minimum required number of
casting ladles is estimated for both options as follows:
Circulation time HEATS PER DAY 27,2 heats

Transport to EAF tap 5 min
Transport from EAF to LF station 5 min TOTAL LADLES CYCLES 4923,2 min
Transport from LF to VD 5 min
Transport from VD to CCM 5 min DAILY PRODUCTION TIME 1440 min
Transport from CCM to
5 min
maintenance
Total transport time 25 min LADLES 3,42 4,00
NUMBER OF LADLES 4
Treatments time
LF 44 min
VD 32 min LADLE LIFE 50 heats
CCM 50 min
heats per
DAILY HEATS PER LADLE 7
day
Total treatements time 126 min
TOTAL PRODUCTION TIME 7,4 days
Other operations time

Deslagging after CCM 10 min Additional ladles
Slide gate maintenance 20 min Ladle in preheater 1 ud
Pre-heating min Ladle in dryer 1 ud
Ladle in refractroy lining 1 ud
Ladle in demolition/maintenance 1 ud
Total operations time 30 min Ladle for spare and emergency 1 ud
Additional ladles 5 uds
TOTAL LADLE CIRCULATION TIME 181 min
TOTAL NUMBER OF LADLES 9 uds

1.4.4 LADLE Stirring

No refining activity, heating, alloying or chemical reactions are possible unless the steel is stirred.
The stirring must be designed to fulfil a number of criteria:
• Fast melting and homogenisation of added material.
• Fast distribution of the energy supplied by the arc when heating in the Ladle Furnace.
• Good kinetic conditions for the slag-metal reactions like de-S.
• Good kinetic conditions for gas-metal reaction like de-H and de-N
• Good kinetic condition for removal of non-metallic inclusions
• Avoid excessive refractory wear caused by stirring force acting too much on the ladle
wall
• Avoid reoxidation by exposing too much of the steel to the furnace atmosphere
• Avoid carbon pick up by to heavy bath movements close to the electrodes
• Good kinetic conditions for vacuum reactions such as removal of H, N and C.
It is obvious that some of these criteria are in conflict. The stirring conditions must then be
controlled to best compromise for the actual refining conditions.
To achieve best possible flexibility the ladles are equipped with 2 porous plugs fed by a dedicated
gas flow control system. The system can operate with Ar and N2. The N2 gas can be used for
grades not sensitive for increased N content and also to control the N content for grades with N
as an alloying element. The maximum flow rate is 2*600 Nl/min for both Ar and N2.
The stirring system has a bypass high pressure system to be used in case of plug blockage.

1.4.5 Automatic Argon Coupling

The purpose is to connect the stirring gas supply automatically by placing the ladle on the
transfer car without need of human intervention.
The system consists in a device comprised of two lower male-section, placed on the transfer car,
an upper female-section, placed on the ladle, corresponding protection against splashes and
interconnection piping. The piping will be executed in such a way that in case of any failure, with
a simple action in a ball valve, allows us to follow normal operation in manual mode until
maintenance stage.
The ladle is placed on car by mean of a crane, both sections are fitted each other and the gas
supply is connected automatically; system design permits approx. +/- 50 mm misalignments.
Both systems, manual and automatic mode, will be in service.
Double coupling in operation (only for reference)

1.5 Ladle Furnace- Twin LF Main Features

The Twin Ladle Furnace is designed for heating, slag formation and alloying. The system must be
designed to meet the productivity demand, 53 minutes dimensional cycle time combined with
power input enough for up to 3% added alloys. Considering the steel grades and the dimensional
cycle time, it is foreseen a Twin LF with one (1) ladle car each with in/output positions for
process/parking respectively. This requires:
• Materials handling with fast and accurate weighing and distribution of material
• As high power as possible considering the selected ladles
• Heating with minimized carbon pick up
• Heating with minimized nitrogen pick up
• Control of the slag chemistry for best S removal and steel deoxidation
• Roof and fume extraction designed for as low steel re-oxidation as possible
• Roof and fume extraction designed for as low dust and gas emissions as possible

1.5.1 Main Twin LF Features

The major process timing is summarized below considering 25MVA:
No. of LF 2
Furnace type mm LF / 120
No. of covers 2
Liquid steel capacity ton 120
Transformer power MVA 25
Electrode diameter “ / mm 18” / 450
Max. secondary current KA 45,0
Electrode pitch circle mm 750
Electrode regulation Sarralle SarCon
Arms design Conductive
Stirring lines 2 (each)
Ladle Car 1 (each)

1.5.2 Twin LF Design

The Twin LF units will be designed with the following main components:
• Two ladle cars
• Gantry frame – swiveling type.
• Water-cooled roof with air suction reducing fumes escaping refining process.
• Roof lifting mechanism by means of hydraulic cylinder.
• Electrode regulation columns with conductive arms and electrode clamps.
• Digital-hydraulic automatic electrode regulation (SARCON by Sarralle). SARCON is based
in “National Instruments” PLC, likewise FPGA technology of extreme robustness and for
display the data capture system is connected to an industrial PC. Working modes can
vary from regulating depending on the current, power, impedance or admittance.
• Water-cooled power cables and delta system closure.
• Transformer.
• Grease lubrication system
• Inert gas (argon/nitrogen) stirring lines with independent gas flow regulation.
• Material addition hopper with upper incoming and bottom discharge valve.
• Two number dedicated four (4) strand wire feeding machine designed to feed different
kinds of wires into the steel through independent track feed tubes shall be provided.
• Emergency purging system
• Electrode Nippling & storage stand
• Automatic Sampling and temperature measuring equipment each (with C and O2
determination facilities).
Ladle Furnace in operation - For Reference Only

1.5.3 LF Process Technology

The total duration of the treatment in the ladle furnace station is based on the periods of heating
(power on) and stirring (power off) times. Additional waiting time may be required to match the
sequences at continuous caster.
In this case the LF station is used as a process buffer.
The main operational sequence related to LF treatment is the following:
• Tapping from the furnace with initial addition of alloys for steel deoxidation and slag
making materials.
• Transfer with EOT crane from EAF tapping position to LF treatment position under
the LF roof.
• Adjustment of inert gas stirring intensity.
• Addition of slag making materials.
• Melting of slag and oxide reduction.
• Steel temperature increase and liquid bath homogenization.
• Sampling and temperature measurement.
• Steel temperature increase and bath homogenization.
• Main alloy addition.
• Further steel temperature increase and bath homogenization.
• Correction of steel composition and temperature.
• Cored wire feeding (if applicable).
• Final liquid bath homogenization with very gentle stirring.
• Final sampling and temperature measurement.
• LF car transfer to parking position.
• Ladle transfer to the Caster area by EOT crane (for heats not subject to vacuum
degassing process).
• Ladle transfer into the VD Tank by EOT crane (for heats subjected to vacuum
degassing process).

1.5.4 LF Transformer and Steel Heating Set Points

The average power for a Ladle Furnace is mainly controlled by the power density, MW/m2 bath
area, and is dependent on the bath area, the stirring intensity and the arc length.
Specific power input, Parc/A < 1.9/2.4 MW/m2

Arc length > 60 mm; < 110 mm
The selected ladle has a bath area equal to 7.66 m2 with new refractory. The theoretical
maximum power input is then within the range:
Parcmax 17.4 MW
Smax 25 MVA
The maximum power should only be used when the time is critical. Normal heating is performed
at reduced power, typically at some 1.7/1.9 MW(Parc)/m2.
Figure below shows the relation between transformer power and heating rate for the current
heat size, 120ton:
7,0
6,0
5,0
Heating Rate, ºC/min
4,0
3,0
2,0
1,0
0,0
10,0 15,0 20,0 25,0 30,0
Trafo Power, MVA

Figure below shows the recommended maximum current for Ladle Furnace Electrodes as
defined by recognized electrode suppliers.
LF Electrode Diameter vs Secondary Current

70
60
50
Secondary Current (kA)
40
30
20
10
0
250 300 350 400 450 500
Electrode Diameter (mm)
The maximum current is 45.0 KA and the electrode dimension should be 18-inch, 450 mm.
1.5.5 LF Auxiliaries
Please, refer to scope of supply to check auxiliary equipment

1.6 Vacuum Degasser – VD Main Features

The Vacuum Station is designed for VD operations.
The main objectives with the VD process are typically:
• Reduced hydrogen content, typically from 3-5 ppm down to less than 1.5 ppm
• Reduce the nitrogen content, typically 30-50% reduction of initial nitrogen
• Reduced sulphur content, close to equilibrium conditions
• Establish slag-metal equilibrium for de-oxidation and inclusion control
To meet these process requirements and get an efficient degassing under vacuum the following
parameters must be considered and optimised:
• pump-down time from atmospheric pressure to low level
• correct pump capacity in the low-pressure range
• final vacuum pressure
• bath stirring intensity
• slag-bath reactions
• alloying system under vacuum

1.6.1 VD Design
Average weight of treated steel t 120
Minimum ladle freeboard mm 800
Tank type Fix type
Quantity of tanks Unit 2
Cover type Fix type
Quantity of covers Units 1
Vacuum pump type Mechanical pumps
No. of stages 5
Suction capacity m3/h 155.000
Dust filtering system Combined Dust separator / Vacuum
filter
Fumes cooling system Water cooler
VD in operation - For Reference Only

1.6.2 VD Equipment Configuration

The VD station will be designed with the following main components:
Vacuum scheme for reference

• 2 Fix type vacuum tanks;
• 1 Movable cover with translation and lifting movements possibility and designed with a
heat radiation shield and a splash shield suspended below the cover, sampling machine
and under vacuum additions hopper.
• Automatic argon stirring connection
• Non-cooled suction line from both tanks to a common vacuum switch;
• 1 Vacuum Switch allowing for alternate vacuum tanks connection to the vacuum pumps;
• Non-cooled suction line from switch point shut-off valve;
• Main shut-off valve of butterfly type, used for vacuum system separation in two volumes
(tank side + pump side);
• Nitrogen Valve for nitrogen flooding before vacuum kill;
• Air Valve to kill the vacuum;
• Non-cooled suction line from main shut-off valve to combined Cyclone/Filter;
• Combined Cyclone/ Vacuum bag filter type dust separator with automatic cleaning after
each degassing cycle;
• Non-cooled suction line from Cyclone/ Vacuum bag filter unit to the inlet of the vacuum
pumps;
• Vacuum pumps;
• Chimney / stack from vacuum pumps outlet to outside the meltshop building for
evacuation of process gases;
• Exhausting line for suction of fumes generated during wire addition at atmospheric
pressure;
• Auxiliary equipment (wire feeding machine, sampling lance, etc.).

1.6.3 VD Equipment dimensioning

Vacuum degassing system dimensioning needs to follow a logical path considering both the
equipment physical dimensions as well as the process conditions.
The typical approach is following the sequence below:

• Analysis of the degassing process and definition of the safe operational conditions
(minimum ladle freeboard);
• Evaluation of available ladle geometry in function of required freeboard and heat size for
degassing;
• Definition of the vacuum tank dimensions allowing for trouble-free ladle insertion
without interference with tank walls;
• Evaluation of the suction line ducts diameter and length from the vacuum tank through
the process dust filtering unit to the vacuum pump entrance;
• Definition of the required size of the process off-gas cleaning equipment;
• Calculation of the vacuum system volumes;
• Evaluation of the required vacuum pump capacity ensuring sufficiently low-pressure
during degassing with an assumed process off-gas generation and air leaks into the
system as well as acceptable evacuation (pump down) time from atmospheric pressure
to degassing pressure;
• Definition of the vacuum pump configuration;
• Definition of the pump control mode;
• Configuration of required auxiliary systems.

1.6.4 Minimun Freeboard Requirement

It is a well-known experience, that steel degassing in a tank-type vacuum degasser may be
seriously disturbed by foaming ladle slag. The problem would seem to appear almost randomly,
although some observations lead to the conclusions that there are certain steel grades more
sensible for foaming phenomena.
Slag foaming is physically inflation of the slag by gaseous matter. The slag volume increases
significantly and may even flow over the ladle top, causing damages to argon piping and flooding
of tank bottom.
Except for a risk of flooding the tank bottom, the other negative effect of excessive slag foaming
is extension of pump down time and consequent reduction of available time for effective
degassing at low pressure. In order to set up safe operational conditions, the ladles for VD
process must ensure the minimum freeboard of 800 mm measured from the liquid steel level
up the top of the ladle.
This condition comes out from the experience of working with tank type vacuum degassing units
and process technology focused on the most efficient removal of dissolved gases from steel.
Table below shows the freeboard recommendations for ladle refining:

1.6.5 Vacuum Tank Cover

The vacuum tank cover consists of a steel dome-shape structure. The cover profile is exactly the
same as the vacuum tank bottom shape. The diameter of the cover is the same as the tank
diameter while its height is 2,010 mm (from the bottom to the highest point).
The top part of the cover is equipped with necessary ports for sampling, wire feeding lance and
visual process supervision (CCTV system). An additional blind flange for a future installation of
the hopper for material addition under vacuum conditions will be provided.
The vacuum cover is lined with refractory material. A water-cooled panel in the centre protects
the cover from the heat. The cover has ports for sampling, a vacuum hopper, wire feeding and
2 TV cameras to monitor the process.
A splash shield, completely water-cooled and suspended underneath the tank cover, rests on
the ladle. The splash shield retains slag and steel splashes in the ladle and is flexibly suspended
on the tank cover. -optional
The losses to the water-cooled splash shield are typically within the range 150-200 kW/m2 bath
area with peak values up to some 300 kW/m2. These losses are higher as compared to the losses
to a refractory splash shield. A refractory system has close to the same losses if the frequency
of VD heats is low. The observed difference is ranging from 0.1 up to 0.6 °C/min where 0.2-0.3
°C/min can be considered typical. The energy balance is more stable with a water-cooled system,
the temperature control is better. The life of a refractory heat shield is 50-200 heats while the
life of the water-cooled system is more than 3000 heats
The following devices are mounted on the tank cover:
• single wall process gas off-take with suction line connector;

• sampling lance;
• guiding tube for cored wire feeding;
• inspection port utilized also for sampling lance introduction;
• TV cameras for visual process supervision.
Vacuum Cover detail (For Reference Only)

Lifting and lowering of the cover is realised by means of hydraulic cylinders. The cover lifting
stroke is 600 mm.
The lower side of the cover dome is provided with anchors for installation of refractory castable.
In the top part of the cover there is a water-cooled radiation shield to reduce thermal load on
the central part of the cover. The radiation shield is made as tube to tube panel, in which the
gaps are filled with refractory material. This design ensures higher resistance of the whole
refractory layer.
Tank Cover with Section View (For Reference Only)
A VD splash cover or shield, suspended underneath the tank cover by means of tie rods is
completely water-cooled. Its flat double-wall side panels with slight inclination prevent
accumulation of heavy skulls inside the shield. Usually formed thin skulls fall down back to the
ladle during or after lifting the tank cover.
The splash cover suspension is of a floating type what ensures that it can always rest on the ladle
top when the tank cower is in the lowest position.
The splash shield is used to reduce slag and steel splashing out of the ladle. To some extent, it
stops the slag escape from the ladle in case of excessive foaming during pump-down working as
kind of extension of the ladle free-board.
A special structure, to be placed on the top of the vacuum tank will be provided to facilitate
mounting/dismounting/exchange of the splash shield.

1.6.6 Suction Line Ducts

The suction line ducts from the tanks cover parting flanges to the vacuum pumps inlet are of
single-wall type and made of DN900 carbon steel pipes.
Man-holes are provided in the critical points for maintenance and cleaning purposes. The exact
location of the man-holes will be defined by the final suction line lay-out.
The suction line will be composed of:
• Duct from each tank to vacuum switch;

• Duct from vacuum switch to Main valve;
• Duct from Main valve to Cyclone / Vacuum filter;
• Duct from Cyclone / Vacuum filter to vacuum pumps.
It is of single wall type, DN 900 type, made of carbon steel.
1.6.7 Vacuum Switch

The vacuum switch is a movable connection device which alternatively connects the system with one of
the 2 tanks. It is a 180º type elbow (non-cooled) equipped with lifting and travelling devices.
Vacuum switch design – For Reference only

1.6.8 Cyclone - Filter

The vacuum pumps tight tolerances’ design requires that process of gas is cooled perfectly
cleaned of dust prior to its entrance to the pumps.
In order to clean the gas, a Cyclone and a Vacuum filter will be installed.
The cyclone design generates the fumes rotating movement and allows the separation of the
coarse particles. This way, bigger particles will be decanted and will not reach the vacuum filter,
avoiding clogging problems in the filter bags and ensuring proper performance of the system.
The dust will be delivered to a collecting hopper by means of a double gate discharge system (as
an alternative, an automatic dust evacuation system shall be installed to the plant general Fumes
extraction system).
Cyclone installation – For Reference only

The bag filter working under vacuum conditions demands certain precautions. The filter body
itself must be designed to withstand rapid changes between atmospheric and vacuum
pressures. It must be completely airtight to avoid any air leaks into the system. During vacuum,
refining of steel metal vapours escape from the liquid steel bath at low pressure. The escaping
metals are those with high vapour pressure at steelmaking temperatures: zinc, magnesium and
manganese. On their way to the vacuum pump, these metals subsequently condensate and
precipitate on cold parts inside the vacuum system, forming a pyrophoric layer which ignites
immediately when exposed to air upon opening the vacuum degasser after degassing.
It is obvious that filter bags will also be covered with pyrophoric layer during each degassing
cycle. After degassing is completed, filter bags must therefore be isolated and back-washed with
pulses of inert gas in order to avoid ignition and destruction when air enters the filter at start of
the next degassing cycle.
The maximum permissible inlet temperature for the vacuum bag filter is 130 °C, whereas the
typical inlet temperature to mechanical pump is 40-60 °C.
Thanks to intensive water-cooling of gases through splash shield and heat shield in the vacuum
cover and sufficient length of the suction line, the process off-gas temperature can been
significantly reduced before reaching the inlet of the dust separation unit.
For off-gas cleaning a special, combined vacuum dust separator and bag filter with nitrogen
cleaning has been developed. The guiding design principle has been to separate the coarser
fraction of dust as early as possible in the system using a cyclone type dust separator. Its
efficiency helps to reduce dust load on the filter bags. This also reduces the pressure drop across
the filter during ongoing vacuum degassing.
Filter cleaning from deposited dust is done automatically between two consecutive degassing
cycles. With main shut-off valve closed and pump remaining in the low pressure, nitrogen is
supplied to the pulse-jet cleaning valves. The pulse-jet operational sequence is selected to avoid
that dust shaken off from one row of bags attaches to the neighbouring one. Instead of being
cleaned sequentially, from the first row and onwards, the bags are cleaned in a staggered
manner to allow the dust to settle after shaking without being blown around by jets from
neighbouring rows.
Usually, three complete cleaning cycles are executed. After completed cleaning, nitrogen supply
is cut off. The dust collected below the bags is automatically discharged to the collecting bin
below the filter lower cone. After that, the dust will be delivered to a collecting hopper by means
of a double gate discharge system (as an alternative, an automatic dust evacuation system shall
be installed to the plant general Fumes extraction system).
After dust discharge, the filter remains pre-evacuated to low pressure, awaiting next steel
degassing cycle. If next degassing cycle is imminent, the vacuum pump is left running with screw
compressors, otherwise it is completely switched off.
The filter will be equipped with broken-bag detection device for a continuous monitoring of the
filter status.

1.6.9 Main Shut-off valve

A large butterfly valve shuts off the suction line duct between vacuum tank and dust separation
unit. Since the valve works against the vacuum pressure, it requires a significant force to be
turned. Its opening speed must also be precisely controlled to avoid damage to vacuum filter
bags and cages from inrush air. It is electrically actuated, which gives excellent control over
angular speed and timing.
The main valve in closed position divides the whole vacuum system into two volumes:
• TANK SIDE, which at the beginning of pump-down operation remains atmospheric

pressure (about 1000 hPa).
• PUMP SIDE with off-gas filter which, before beginning of pump-down operation, is
typically pre-evacuated to a pressure of < 5 hPa. The pre-evacuation substantially
reduces the pump down time duration as compared with starting at atmospheric
pressure
With pump side of the system pre-evacuated, once the main shut-off valve is opened the
pressure is equilibrated between the two system volumes at a controlled rate so that filter bags
and cages will not become damaged by high air inrush velocity.
As well as reduction of pump down time, operating in pre-evacuation mode with the division of
the vacuum system into separate volumes by means of the main valve allows for separate testing
of vacuum tightness (air leak testing) and trouble-shooting on tank side and pump side of the
system.
As a rule of thumb, the diameter of the shut-off valve is selected 100 mm less than the suction
line diameter. The increase is pressure drop caused by diameter differences is insignificant when
the suction line is designed with smooth, conical connections to the valve. Therefore, the suction
line will be DN 600 and the main shut-off valve DN 500.

1.6.10 Vacuum Pumps

The complete vacuum pump, creating the low pressure required for the technological process
will be engineered using only dry machines.
Dry pump system means that there is no contact between VD process off-gas and water or oil
in the vacuum pump.
Dry mechanical pumps offer an operational advantage over traditional steam ejector pumps
used in steelmaking plants. No steam or water for steam condensation are required and
therefore no systems for steam generation and condenser water treatment. Therefore, running
costs of mechanical pumps are much lower than those of steam ejectors.
There is the additional advantage of the dry pumping system, which allows reaching lower final
vacuum pressures due to much lower humidity content in the whole system, which is normally
a problem with steam ejector pumps.
The pump components will be arranged according to modular concept. The required vacuum
pressure is created by the combined action of multiple modules of a similar configuration
installed in parallel to ensure the required suction capacity. The modules which fail shall be easily
isolated from the system until the nearest scheduled maintenance stop during which the faulty
module/component can be repaired/replaced. Eventual loss of the suction capacity caused by
modules which fail are compensated by excess capacity of the pump (typically 10%) what allows
to run the vacuum degassing process with acceptable extension of the cycle times.
The number of critical pump elements that may cause leaks, operational, maintenance or safety
problems will be reduced as much as possible.
Dimensioning of the vacuum pump considers;
• acceptable pump-down time

• operating pressure towards end of degassing
• air leaks
All data refer to a completely dry system. A new system will be dried out after about 50 degassing
cycles.

The offer is based on mechanical pumps. The recommended pump is designed as a modular
system approaching a total suction capacity of 155.000m3/h at 0.5 torr (0,67hPa).
VD process required pump capacity in the low-pressure range is estimated in the table below:
Flow %
Argon Volume Flow Rate Nm /h3
21,6 34,1% Ar
Hydrogen Volume Flow Rate Nm3/h 12,0 19,0% H2
Nitrogen Volume Flow Rate Nm3/h 19,3 30,5% N2
Water Vapour Flow Rate Nm3/h 7,5 11,8% H 2O
Air Flow Rate Nm3/h 2,9 4,5% O2
Carbon Oxyde Flow Rate Nm3/h 0,1 0,1% CO
Total Volume Flow Rate Nm /h3
63,3 100,0%
Nom. Suction Capacity @ Pump Inlet m /h 116.130
3
Pressure @ Pump Inlet hPa 0.67

Nom. Suction Capacity @ 0.67 hPa air 20° kg/h 92,5
1.6.10.1 Air leaks into the vacuum system

Correct estimation of the air leaks into the vacuum system is critical for a definition of the
required pump capacity. For new VD installations, the total air leaks are below 20 kg/h and this
value is usually taken as a reference. It is vitally important that the degasser is engineered and
maintained with minimum air leaks in mind.
Any excess leaks may unnecessarily require a higher pump capacity to compensate them. In case
of mechanical pumps, this however may influence the investment cost resulting in unacceptable
costs and/or extended return of investment.
1.6.10.2 Pump Down Time

Pump-down time is defined with a hot, clean and empty ladle (no liquid steel, no Ar) in the
tank. The pump-down time to 1.33 hPa is typically in the range 5-6 minutes with pre-
evacuated filter, which is the normal way of operating the degasser.
The proposed pump-down time is a compromise: shorter pump-down time means clearly higher
investment cost; longer pump-down time may limit sequence casting.

1.6.10.3 Required Suction Capacity of the Vacuum Pump

VD process calculations have been done to estimate the gas flow from the vacuum tank and
related gas flow at the pump entrance.
The following parameters have been taken into account:
• Steel weight max 120 tonnes (VD);

• air leaks into the vacuum system (assumed as 20 kg/h for VD);
• hydrogen removal rate (0.15 ppm/min);
• nitrogen removal rate (1.5 ppm/min);
• flow of water vapour from humidity normally accumulated in the vacuum tank
refractories (0.1 l/min after approx. 50 heat treated and fully dried refractories of the
vacuum tank and the cover);
• average argon flow for liquid bath stirring 125 Nl/min.
1.6.10.4 Vacuum Pump Control

In a standard operation, the pumps are controlled in fully automated manner.
Four operational modes are utilized:
• STAND BY START - with main shut-off valve closed, the pumps are running to pre-
evacuate the bag filter and suction line up to the main valve - when the low pressure is
reached (< 3 hPa) the pumps are slowed down to maintain the achieved pressure;
• VACUUM ON - starts with opening of the main valve, the pumps are running to reach
desired pressure and time set points imposed by VD or SD practices, manual control of
suction speed is possible through frequency control of pump motors;
• VACUUM STOP - the main valve is closed dividing the vacuum system into two volumes.
The pump side remains at low pressure while the tank side is flooded to return to
atmospheric pressure; on the pump side an automatic filter cleaning procedure is
activated;
• STAND-BY STOP - all machines are stopped; the pump side remains in low pressure to
avoid air infiltration into the bag filter (if necessary, the filter can be flooded manually to
reach the atmospheric pressure).
The activation of the STAND-BY STOP procedure is not used until the last heat of the scheduled
sequence is completed. In this case, after end of VACUUM STOP sequence which is tied to the
end of filter cleaning, the STAND-BY STOP procedure is activated to shut down the system.

1.6.11 Auxiliary Systems

1.6.11.1 Sampling Lance
A single-lance Automatic sampler for working under atmospheric conditions will be installed on
the vacuum cover.
The sampler can be operated from the vacuum cover upper platform and from the control room.
Sampling cartridge probes and thermocouples will be replaced manually.
1.6.11.2 Wire Feeder

Up to 4 different material wires may need to be fed on one and the same steel grade (Al, C,
CaSi). The VD station will therefore be equipped with two (2) 4-strand wire feeding machines for
post-vacuum steel composition trimming and inclusion modification.
Wire feeding is performed with the tank cover closing the vacuum tank (but at atmospheric
pressure) so that any fumes generated during wire feeding will be captured and filtered.
1.6.11.3 Vacuum Measuring Instruments

Correct measurements of pressures in various parts of the vacuum system are indispensable for
process and pump operation control.
The measurements on the tank side are done inside the control room on the measuring line
connected to the suction line. In addition to electronic instruments (capacitance diaphragm
gauges) as a back-up a mechanical vacuum gauge (capsule type) is used. Furthermore, a flange
for connection of a portable vacuum meter is provided.
Additional flanges for connection of portable instruments are foreseen along the suction line
and close to the vacuum pump inlet.
Electronic instruments are located in the pump room for supervising and controlling vacuum
pump operation. Also, inside the pump room there is a special flange terminal for connecting
calibrated nozzles used for measuring pump suction capacity.
Arrangement of Vacuum Measuring Instrumentation

1.6.11.4 Process Monitoring System

The whole degassing process and especially its most critical part, i.e. pump-down, must be
visually controlled by the operator. A TV camera system and a sight glass are used for this
purpose.
The TV camera(s) used for this purpose will point to the bubble plume rising from the porous
plugs and the ladle wall above it so that boiling intensity can be assessed and controlled by the
operator by regulating tank pressure and Ar flow.
1.6.11.5 CO-CO2 Analyzer

Control of VD process parameters.
Heated measuring probe for process gas provided of climatic protection and filtering
component.
Compressed air cleaning system for probes.
Heated line for process gas.
Analyzer cabinet containing conditioning system and CO-CO2-O2 analyser.
Process gas conditioning system before analyser treatment.
Analyzer measuring two components after infrared and oxygen absorption.
Analyzer probe catcher and cabinet for reference

1.6.11.6 Hydrogen Measuring Equipment (Hydris)

Hydrogen activity measurement in liquid steel.
H2 measuring range: 0,5 - 14 ppm
Hydrogen sensor system uses the principle of hydrogen partial pressure distribution between
gas and liquid phase.
The Hydrogen measuring system gets a certified gas composition into equilibrium with the liquid
metal to be measured. Using Sieverts’ law (prediction the solubility of gases in metals) the
hydrogen concentration in liquid metal can be calculated.
Immersion of probe and reading are like a normal sample/temperature test, just the immersion
time of the probe is a little longer, but typically less than a minute. Machine precision is today
the industrial standard of hydrogen measurement in liquid metals, operator independent and
free from previous sample preparation and analysis errors.

1.7 Material Handling System - MHS

1.7.1 MHS Main Features
The Material Handling System is designed for feeding materials to the EAF plus tapping and for
the additions within the Twin LF.
The MHS is designed to charge and stock into bins and charge automatically additives and
ferroalloys during melting, tapping and steel refining process.
Taking into account the melt shop layout, logistics and material flow, the material handling will
be described in the next chapters.

1.7.2 MHS bins dimensioning

The proposed bins are calculated considering its autonomy for a convenient use:
TtT mn 53
tn/heat 120
hr/day 24
Heat No./day 27,2
tn/hr 135,8
tn/day 3260
Bulk
Material Consumption Proposed Bins Autonomy
Density
OUTSIDE
tn/m3 Kg/t Kg/heat m3/heat # m3/each total days

DRI 1,6 802,5 96300 60,2 1,0 175 175,0 0,1
Lime 1,1 45 5400 4,9 3,0 115 345,0 2,6
Dolo 1,6 12 1440 0,9 2,0 115 230,0 9,4
Alloys 6,0 30 180,0
INSIDE
EAF # m3/each total

Lime / Dolo 2,0 7,5 15,0
TAPPING # m3/each total
Tapping
2,0 3 6,0
materials
TWIN LF # m3/each total
Alloys 3,0 3 9,0
Alloys 3,0 4,5 13,5
Alloys 2,0 5 10,0

MHS Plant Diagram for reference

1.8 Fumes Exhaust System – FES

1.8.1 FES Design
The purpose of the FES is the control and treatment of the following emission sources:
• Primary emissions from EAF generated during power-on and charge phase.
• Secondary emissions from EAF generated during furnace power-on and charging and
tapping operations.
• Emissions from TWIN LF generated during ladle treatment operations.
• Emissions from VD generated during trimming operations.
• Emissions in ladle & tundish deslagging operations.
• Emissions in ladle and ladle dryer debricking operations.
• Emissions from MHS generated during additives handling operations.
• Emissions from CCM generated in Mould and oxy-cutting area (dedicated plant).
The main tasks of the system are:

• Suction of the EAF primary emissions from the roof 4th hole elbow.
• Suction of the EAF secondary emissions from the canopy hood installed on the roof
building.
• Suction of the TWIN LFs primary emissions from the LFs roofs.
• Cooling of EAF primary emissions by means of Combustion chamber, water cooled ducts
and forced draft cooler.
• Mixing of primary and secondary emissions and control of filter inlet temperature.
• Filtering of the dirty gases by means of a bag filter.
• Exhausting of the cleaned gases by means of fans driven by AC motors.
• Discharge of clean gas in atmosphere by means of dedicated stack.
• Transportation and storage of the dust collected in the system

1.8.2 Main FES Features

The main features of the proposed FES are as follows:
FES maximum capacity m3/h 2,400,000

Fumes cooling Combustion chamber, water cooled ducts and
natural draft cooler
Bag cleaning method Air-pulse jet
Bag filter operational mode during cleaning OFF-LINE
Main ID fans capacity kW 3 (+1) x 2,400 for EAF
kW 1 x 132 for TWIN LF
kW 1 x 22 for VD
kW 1 x 200 for Ladle Debricking
kW 1 x 200 for Deslagging
kW 1 x 110 for MHS tapping additions
kW 1 x 55 for MHS ferroalloys additions

1.8.3 Main FES flow rates and main data
OPERATION DIAGRAM
Pos. Description Normal flow Real flow Normal flow Real flow
T [ºC] T [ºC]
[Nm³/h] [m³/h] [Nm³/h] [m³/h]
- EAF Outlet 4th hole 47.663 1.620 330.000 - - -

- EAF dilution air inlet 142.990 60 174.000 - - -
A EAF CC Inlet 191.000 930 842.000 - - -
B EAF Water Cooled Duct Outlet 191.000 600 611.000 - - -
C Cooler Inlet 191.000 560 583.000 - - -
D Cooler Outlet 191.000 380 457.000 - - -
E Canopy 688.000 60 840.000 1.134.000 80 1.470.000
E' FES spare extraction capacity 330.000 60 400.000 330.000 60 400.000
F TWIN LF 70.200 150 110.000 70.200 150 110.000
G VD 10.000 150 20.000 10.000 150 20.000
H Ladle debricking 130.000 40 150.000 130.000 40 150.000
I Ladle/tundish deslagging 125.000 60 150.000 125.000 60 150.000
J MHS (Ferroalloys) 110.000 40 126.000 110.000 40 126.000
K Total at BFH inlet 1.654.200 98 2.251.000 1.909.200 73 2.420.000
L Total Flow Outside 1.654.200 96 2.250.000 1.909.200 72 2.400.000
Filtering area [m²] 28.953 30.883
FILTERING CAPACITY
Flow speed [m/min] 1,30 1,30

FES Plant Diagram for reference

1.8.4 MHS FES Features

The main features of the proposed MHS FES only for DRI circuit are as follows:
DRI MHS FES maximum capacity m3/h 57.000

Bag cleaning method Air-pulse jet
Main ID fans capacity kW 1 x 132
OPERATION DIAGRAM MHS
Normal flow Real flow

Pos. Description T [ºC]
[Nm³/h] [m³/h]
A MHS (DRI circuit) 50.000 40 57.000

Filtering area [m²] 757
FILTERING CAPACITY
Flow speed [m/min] 1,26
MHS FES Plant Diagram– For Reference Only

1.9 EAF Process Calculations

Find onwards tentative process calculations related on received customer information.
1.9.1 70% CDRI - 30% SCRAP (Base Case)
MAIN FURNACE DATA

EAF Type AC
Upper Shell Diameter [mm] 6900
Electrode Diameter 610
Tapped Steel Weight [t] 120
Hot Heel Weight [t] 60
Total EAF Capacity [t] 180
Charge Weight [t] 137,6 % Charge

Scrap [t] 41,3 30%
Pig Iron [t] 0,0 0%
DRI [t] 96,3 70%
HBI [t] 0,0 0%
Hot Metal [t] 0,0 0%
EAF OPERATIONAL CYCLE:

Preparation / Delays [min] 3
Bucket charging [min] 1,5
Tapping [min] 3
Total Power OFF [min] 7,5
Melting [min] 40,0
Superheating [min] 5,5
Total Power ON [min] 45,5
TAP-TO-TAP TIME [min] 53

PRODUCTIVITY [t/h] 135,8

ELECTRICAL ENERGY INPUT

EAF Transformer Power [MVA] 150
Overload [%] 0
Power Input Data:
Charge Perforation [MW] 50,7
Melting Step 1 [MW] 87,4
Superheating [MW] 79,1
Average Power [MW] 85,1
Average Power Factor [cos phi] 0,80
Average Secondary Current [kA] 58,0
TENTATIVE FURNACE PERFORMANCE
Energy Consumption [kWh/t Liquid Steel] 538

Natural Gas Consumption [Nm3/t Liquid Steel] 5,6
Total Oxygen Consumption [Nm3/t Liquid Steel] 31,4
Lime + Dolo Cons. [kg/t Liquid Steel] 55,0
Charge Carbon Consumption [kg/t Liquid Steel] 3,0
Injection Carbon Consumption [kg/t Liquid Steel] 4,2
Electrode Consumption [kg/t Liquid Steel] 1,62
Yield Charge to Liquid Steel 87,2%

MASS BALANCE
INPUT kg/t LS kg/t LS OUTPUT
Scrap 344,0 1000,0 Tapped steel
Pig iron 0,0 SLAG
DRI bucket 0,0 5,8 Mettalic particles
DRI continuous 802,7 54,9 Additions / refractories
Fe-alloys 0,0 0,7 Ash from carbon
Lime 44,0 -0,2 Fe2O3 additions and ashes
Dolo 11,0 49,9 Non metallic scrap components
Limestone 0,0 4,4 Oxides (Mn, Si, P, Cr ...)
Others 0,0 44,4 FeOx
Tot. Carbon 7,2 159,9 TOTAL SLAG
Total oxygen 44,4 FUMES / DUST
Electrodes 1,61 7,7 Volatiles from scrap
Refractories 5,6 14,3 Carbon from scrap
6,5 Carbon from scrap
45,9 Oxygen (burning gas)
1,61 Electrodes
2,1 Additions
18,9 Dust
97,1 TOTAL FUMES / DUST


1.9.2 100% CDRI (Option 1)
MAIN FURNACE DATA

EAF Type AC

Scrap [t] 0,0 0%
Pig Iron [t] 0,0 0%
DRI [t] 138,7 100%
HBI [t] 0,0 0%

Bucket charging [min] 0
Tapping [min] 3
Total Power OFF [min] 6
Melting [min] 48,5
Total Power ON [min] 54



Overload [%] 0
Power Input Data:


MASS BALANCE
Pig iron 0,0 SLAG
DRI bucket 0,0 6,8 Metallic particles
Dolo 15,0 53,8 Non metallic components
Electrodes 1,88 1,2 Volatiles
Refractories 6,1 20,3 Carbon
4,5 Carbon
1,88 Electrodes
2,4 Additions
20,1 Dust

Chapter 2 – Project Description

1.9.3 90% CDRI – 10% SCRAP (Option 2)

MAIN FURNACE DATA
EAF Type AC

Scrap [t] 13,8 10%
Pig Iron [t] 0,0 0%
DRI [t] 124,6 90%
HBI [t] 0,0 0%

Tapping 3
Melting [min] 45,0



Overload [%] 0
Power Input Data:


MASS BALANCE
Pig iron 0,0 SLAG
1,78 Electrodes
2,3 Additions
19,9 Dust


1.9.4 80% CDRI – 20% SCRAP (Option 3)
MAIN FURNACE DATA

EAF Type AC

Scrap [t] 27,6 20%
Pig Iron [t] 0,0 0%
DRI [t] 110,5 80%
HBI [t] 0,0 0%

Tapping [min] 3
Melting [min] 43,0



Overload [%] 0
Power Input Data:


MASS BALANCE
Pig iron 0,0 SLAG
1,71 Electrodes
2,2 Additions
19,4 Dust


1.9.5 Scenarios Comparative
BASE CASE OPTION 1 OPTION 2 OPTION 3
70% CDRI - 100% CDRI 90% CDRI – 80% CDRI –

30% SCRAP 10% SCRAP 20% SCRAP
Total Power OFF min 7,5 6 7,5 7,5
Total Power ON min 45,5 54 50,5 48,5
TAP-TO-TAP TIME min 53 60 58 56
PRODUCTIVITY t/h 135,8 120,0 124,1 128,6
TENTATIVE FURNACE
PERFORMANCE
Energy Cons kWh/tls 538 598 582 558
Tapping Temp ºC 1620 1620 1620 1620
Total Oxygen Cons Nm3/tls 31,4 33,8 33,2 32,6
Lime+Dolo Cons. kg/tls 55,0 60,0 58,0 57,0
Charge C Cons kg/tls 3,0 1,0 2,0 2,0
InjC Cons kg/tls 4,2 4,0 4,1 4,1
Electrode Cons kg/tls 1,62 1,88 1,78 1,72
Yield Charge to tls % 87,2 86,5 86,6 86,9

1.10 LF + VD Process Calculations

The estimations are done with the following assumptions:
• The ladles are in regular hot circulation
• The slag volume is controlled not to interfere with the performance
• The heat is shipped to the casting area at 91 ºC over liquidus
The major process timing is summarized below considering 25MVA:
LF Unit
Power on (LF) 30 minutes
Pump down time (VD) 5 minutes
Total process time (LF+VD) 82 minutes
LRS
Note: if no activity input 0 value stirring temperature T liquidus Superheat
power chk
LF+VD single prog % MVA % °C °C °C
EAF 0 0 min 0 0 0 1659 1526 133 OK EAF Tapping
Addition1 (tap) 1 1 min 0 0,00 0 1565 1500 65 OK EAF Tapping
Transport to LF 5 6 min 0 0,00 0 1550 1500 50 OK Transfer to LF
Wait at LF 1 7 min 0 0,00 50 1552 1500 52 OK LF
Homog+slag 12 19 min 95 23,75 30 1590 1500 90 OK LF
Analysis 3 22 min 0 0,00 30 1586 1500 86 OK LF
Addition 2 5 27 min 0 0,00 50 1536 1486 50 OK LF
Heating 2 9 36 min 95 23,75 30 1572 1486 86 OK LF
Analysis 3 39 min 0 0,00 30 1574 1486 89 OK LF
Addition 3 0 39 min 0 0,00 0 1574 1486 89 OK LF
Heating 3 9 48 min 95 23,75 0 1611 1486 125 OK LF
Wire Feeder 2 50 min 0 0,00 0 1608 1486 122 OK LF
Wait 1 51 min 0 0,00 0 1607 1486 122 OK LF
Transport to VD 5 56 min 0 0,00 0 1603 1486 117 OK Transfer to VD
Wait 1 57 min 0 0,00 0 1602 1486 117 OK VD
Preparation 3 60 min 0 0,00 0 1600 1486 114 OK VD
Pump Down 5 65 min 0 0,00 0 1597 1486 111 OK VD
Vacuum Degassing 18 83 min 0 0,00 0 1583 1486 97 OK VD
VD Trimming 4 87 min 0 0,00 0 1581 1486 95 OK VD
Wait 1 88 min 0 0,00 0 1580 1486 94 OK VD
Transport to CCM 5 93 min 0 0,00 0 1577 1486 91 OK Transfer to CCM
Tundish filling 2 95 min 0 0,00 0 1576 1486 90 OK
Cast 50 145 min 0 0,00 0 1554 1486 69 OK
TOTAL Process Time 145 min

1.10.1 VD Material Balance
Air Leaks
20 kg/h Off Gas Flow
73,9 kg/h
Hydrogen Red 63,3 Nm 3/h
1,1 kg/h 1013,25 mbar
0 °C
Nitrogen Red
24,2 kg/h Vessel Outlet Pump Inlet
73,9 kg/h 73,9 kg/h
Water Vapour 238.837,2 m 3/h 116.129,7 m 3/h
6,0 kg/h 0,86 mbar 0,67 mbar
600,0 °C 58,0 °C
Carbon Oxyde
0,1 kg/h
Argon Stirring
38,5 kg/h

1.10.2 Hydrogen Removal

The vacuum time is for most applications controlled by the hydrogen removal.
Most of the hydrogen removal takes place at the interface between stirring gas and the
steel. The interface area is controlled by the gas flow and the pressure and shall not be
mistaken for the stagnant bath area.
Surface active elements, mainly S and O, has a minor negative influence on the hydrogen
removal. There is for normal operation no significant influence on the H removal.
Practical case:
Project AM JUBAIL
Ho 8 ppm
W 120 ton
A 6,73 m2
Slag 0,05 m
overruled by slag
VCD 0 0=no; 1= yes restriction
Used if not taken from the
Final P 0,7 mbar plc
to 1.2 * final pressure, used if
Pump down 5 min not taken from the plc
Argon pump
down 0,4 Nl/ton*min
Argon vacuum
hold 3 Nl/ton*min

1.10.3 Nitrogen Removal

The nitrogen removal is controlled by the same mechanism as the hydrogen removal but
with far bigger influence from the surface active elements S and O.
The nitrogen is typically removed to 30-50 % of the initial content provided the S is
controlled to max 0.005 %.
Practical case:
Project AM JUBAIL
No 0,008 %
W 120 ton
A 6,73 m2
Slag 0,05 m
0=no; 1=
VCD 0 yes overruled by slag restriction
Final P 0,7 mbar Used if not taken from the plc
%S 0,02 before vd
%O 3E-04 before vd
to 1.2 * final pressure, used if not taken
Pump down 5 min from the plc
Argon pump down 0,4 Nl/ton*min
Argon vacuum
hold 4 Nl/ton*min

2 Billet caster process

2.1 Project requirements
This design concept will be related to installation of a new 4 continuous casting machine
(CCM) for production of round bloom diameter 200, 280 and 350 mm mm up to >750.000
ton/year.
Machine will be prepared (space) for additional 5th strand addition in future.
Please refer to the information within this technical document for more details.

2.1.1 Casting machine

The CCM main data shall be as follows:
CCM GENERAL INFORMATION
Ladle size: 120 ton
Machine radius: 12/16.5/30/∞ m
Strands number: 4 /(5)
Distance between strands: 1500
Design limits: Round billets/blooms up to 350 mm diameter
Casting method: Submerged casting with Stopper rod system
Cast sections: Ø200 mm, Ø280 mm, Ø350 mm diameter
Ladle support: Ladle turret with lifting system
Approx. 25 t liquid steel max capacity.
Tundish: - Steel level (working level) approx. 800 mm
- Steel overflow level approx. 850 mm
Tundish car: Cantilevered type, with weighing system
Tundish flow control system: Stopper rod system
LADLE to TUNDISH: LS (Ladle Shroud) + Tundish covering
powder
Stream protection:
TUNDISH to MOULD: SES (Submerged-Entry shroud) +
Casting Powder
Mould length: Approx. 800 mm
Mould type: Tubular
Mould level control: Radioactive Co60
EMS: M-EMS External type + F-EMS
Mould oscillation: Hydraulically actuated
Spray cooling: Air mist, 3 cooling zones
Exhaust system: Steam exhaust system for cooling chamber
Withdrawal Straightening
Modular type (5 modules) with 3 unbending points.
Unit:
Dummy bar: Rigid dummy bar
Metallurgical length: Approx. 24 m
Cutting unit: Oxy torches

Cutting length: 12 m
Discharge type: Cross transfer mechanism with lifting system.
Cooling bed: TOCB
Tertiary cooling Controlled cooling (cooling pits)
Table 1, CCM general information.

2.1.2 Steel grades classification and casting speed

The casting speed of the CCM for a certain grade is defined by several factors. The main
ones are:
− Casting sections
− Machine radius
− Cracking tendency (related to steel grade composition)
Some other important points such as the cooling water and the number of strands are
calculated upon other features, including maximum output and quality requirements.
The present document will evaluate the capability of the supplied equipment to process the
proposed steel grades in the given time with required quality.
CCM radius affects billet quality due to the elongation at the strand surface and the
elongation at the solidification front during the straightening process.
The configuration of the machine, i.e. number of unbending points and main radius of the
machine, together with the cooling program, results in a strain value on the surface and at
the solidus/liquidus interface of the cast product.
Strain, on this critical condition of temperature, is studied with special attention to achieve
the desired quality, and the typical Strain tolerances for different grades, related to steel
composition, are reported in the following pictures.
Figure 1, critical solidus/liquidus interface strain values according literature sources

Graph 1, critical solidus/liquidus interface strain values.
The same, related to surface strain, is reported in following graph:
MAXIMUM SURFACE STRAIN

Mn/S>28
Mn/S<25
1,5
1,4 Mn/S<10
>0.5
1,4
Equivalent C
1,6
0.15-0.50 1,55
1,5
1,75
<0.15 1,65
1,6
1,3 1,35 1,4 1,45 1,5 1,55 1,6 1,65 1,7 1,75
% Strain
Graph 2, critical surface strain values.
Taking into consideration above criteria, Sarralle defined a maximum casting speed for
typical cast grades and for the different casting sections.

2.1.2.1 Steel grades

The plant is designed to produce >750.000 t/year of quality grades. Hereafter typical steel
grades list.
Cast sections Steel grades

200, 280, X 52; X 60; X65; B; C90; Gr, 5; Gr. 6; Grade C; Green to T95; Green to P
350 mm dia 110; J 55; K 55, L 80; L 80 1% Cr; R 95; T 95 HS.
Table 2, typical steel grades list

2.1.3 Production calculation

The production calculation aims to show the relations between the melt shop
requirements, in terms of production calculation, productivity and the feasibility of the
required amount of different as cast products produced in the CCM according to the
design criteria showed above.
Although it has been settled that the speed required are within the range of typical
parameters to fulfil the melt shop requirements, a further study of the combination of
different strands number of sections, combined with different heats in sequence, needs to
be done to ensure the complete coordination of the plant in order to reach the required
productivity within expected available production time.
The conclusion after this calculation is that CCM, as designed, will be able to match the
proposed productivity of more than 750000 ton/year based proper liquid steel supply is
available and working hours will correspond to the defined working time of (7200 h/year).
Hereafter respective calculations are reported:
Table 3, productivity calculation.

2.1.4 Casting speed

The following table shows the maximum casting speed for actual casting section.
Max casting speed (m/min)
200 mm 280 mm 350 mm
API grades 2.3 m/min 1.2 m/min 0.7 m/min
Prime quality 1.9 m/min 1.0 m/min 0.6 m/min
Table 4, maximum casting speed for actual casting section and steel grade.
2.1.5 Strain Calculation

As it has been already introduced in previous chapters, strain is a critical design factor in
the CCM.
The Strain is defined as the deformation suffered by the interface between liquid and solid
front, usually named solidification front, as well as the strains suffered by the external
surface, already solidified, during the straightening (unbending) process.
The superimposed mechanical forces to the solid parts of the steel, resulting by strain, may
result into important quality problems into the billet / bloom produced. This point
therefore, deserves a particular analysis.
The strain is affected by the design of the machine through the unbending practice:
according to the product to be cast, we can find single or multiple unbending points and
we can have total unbending distance divided in several segments.
Apart of the design of the CCM, the strain is mainly affected by the thickness of solid
fraction in the unbending point. So it is needed to know the thickness of the solidified part
in this particular point.
This thickness is different from one section to another, and related to casting speed, cast
grade, cooling patterns and else, therefore for the analysis a solidification factor “K” is
usually considered, representing the tendency of the product to solidify in respect with
casting length and casting time. A resulting K value ranging between 28 and 30 depending
of the product is used for first definition of solidification length.
The value taken into consideration for the evaluation of internal strain would be the
individual Strain at each unbending radius, as in different points the position (thickness) of
solidified part is changing.
For this project three unbending points are considered, with machine radius
12000/16500/30000 mm. This arrangement allows the reduction of the strain values
respect to a single radius machine, keeping the values lower than required limits when
proposed casting speeds are used.

Considering the sections and average speeds for this project, the following table shows the
obtained strain levels, which are below the limits imposed by steel grade chemistry at
project casting speed.
3 unbending points
Figure 2, triple unbending philosophy.
The values for surface strain at maximum speed for the bigger cast section in the different
unbending radius are reported separately as per the following table:
Surface Strain at 3nd
Surface Strain at 1st Surface Strain at 2nd
Section Unbending point
Unbending point (U.P.1) Unbending point (U.P.2)
(U.P.3)
200 mm
0.23 % 0.28 % 0.33 %
diameter
280 mm
0.32 % 0.39 % 0.47 %
diameter
350 mm
0.41 % 0.49 % 0.59 %
diameter
Table 5, values for surface strain at maximum Cs.

Values for internal (liquidus/solidus interface) strain at maximum speed in the different
unbending radius are shown in the following table:
Solidus/liquidus Solidus/liquidus Solidus/liquidus

Strain at 1st Strain at 2nd Strain at 3rd
Section
Unbending point Unbending point Unbending point
(U.P.1) (U.P.2) (U.P.3)
200 mm
0.026 % 0.030 % 0.036 %
diameter
280 mm
0.040 % 0.047 % 0.056 %
diameter
350 mm
0.058 % 0.068 % 0.081 %
diameter
Table 6, values for internal strain at maximum Cs.
According to the strain criteria, defined in previous paragraph of present document, the
design of the machine and the required speed for reaching design productivity could be
validated.

2.1.6 Oscillation
Hydraulic type oscillation will be utilized, having following main characteristics:
− Max total stroke: 16 mm
− Remote control and adjustment of stroke and frequency
− Frequency 20-240 o.p.m
− Possibility of working with optimum NST for each speed and format
The oscillation parameters play a fundamental role in the surface quality primary and sub-
surface defects.
Good oscillating parameters should ensure the correct Negative Strip Time for the
different sections at all the range of speeds, while maintaining acceleration and some
other factors within certain limits.
These values, added to the mould taper design and lubrication media (oil or mould
powder) used during casting will be the responsible of the surface quality of cast products.
NST Vs Speed (indicative only)

0,170
240
0,160
220
0,150
200
0,140
180
NST (sec)
0,130 160
OPM
0,120 140
0,110 120
0,100 100
0,090 80
0,080 60
1,80 1,90 2,00 2,10 2,20 2,30 2,40 2,50 2,60
Cs (m/min)
NST NST min NST max OPM
Graph 3, NST vs. Casting Speed.
In order to minimize the depth of oscillation marks, correct combination of stroke and
frequency will be selected accordingly.

2.1.7 Electro Magnetic Stirring

The CCM will be equipped with external type Mould Electromagnetic Stirrer (M-EMS) to
enhance the internal quality of steel.
Mould stirring is enhancing quality of as cast products, especially concerning internal
quality, improving results in terms of segregation, internal structure, equiaxed zone,
presence of pin-holes/blow-holes, centre porosity and the like.
Final stirrer (F-EMS) will be added at the end of the cooling zones in order to ensure
optimum solidification pattern and further reduce center segregation

2.1.8 Secondary cooling

The secondary cooling layout of the caster shall be designed to provide the correct value of
specific cooling water intensity (l/kg) for a specific range of casting speeds of interest.
The range of casting speeds and secondary cooling intensities required define a
rectangular area in a “casting speed vs. specific cooling water intensity diagram”, called
“working window”.
When casting different sections, which could require different “working windows”, the
spray nozzle layout is optimized, if it is possible, to cast all steel grades without change the
spray nozzles.
As it can be seen in the formula above, the flow (for only water) is depending of square
root of the ratio of pressures. Considering pressure between 2 and 10 bars, the maximum
flow achievable would be:
10
𝐹𝐹Max = � 𝑋𝑋 𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹
2
Due to the requirement of uniform cooling over the full perimeter of the cast product and
use of “soft cooling” pattern, air mist type sprays will be used, granting more efficient cooling
even at lower specific cooling values due to better water atomization and increase of impact
force.

2.2 CCM Design

2.2.1 Ladle Turret
Ladle turret with fixed arms and independent ladle lifting and lowering devices mounted in
each side of the rotating arms.
The supported ladle is weighed by dedicated system for each side of the rotating arm. The
transmission of weight signal is made through a rotary slip ring in the centre of the arm.
The ladle turret rotation movement is performed by means of an electrical motor
controlled by frequency converter for smooth acceleration and deceleration. An
emergency system, composed of a pneumatic motor and related accessories ensure the
rotation in case of main power failure.
Figure 3, H type Ladle Turret.

2.2.2 Tundish
Design of the tundish supports inclusion removal and ensures a stable steel flow and
temperature parameters homogenized between the casting strands.
The size of the tundish and its shape as well as the design of inhibitors of turbulence
("turbostop", dams and weirs) are optimized by fluid dynamic studies.
PRELIMINARY DATA
Type Delta type
Nominal condition ≥ 23 ton / 800mm (4 strands)
Overflow 25 ton / 850mm (4 strands)
Residence time at maximum productivity ≥10 min
Table 7, preliminary data for tundish design.
Figure 4, Tundish.

2.2.3 Tundish Cars

Cantilevered high runways design allows installation without rails on the casting platform.
Such solution increases the safety conditions in case of steel overflow and leaves large
space available on the turret side.
Figure 5, cantilever type Tundish Cars.
The tundish car will be designed to be equipped with lifting device to lift the tundish,
facilitating the shroud insertion for submerged casting technique.
Lifting is hydraulically actuated by means of hydraulic cylinders installed on the tundish
support arms. To ensure the horizontal lifting of the tundish, position detectors are
installed at each arm and the lifting cylinders are controlled by means of separate
hydraulic valves.

2.2.4 Casting Technique

The machine is designed to cast in:
Submerged casting mode

The provided stopper control system for submerged casting presents the following main
features:
− Accurate and fast control of stopper position.
− Reliable and designed for low-maintenance.
− Fully automatic strand start-up procedure with section size and steel grade related
parameters.
Figure 6, tundish stopper rod mechanism.
2.2.5 Automatic start of the hot strands

The mould level detection system is used to make automatic start of casting strand in case
of open casting mode. The start function is included in the PLC line control and has initial
velocity parameters to get a soft start casting.
When casting in submerged mode, automatic start is granted by pre-set opening ramps of
the stopper rod, allowing a safe and smooth filling of the mould till automatic mould level
control takes over.

2.2.6 Mould level detection system

The function of the detection system is to measure the actual steel level in the mould and
to transmit this information to the Strand PLC.
The system consists of a radioactive source, a detector and a processor for each casting
strand.
The radioactive source irradiates the mould. The gamma radiation field is attenuated by
molten steel so that the scintillation detector crystal, located on the opposite side of the
mould, senses a different field strength according the amount of steel inside the mould.
Within the detector crystal, the radiation generates flashes of light which are converted to
electrical pulses through a photomultiplier tube.
The measure of level is generally given as percentage of the total reading field
(approximately 200mm) of the system. The working range is typically between 65% and
85% of the measuring range, and the meniscus position is generally placed approximately
between 80 and 120 mm from top of copper tube

2.2.7 Mould
When casting round sections, a cartridge mould will be used.
Cartridge mould is section size related and is designed to allow quick change of the mould
without disconnecting:
- Mould Stirrer
- Mould level control system
Cartridge mould technology is composed mainly by two parts:
An external, fixed, mould cartridge support common to all sections and set on the mould
oscillation table.
A set of cartridge moulds containing copper tube, water jacket, flanges, foot rolls and spray
ring. Cartridge moulds are pre-assembled in the mould preparation area/workshop and
quickly removable from the mould cartridge.
Cartridge moulds are inserted inside the cartridge support.
The external type mould stirrer is placed in the external part of mould cartridge and can be
designed for a wide range of cast sections.
Figure 7, Cartridge Mould.

2.2.8 Mould and Primary cooling

Casting section 200 mm diameter
Curved type, parabolic or
Mould type
multitaper
Copper tube length Approx. 800 mm
Copper tube thickness 18 mm
Chromium Plating thickness 0.10-0.12 mm
Mould material CuAg
Water Gap 3.5 mm
Min/max water flowrate (approx. each
1400/1850 l/min
strand)
Inlet pressure ≥ 8 bar

Mould type
multitaper
Mould material CuAg
Water Gap 3.5 mm
1950/2600 l/min
strand)

Mould type
multitaper
Mould material CuAg
Water Gap 3.5 mm


2400/3200 l/min
strand)
Table 8, preliminary data for mould and primary cooling.
2.2.9 Mould Electromagnetic Stirring (M-EMS)

The CCM will be equipped with Mould-EMS, external type, to enhance the quality of as-
cast products.
The main advantages of the utilization of Mould EMS are the reduction of problems
generated by:
− Surface slag
− Pinholes
− Blowholes
− Subsurface slag
− Breakouts
− Internal cracks
− Columnar structure
− Centreline segregation
− Centre porosity Figure 8, M-EMS.
− V-segregation
Coil dimensions, power and magnetic field will be designed in such a way that same coil
will be used for both existing and possible future sections.

2.2.10 Foot Rolls and Containment

For square sections billet is guided at the mould exit from guiding rolls, (foot rolls)
maintaining proper centering of cast product and ensuring support of forming shell.
Foot rolls are attached to the mould to avoid bulging of the billet and to keep the cast
strand centred. This arrangement increases mould performance, supporting uniform
contact between mould tube and the shell while causing less wear to the tube.
Section Size Total containment Length

Foot rolls
(mm) (from meniscus)
200 mm diameter 1 row approx. 800 mm
280 mm diameter 2 rows approx. 900 mm
350 mm diameter 3 rows approx. 1000 mm
Table 9, preliminary data for foot rolls and containment.
Figure 9, foot rolls arrangement

2.2.11 Oscillation
Main advantages of the hydraulic oscillation are:
− Remote-controlled change of stroke and frequency resulting in faster section change
time.
− Possibility to select any value stroke within the design range and even to operate with
variable stroke.
− Possibility to operate with non-sinusoidal curves.
− Possibility of working with optimum Negative Strip Time (NTS) for each speed and
format.
Good oscillating parameters should ensure the correct negative Strip time for the different
steel grades and casting modes, maintaining mould lead, acceleration and some other
factors within predefined limits.
These values in accordance with the mould taper design and mould powder used during
casting will be the responsible of the surface quality of products.
Figure 10, hydraulic oscillation.

2.2.12 Spray Cooling System

Approximately 20% of the heat of a casting strand is removed in the mould. Once left the
mould the formed bar enters in the secondary cooling chamber.
In the secondary cooling area additional 30-40% of existing heat is then removed trough
adoption of forced cooling by sprayed water onto the surface of solidifying product.
The secondary cooling layout of the caster shall be designed to provide the same value of
specific cooling water intensity (l/kg) for a specific range of casting speeds of interest.
200 mm 280 mm 350 mm

Section:
diameter diameter diameter
Max. specific water: 0.55 l/kg 0.45 l/kg 0.35 l/kg
Max. water flow per
290 l/min 240 l/min 185 l/min
strand:
Z1 Water
Cooling zones: Z2 Air Mist
Z3 Air Mist
Table 10, preliminary secondary cooling values

Section: ∅200, ∅280, ∅350 mm

Number of sprays
3 (4) X 8
Zone 1, length approx. Type of sprays
400-500 mm ,
Full cone, water sprays
section related
Zone design
(3) Rows of 8 sprays each, Position of sprays in following row
staggered 25 ° each
Number of sprays
5 (6) X 6
1400-1500 mm,
Full cone, air mist sprays
section related
Zone design
(6) Rings with 6 sprays each, Position of sprays in following
row staggered 30 ° each
Number of sprays
4 (5) X 6
1800-2000 mm,
Full cone, air mist sprays
section related
Zone design
(5) Rings with 6 sprays each, Position of sprays in following
row staggered 30° each
Table 11, preliminary data for secondary cooling design

2.2.13 Strand Guide

Guide rolls will be installed to maintain perfect alignment of the bars along the theoretical
curve to provide a symmetrical cooling, as well as guiding the dummy bar during the
insertion and extraction operation.
The bending sector will be designed for chain dummy bar and it is made up of a set of
rollers mounted on bearings, each with its own supporting frame. The rollers, positioned
along the casting radius, are installed above steel frames fixed on concrete foundations.
Spray nozzles are positioned at the gap between the rolls, to provide a uniform application
of spray water in this critical area.
Figure 11, strand guide and cooling zones.
2.2.14 Final Electromagnetic Stirrer (F-EMS)

Final electromagnetic stirrer will be installed in the lower part of the strand curve in order
to enhance quality of as cast product, especially concerning segregation and center porosity.
Proper position of F-EMS will be defined according analysis of solid fraction curves.
Position of F-EMS will be defined according prevailing casting conditions, at a distance of
approximately 9.0 - 10 m from meniscus. F-EMS will have the possibility to be shifted by
approximately 1.5 m to define the optimal position respect to cast sections/cast grades.
Figure 12, Final-EMS

2.2.15 Withdrawal and straightening unit modular type

The withdrawal and straightening unit is modular type. It is designed with five modules in
order to better distribute straightening stress and decrease deformation of cast product.
Each module is composed by a driven upper roll and an idle lower one, with hydraulic
cylinder to lift and lower the upper roll.
The units are designed with a multi-point straightening philosophy to minimize the internal
stresses in the solid-liquid interface.
In order to maintain deformation of round sections within tolerance, rolls will be shaped
and additional pinch roll unit will be added in horizontal position (after straightening).
WSU preliminary data

Unbending radiuses: 12/16.5/30 m
Unbending points: 3
Machine speed: 0,6 ÷ 5 m/min
Driven Rollers: 5
Idle Rollers: 5
Hydraulic cylinders: 5
Working pressure: 10 ÷ 50 bar
Pinch roll: In horizontal position, active after disconnection.
Table 12, modular type WSU preliminary data.
Figure 13, modular type WSU.

2.2.16 Chain dummy bar and storage unit

Chain dummy bar and dummy bar storage unit will be designed according machine
geometry.
Chain dummy bar will ensure possibility of automatic disconnection of strand at WSU area
after machine start.
After disconnection dummy bar will be placed on a parking device outside the strand.
2.2.17 Torch Cutting Machine

The produced bars will automatically cut through an oxy-torch cutting machine.
During the cutting phase, the machine is mechanically connected to the produced bar and
the torch speed, controlled by an electric motor, depends on the steel grade.
At completion of the cut, the machine is disconnected from the bar and returns to the
initial position by means of electric motors.
Figure 14, torch cutting machines.

2.2.18 Discharge Equipment

Cut bars are transported to the discharge area by means of roller tables. Dedicated stops
are used to form, according to length, the banking for proper discharge.
With the correct banking, bars are lifted to a transferring level above the discharge roller
table and shifted by a later cross-transfer mechanism towards the cooling device.
Figure 15, discharge area with lateral cross transfer
2.2.19 Turn over cooling bed (TOCB)

Transferred bars are individually loaded into a TOCB which is designed to cool them during
transportation turning of 90° at each step to maintain the straightness in case of casting
billet sizes.
Machine is made up of modules, each one comprising two frames having a set of mounted
rakes. One frame is fixed while the other is alternately moved in vertical and horizontal
direction by hydraulic cylinders.
Figure 16, TOCB.

TOCB cycle is shown on the following sketch:

Figure 17, TOCB cycle.
The dimensioning of the TOCB is based on the following inlet and outlet temperatures:
Bars average temperature
– at Withdrawal unit [ TWSU ] °C 1000-1100
– at TOCB exit [ TEXIT ] °C Approx. 450
Table 14, bars average temperature.
It is considered a minimum distance between bars to ensure an efficient cooling. This

minimum distance is 70 mm.
2.2.20 Controlled Tertiary Cooling (slow cooling)

In order to avoid problem of brittleness connected with H diffusion and phase
transformation, cast product (when required from chemical composition and H content
requirement) will be subject to controlled tertiary cooling.
The as cast product will be removed by crane from the packaging ramp when temperature
is between 700 and 800°C and will be subject to controlled cooling in cooling pits or under
cooling hoods at cooling rate of 10-15°C / h to a minimum exit temperature of 200°C. This
process will last 24 to 72 h according initial temperature and chemical composition.
Figure 18, cooling pits

2.3 CCM specific consumption figures

SPECIFIC CONSUMPTION FIGURES
Ladle shroud 1 piece per 6 heats in sequence
Refractories 3 - 4 kg/t
Tundish covering powder 0,3 kg/t
Stopper rod 1 piece per 8 hours of casting
Mould powder 0,4 – 0,5 kg/t
Bloom mould copper 70.000 t/mould copper
Submerged nozzle, SEN 1 per 8 operation hours
Temperature measuring system 3 tips per ladle
Sample measuring probe 1 per heat
Table 15, CCM specific consumption figures

3 Technical Requirements
3.1 Electrical Power
PRELIMINARY TOTAL POWER SUPPLY Installed Power
MAIN VOLTAGE 400V AC± 10%
FREQUENCY 60 Hz ±2%
HV POWER REQUIREMENT - 33kV
EAF 150 MVA
TWIN LF 25 MVA
MV POWER REQUIREMENT – 24,5Kv - 4,16kV
FES 3(+1) x 2400kW
LV POWER REQUIREMENT - 400V
EAF 340kW
TWIN LF 225kW
VD 600kW
FES 560KW
FES (TWIN LF) 1X132kW
MHS 350kW
Auxiliary equipment 250kW

3.2 Compressed Air

COMPRESSED AIR SUPPLY
PRESSURE 6 bar
QUALITY
STANDARD ISO 8573-1
PARTICLES Grade 2
OILS Grade 3
WATER Grade 4
DEW POINT -20ºRe
AVERAGE CONSUMPTION FLOW RATES
EAF GENERAL 20 Nm3/h
EAF CARBON INJECTION 900 Nm3/h
EAF OXYGEN INJECTION 240 Nm3/h
TWIN LF 50 Nm3/h
VD 50 Nm3/h
FES MAIN - BAG FILTER 1500 Nm3/h
FES (MHS) – BAG FILTER 240 Nm3/h
FES GENERAL 50 Nm3/h
MHS 120 Nm3/h

3.3 Cooling Water
COOLING WATER SUPPLY

GENERAL PRESSURE 6 bar
INLET TEMPERATURE 35 °C
TEMPERATURE INCREASE (MAX.) 15 °C
CIRCUITS
A Indirect cooling – CCM Mould circuit.
B Indirect cooling – Machines.
C Direct cooling – CCM sprays.
QUALITY A B C
pH value 8.5 – 9.5 7.5 – 8.3 7.5 – 8.3
Conductivity (max) µS/cm 550 500 2
Total Dissolved Solids (max.) mg/l 300 900 1,5
Total hardness Dh 0.5 10 20
Total hardness as CaCO3 ppm 9 180 250
Carbonate hardness dH 0.5 10 20
Acid capacity KS4,3 mmol/l 0,18 1,8 3,6
Chlorides (Cl-) mg/l 50 30 250
Floride mg/l 0,1 0,1 20
Sulphate (SO4) mg/l 100 300 400
Fe total mg/l 0.3 0.5 0.5
Fe solute mg/l 0.2 0.2 0.3
Copper (Cu) mg/l 0.05 0.05 0.05
Silicate SiO2 mg/l 10 10 100
Filterable solids mg/l 10 10 20
Partial dimension mm 0.2 0.2 0.2
Oil and grease mg/l 5 5 20
AVERAGE CONSUMPTION - CIRCUIT A
Mould cooling system
Process flowrate 820 Nm3/h
Inlet temp. 35 °C
Outlet temp. 45 °C
Inlet press. 9 bar
Outlet press. 3 bar
Emergency mould cooling system
Emergency flowrate 240 Nm3/h
Inlet press. 3.5 bar
Emergency time 20 min
AVERAGE CONSUMPTION - CIRCUIT B

INDIRECT COOLING - MACHINES

EAF 1500 m3/h

TWIN LF 350 m3/h
VD 250 m3/h
FES 2200 m3/h
CCM (Rolls & bearings)

Inlet temp. 35 °C
Outlet temp. 50 °C
Inlet press. 6 bar
Outlet press. 3 bar
CCM emergency machine cooling
CCM-AUX
Inlet temp. 35 °C
Outlet temp. 50 °C
Inlet press. 9 bar
Outlet press. 3 bar
CCM-AUX emergency cooling
Emergency flowrate -
Inlet press. -
Emergency time -
MAKE UP WATER 3%
AVERAGE CONSUMPTION - CIRCUIT C (DIRECT
COOLING - CCM SPRAYS)
CCM (bloom cooling system)
Inlet temp. 35 °C
Outlet temp. -
Inlet press. 9 bar
Outlet press. 3 bar
CCM Open machine cooling
Inlet temp. 35 °C
Outlet temp. 45 °C
Inlet press. 9 bar
Outlet press. 3 bar
CCM emergency open machine cooling

EMERGENCY REQUIREMENTS
EAF (for 20 min) 390 Nm3/h
VD (for 10 min) 50 Nm3/h
3.4 Oxygen
OXYGEN SUPPLY
PURITY >98,0%
EAF (12bar) (peak flow) 8760 Nm3/h
EAF (12bar) (average flow) 4270Nm3/h
CCM equipment and auxiliaries

Peak flowrate 620 Nm3/h
Inlet press. 6 bar
3.5 Natural Gas

NATURAL GAS SUPPLY
PRESSURE 3-4 bar
CALORIFIC VALUE >8500kcal/Nm3
PREHEATING AND DRYING 1000 Nm3/h
EAF (peak flow) 1240 Nm3/h
EAF (average flow) 763 Nm3/h

3.6 Inert Gas

INERT GAS SUPPLY
ARGON
PRESSURE 12bar
QUALITY
PURITY >99,99%
OXYGEN CONTENT <10ppm
EAF - LADLE STIRRING 72 Nm3/h
TWIN LF- LADLE STIRRING 72 Nm3/h
VD- LADLE STIRRING 72 Nm3/h
NITROGEN
PRESSURE 12bar
QUALITY
PURITY >99,99%
EAF - OXYGEN LANCE 180 Nm3/h
EAF - INSTRUMENTATION 20 Nm3/h
TWIN LF - INSTRUMENTATION 10 Nm3/h
VD – VACUUM BREAKING 40 Nm3/h
VD– INSTRUMENTATION 20 Nm3/h
MHS-DRI BINS 20 Nm3/h

Chapter 3 – Technological equipment
Unit 1 – Scrap Yard (SY)
Chapter 3
Technological equipment
Unit 1
Scrap Yard (SY)

File name: 3.1-Technological equipment-SY-19338-R1 Page 0 of 6
Content
Scrap Yard ........................................................ 2

1.1 Scrap bucket ........................................................................ 2
1.2 Scrap bucket transfer system.............................................. 3
1.2.1 Scrap bucket transfer car .............................................................................................. 3
1.2.2 Weighing system ........................................................................................................... 4
1.2.3 Rails, end stops and installation material...................................................................... 4
1.2.4 Position control laser detectors .................................................................................... 5
1.2.5 Presence sensing device ............................................................................................... 5

Scrap Yard
This chapter describes the main equipment composing the Scrap Yard.
All the included drawings and images are for reference only. The final configuration and final
details of the equipment are defined only after the detailed engineering is completed.
1.1 Scrap bucket

Function
Containment and transfer of the scrap to the EAF when required.
Technical data
Capacity 120 m³ approx.
Diameter (internal) 5.700 mm approx.
Total height 5.100 mm approx.
Scrap bucket
Design and details

The scrap bucket is made of welded steel plates and reinforcing sections and is equipped with
two clamshell valves which open by means of the crane auxiliary hook lifting movement when the
bucket is located over the EAF.
The special design of the upper part of the bucket allows the utilization of the existing ladle crane
hooks.

1.2 Scrap bucket transfer system

1.2.1 Scrap bucket transfer car
Function
To transport the EAF charging bucket from pick-up/charging position (inside EAF bay) to the EAF
bay and support it during charging sequence.
Technical data
Quantity 2
Car drive Electrical motors frequency converter controlled
Power supply Diesel generator
Car speed 20 m/min approx.
Weighing system four (4) load cells
Design and detail

Car in steel construction, with 4 wheels and powered by electrical motors fed by frequency
converters.
Parts
Each car mainly consists of:
a 1 Main car lower frame
b 1 Bucket support platform
c 2 Units of idle wheels with rail cleaning device
d 2 Units of driven wheels with rail cleaning device
e 2 Gear motors with brake directly connected to the wheels
f 2 Set of mechanical bumpers
g 1 Set of electrical devices for movement signalization

Scrap bucket transfer car
1.2.2 Weighing system

Technical data
Weighing system Four (4) load cells
Design and detail

The car is equipped with a weighing system to continuously measure the bucket weight. The
system is designed to reduce the risk of lateral stress to the load cells when the bucket is loaded
on the support platform.
The weight signal is continuously detected, conditioned and transferred to the PLC for a correct
scrap-charging practice.
1.2.3 Rails, end stops and installation material

Function
Rails and related installation material for the guide car.
Technical data
Rails A120

1.2.4 Position control laser detectors

The laser detector installation allows the continuous detections of the car position. The large
distance sensor (laser) is installed in the fix part (as safe and clean possible area) and deflector is
fixed in the movable part (car).
Ladle pick up position and working positions are defined during the erection time. During the
production, the position accuracy and accordingly break, stop and emergency stop positions, are
defined by means of the laser detector.
Large distance laser sensor
Deflector
Car
Ladle Car laser detectors - For Reference Only Deflector
1.2.5 Presence sensing device

In order to improve the safety of the operators in the way of the cars (from pick-up position to
working position), laser detector is installed for the continuous detection of obstacles.


Unit 2 – Electric arc furnace (EAF)
Chapter 3
Unit 2
Electric Arc Furnace (EAF)

File name: 3.2 Technological equipment-EAF-19338-R1 Page 0 of 96
Content
1 EAF Mechanical Equipment ............................ 5

1.1 EAF tilting system ................................................................ 6
1.1.1 Tilting frame with rockers ............................................................................................. 6
1.1.2 Tilting rockers bases ...................................................................................................... 7
1.1.3 3rd support ................................................................................................................... 7
1.1.4 Tilting mechanism ......................................................................................................... 8
1.1.5 Tilting locking device ..................................................................................................... 9
1.1.6 Inclinometer .................................................................................................................. 9
1.2 Roof guiding ...................................................................... 10

1.2.1 Gantry for arms and roof (single point) ...................................................................... 10
1.2.2 Electrode column guiding system ............................................................................... 11
1.2.3 Roof lifting system....................................................................................................... 12
1.2.4 Roof swivelling system ................................................................................................ 13
1.2.5 Swivel locking mechanism........................................................................................... 14
1.3 Electrodes sytem ............................................................... 15

1.3.1 Electrode guiding system ............................................................................................ 16
1.3.2 Electrode arms insulation and fixation........................................................................ 17
1.3.3 Current conducting electrode arms ............................................................................ 18
1.3.4 Electrode clamping devices ......................................................................................... 20
1.3.5 Electrode spray cooling system ................................................................................... 23
1.3.6 Current cables fixation clamps .................................................................................... 23
1.4 Furnace shell and tapping system..................................... 25

1.4.1 Lower shell – EBT type ................................................................................................ 26
1.4.2 EBT Tap hole opening system ..................................................................................... 28
1.4.3 Upper shell- Cage type ................................................................................................ 29
1.5 Roof assembly ................................................................... 34

1.5.1 Water-cooled roof - Cage type.................................................................................... 34
1.5.2 EAF Centrepiece Template .......................................................................................... 36
1.6 Maintenance platforms..................................................... 37

1.6.1 Roof access platform................................................................................................... 37
1.6.2 EBT balcony access...................................................................................................... 37
1.6.3 EBT hole access retractable platform ......................................................................... 38
1.7 Grounding network ........................................................... 39

1.7.1 Copper braid joining each cooling circuit of water-cooled panels to the upper shell
structure.................................................................................................................................... 39
1.7.2 Copper braids from the upper shell to the lower shell ............................................... 39
1.7.3 Connection from the lower shell to the fixed pike inserted into the floor ................. 39
1.7.4 Copper braid connecting the roof and the gantry ...................................................... 39
1.7.5 Copper braid joining the moving part of the gantry to the fixed part of the tilting
platform 39
1.7.6 Copper braids between the centre piece and the roof structure ............................... 40
1.7.7 Copper braid joining the tilting frame is joined to the fixed pike fixed located into the
floor 40
2 EAF Media distribution .................................. 41

2.1 Cooling Water system ....................................................... 41
2.1.1 Equipment for control and regulation ........................................................................ 41
2.1.2 Interconnection Piping ................................................................................................ 44
2.2 Hydraulic system ............................................................... 45

2.3 Lubrication ........................................................................ 52

2.3.2 Interconnection piping ................................................................................................ 53
2.4 Compressed air system ..................................................... 54

2.5 Oxygen............................................................................... 57

2.6 Fuel gas.............................................................................. 57

3 Chemical package equipment ....................... 58
3.1 Oxygen and gas injection equipment ............................... 58
3.1.1 Oxygen – Gas injector ................................................................................................. 58
3.1.2 High Speed Panel (Water box) .................................................................................... 59
3.1.3 Oxygen - Gas valve stand ............................................................................................ 61
3.1.4 Interconnection piping ................................................................................................ 63
3.2 Carbon injection equipment ............................................. 64

3.2.1 Carbon storage silo ..................................................................................................... 65
3.2.2 Carbon dispenser ........................................................................................................ 66
3.2.3 Carbon transportation ................................................................................................ 67
3.2.4 Carbon injection pipe .................................................................................................. 67
3.3 Lime injection equipment ................................................. 68

3.3.1 Lime storage silo ......................................................................................................... 68
3.3.2 Lime Dispenser ............................................................................................................ 69
3.3.3 Lime transportation .................................................................................................... 70
3.3.4 Lime injection pipe ...................................................................................................... 71
3.4 Dololime injection equipment .......................................... 72

3.4.1 Dololime storage silo................................................................................................... 72
3.4.2 Dololime Dispenser ..................................................................................................... 73
3.4.3 Dololime transportation.............................................................................................. 74
3.4.4 Dololime injection pipe ............................................................................................... 75
4 Auxiliary equipment ...................................... 76

4.1 Electrode nippling stand ................................................... 76
4.1.1 Manual clamping mechanism ..................................................................................... 76
4.1.2 Hydraulic clamping mechanism .................................................................................. 77
4.1.3 Hydraulic unit .............................................................................................................. 77
4.2 EAF automatic electrode jointer ....................................... 78

4.2.1 EAF Electrode deposit and hoisting station................................................................. 79
4.3 EAF Automatic temperature and sampling robot - Optional

80
4.3.1 6 axis robot.................................................................................................................. 81
4.3.2 Consumable lances ..................................................................................................... 81
4.3.3 Protection equipment ................................................................................................. 81
4.3.4 Robot tools warehouse ............................................................................................... 81
4.3.5 Automatic cartridges dispenser .................................................................................. 82
4.3.6 Probes unloading station ............................................................................................ 83
4.3.7 Jumper point ............................................................................................................... 84
4.3.8 Sample probe tip cutting unit ..................................................................................... 84
4.3.9 Safety barriers and interlock ....................................................................................... 85
4.4 Manual sampling and temperature equipment - Optional

86
4.5 Other auxiliaries ................................................................ 87
4.5.1 Furnace lifting beam ................................................................................................... 87
4.5.2 Shell relining and debricking stand ............................................................................. 87
5 Technological auxiliaries................................ 88
5.1 Automatic EBT Sand feeding ............................................. 88
5.2 EBT opening robot - Optional ........................................... 90
5.2.1 6 axis robot.................................................................................................................. 90
5.2.2 Oxygen lances ............................................................................................................. 90
5.2.3 Protection equipment ................................................................................................. 92
5.2.4 Oxygen system ............................................................................................................ 92
5.2.5 Pneumatic system ....................................................................................................... 93
5.3 EBT inspection camera ...................................................... 95

5.4 Slag detection camera....................................................... 95
5.5 EAF internal inspection camera ........................................ 96
1 EAF Mechanical Equipment

The following chapter describe main equipment composing the Single EAF plant and its media
distribution and auxiliaries equipment.
All drawings and images have to be considered as for reference only. Final configuration is
defined after detail design engineering definition only.

1.1 EAF tilting system

1.1.1 Tilting frame with rockers
Function
To accommodate furnace shell and swivel gantry.
Location
Mounted on the furnace foundations.
Technical data
Cradle distance 7.600 mm
Tilting actuation Hydraulic
Furnace base frame.
Design and details

Consists of a base frame with two attached (welded) tilting rockers. A heavy box type
construction including heat shield protection, splash protection, as well as a working platform
and hand-railing are included.
During roof lifting and swivelling, the base has a third support to avoid problems due to furnace
center of gravity displacement.
This added support will properly distribute the generated shell tensions, thus avoiding
deformations and cracks on the lower shell and extend its life expectancy

Parts
Tilting platform
Oxygen/gas interconnection piping on board
Cable routing & jb on board
Hand rails
Maintenance platform for bearing and swivelling cylinder
1.1.2 Tilting rockers bases

Function
To guide the tilting movement of the furnace base frame.
Location
Bolted to the furnace foundation.
Technical data
Track width 390 mm approx.
Roller track and 3rd support.
1.1.3 3rd support

Function
To support the furnace base frame during shell replacement.
Location
Support bolted to furnace foundation.
Roller track and 3rd support detail

1.1.4 Tilting mechanism

Function
To tilt the furnace in tapping and deslagging direction.
Location
On the furnace foundations.
Technical data
Tilting angle
Forward max. 15°
Backwards max. 10°
Tilting speed
Nominal 1°/sec.
Max. (Fast back) 3.5°/sec.
Tilting mechanism.
Parts
Furnace tilting mechanism, composed of:
Cylinder pedestal block: 2 cylinders pedestal block mounted on the furnace foundation, for
the support of the tilting cylinders
Cylinder seat: 2 cylinders seat for the support of the tilting cylinders welded on the furnace
base frame
Double acting tilting cylinder: 2 double acting tilting cylinder with built-in actuated check valve
to hold the furnace in tilting position in case of loss of pressure on the feeding line

1.1.5 Tilting locking device

Function
To lock the furnace base frame in horizontal position and allow the roof opening movement
function.
Location
On the furnace foundations.
Technical data
Quantity of devices 2
Locking cylinder stroke 240 mm
Tilting locking device
Parts
The furnace titling locking mechanism consists of:
Tilting locking device frame: frame composed by heavy welded and machined parts.
Tilting locking cylinder: 2 mechanical tilting locking devices, hydraulically actuated, each with 1
hydraulic cylinder
Limit switch: 2 hydraulic cylinders for the tilting lock activation
The locking devices are placed in diagonally opposite sides of the bottom shell.
1.1.6 Inclinometer
Function
To detect the inclination of the tilting frame.
Location
On the tilt platform, in a protected area to avoid any damages.

1.2 Roof guiding

1.2.1 Gantry for arms and roof (single point)
Function
To support and guide the electrode columns and the roof lifting system.
Location
Attached to the lower tilting frame by the swiveling bearing.
Technical data
Electrode column distance 800 mm
Gantry
Design and details

Gantry support frame is attached to the furnace tilting platform via a roller swiveling bearing.
This bearing is mounted in a dedicated support ring and acts as connection element between the
gantry frame and the furnace tilting platform.
Roof lifting mechanism integrated into the gantry. The roof lifting mechanism is integrated to this
gantry frame and designed for an ease of replacement.

The gantry is composed of:

Main body structure supporting the electrode regulating cylinders, the furnace roof and
installed on the swivel bearing.
Roller swiveling bearing, installed between the tilting frame and gantry, including fastening
screws for the roller swiveling bearing.
Support structure for the electrode regulating cylinders, fixed to the lower part of the gantry.
Lubrication lines are included for the greasing of the roller swiveling bearing, guide rollers, and
lifting arm.
Operator and maintenance platform to allow access to the gantry columns and working
platform on the water cooled roof. The access to the furnace gantry is interlocked with the
furnace circuit breaker.
Shielding to protect the high current cables and electrode guide columns during charging.
1.2.2 Electrode column guiding system

Function
To support and guide the electrode columns and the roof lifting system.
Technical data
Number of guide assemblies 2 per each column

Number of rollers 8 per each column (4 upper & 4 lower)
Arrangement Prismatic
Roller material 42 Cr Mo4
Roller eccentricity 5 mm
Guide Roller Frame Roller guides
Roller guides detail

Design and details

The gantry supports the electrode column by means of prismatic guide roller system.
Each column is guided by 2 prismatic guide roller boxes, welded to the gantry support frame.
Each set includes 4 eccentric adjustable guide rollers, mounted on roller bearings, connected to
the central lubrication system.
1.2.3 Roof lifting system

Function
To provide roof lift in the vertical direction.
Technical data
Lifting actuator 1 Hydraulic cylinder
Lifting stroke 600 mm
Lifting speed 50 mm/sec
Design and details

The single point roof lifting mechanism consists of a fabricated carbon steel housing which
houses the hydraulic roof lifting cylinder, thus providing movement and guiding to the furnace
roof. Vertical movement is accomplished by means of a pin which engages the roof arm
assembly.
The roof lifting mechanism is composed of:
Roof lifting is accomplished by a single hydraulic cylinder with built-in control block with non-
return devices to guarantee the roof position. This guarantees that the roof remains in its
position in the event of a hydraulic failure
Roof lift arm mechanism laterally integrated into the gantry
Roof lifting system

1.2.4 Roof swivelling system

Function
To swivel the EAF roof.
Technical data
Roof opening angle approx. 75 °
Roof swiveling actuator 1 x Hydraulic cylinder (Double acting)
Roof swiveling speed 4.5 °/sec
Roof opening time <20 sec
Design and details

The swiveling cylinder is mounted inside a protected enclosure that ensures it will not be
damaged due to heat radiation.
As a safety measure, the swiveling device is interconnected to the other motion devices on the
furnace, preventing roof swiveling while in its lower position. Some pre-conditions will be
required before roof swiveling is allowed.
The base frame features a manhole for maintenance purposes.

1.2.5 Swivel locking mechanism

Function
To lock the swing gantry’s swiveling movement.
Technical data
Swiveling interlock actuator 1 x Hydraulic cylinder
Interlock type Hook type
Design and details

The roof swiveling locking mechanism is composed of:
1 double acting hydraulic cylinder for the gantry interlocking
1 mechanical interlock to only allow roof swivel if the tilting frame is horizontal and locked
The system prevents roof swiveling in the event the tilting frame is not in the horizontal position
and tilting interlocking device activated.
Roof swivel locking mechanism

1.3 Electrodes sytem
Sarrlle´s electrode arm manufactured

1.3.1 Electrode guiding system

Function
Provides lift to the electrodes and houses the electrode lifting cylinders.
Location
In the gantry.
Technical data
Quantity of columns 3
Quantity of cylinders 3
Regulation cylinders type Hydraulic cylinders (single acting)
Columns stroke approx. 4,300 mm
Column material S235JRG2
Guide rail material St52-3
Electrode arm insulation material HGW, designed for high pressure forces
Electrode column

Design and details

Three fabricated carbon steel columns for the electrode’s movement with machined surfaces to
ensure proper guiding.
Regulating cylinders (plunger type) are installed inside each column for electrode regulation. The
rod is designed with a hard-chromium surface.
A water-cooled mast head holds the main insulation and the electrode arms.
This arm supporting mast head and the first meter of each column are water cooled.
Manual locking system has been considered for safety, even though the hydraulic system offers
the possibility of locking the column at any point.
Parts
Guiding column
Lifting/lowering cylinder
1.3.2 Electrode arms insulation and fixation

Function
To insulate the arms from the columns
Location
Between the electrodes arms and the relatives columns.
Design
The main insulation is installed between electrode arm and column head. The insulation is
mounted by using 3 pre-stressed bolts for a dust tight connection. This prevents arcing in this
critical area.
Columns and electrods insulated connection Insulation Detail

Highlighted in green others insulated electrodes connections
The insulation is indirectly water cooled by the electrode arm body and the arm head, ensuring
long life of the insulation.
The arm design requires this main insulation only. This means that insulation problems, as they
frequently occur in conventional arms, are eliminated.
Fixing between electrode arm and high current cables is done be means of a cylindrical clamping
system. This system allows very easy and fast exchange of the cables.
1.3.3 Current conducting electrode arms

Function
Current conduction and to hold the electrodes.
Location
Located on the columns attached to the swing gantry frame.
Technical data
Electrode arms type Copper plated, current conducting, designed
and manufactured by Sarralle.
Electrode diameter 610 mm - 24"
Electrode pitch circle diameter 1,200 ± 50 mm.
Electrode regulating speed:
Automatic mode 60-150 mm/sec
Manual mode 60-300 mm/sec

Copper current conductive arms
Design and details

The Electrode arm bodies consist of a welded steel-copper box type design with a copper overlay.
A guide opening for the electrode holder and contact pad on one end and the copper terminals
for the high current cables, the cooling water, and the hydraulic connections at the other end.
The current conducting electrode arms represent the state-of-the-art in electrode arm design
and are unique in design and results.
The Electrode arm bodies consist of a welded steel-copper box type design with a copper overlay.
A guide opening for the electrode holder and contact pad on one end and the copper terminals
for the high current cables, the cooling water, and the hydraulic connections at the other end.
The arm design allows for the smallest electrode pitch circle diameter, which is very important
for the furnace life, by maintaining a larger distance between electric potential carrying parts.
This is possible due to a special electric insulation.
The special system assures to the high-current system the "electrical symmetry" and allows the
utilization of electrode arms in coplanar arrangement. The electrical symmetry offers better
results than the geometrically triangulated design.
Quick connection couplings (for the water cooling) expedite ease of removal and replacement.
All piping including the electrode spray water is maintained within the electrode arm bodies.
Connections for the hydraulic cylinder of the clamping device.

1.3.4 Electrode clamping devices

Function
To hold the electrode ensuring continuous contact to electrode column and energy transmission.
Technical data
Design Belleville washer disc spring loaded with
hydraulic release.
Release cylinder qty. 3 (1 per arm)
Release cylinder type Hydraulic (single acting)
Stroke 30 mm
Parts
Clamping mechanism
The electrode clamping devices consisting of “Belleville” type spring washer arrangement for
continuous clamping. A hydraulically operated cylinder is used for release and is integrated into
the electrode arm.
Detail of the Electrode Clamping device
This design presents the advantage of applying tension forces during clamping and only
compressive strains during release, without deforming the tie rod.
The clamping device is safely integrated in the electrode arm and protected against induction
currents and also accessible for maintenance. No mechanical damages.
Cooper contact pad

Cooper contact pads are designed with channels for water cooling and two defined contact
surfaces. Each contact pad consists of forged copper with drilled cooling channels to achieve a
good heat transfer. Contact pads are designed to be bolted to the electrode arm body.

Copper Contact Pad
Electrode holder
The movable electrode holder, consists of water-cooled ring profile held by the guide in front of
the electrode arm and fastened to the clamping system.
The electrode holder is intensively water cooled and electrically insulated against the arm body
and the electrode or in case of very low current intensities made of non-cooled non magnetic
steel.
Electrode Holder
The cooling water supply to the electrode holder is assured by a bolted connection, avoiding any
kind of leakage by using special flexible joints suitable for high temperatures. No hoses are
required.
The contact is characterized by 2 contact surfaces to guarantee a good current transfer from the
contact pad into the electrode. The electrode is hold safely in 3 points

Hydraulic cylinder
Hydraulic cylinder to ensure the release of the “Belleville” springs.
The electrode is supported by the

strength that are made the “Belleville”
springs to the clamp.
Electrode clamp - holding
The electrode is released by force

performing by the hydraulic cylinder
against the springs.
Electrode clamp - releasing
Once the clamp is unlocked, the

electrode can be removed or
readjusted easily
Electrode clamp - electrode removing

1.3.5 Electrode spray cooling system

Function
The spray cooling system is designed to spray water on the electrode surface.
Location
Below the electrode holder
Technical data
Flow-rate 50 l/min max. for the 3 arms
Electrode spray cooling
Design and details

A spray cooling ring is attached to the electrode holder.
A dedicated water circuit inside the electrode arm supplies water to the spray ring system.
The system is designed to spray water during Power-ON and air during Power-OFF.
The system is composed of:
− 3 Electrode spray cooling rings attached to the electrode holders.
− 3 Water cooled protection shield underneath the contact pads.
1.3.6 Current cables fixation clamps

Function
To clamp the electrode cooled cables.
Location
In the rear part of the electrode arms.

Design
A cylindrical clamping system is used to connect the high current cables to the electrode arms.
This system enables a quick and easy cable exchange.
High current cables fixing detail.

1.4 Furnace shell and tapping system

Function
EAF shell designed to contain the raw materials (upper shell) and the liquid steel produced during
melting phase.
Location
On the tilting frame.
Technical data
Total liquid steel capacity 180 t
Tapping weight 120 t
Hot heel 60 t
Furnace shell diameter
Lower shell 6.800 mm
Upper shell (between panels) 6.900 mm
Furnace volume 135 m3
Bath level 1.170 mm

1.4.1 Lower shell – EBT type

Function
Lower part of the EAF designed to contain the molten steel.
Technical data
Refractory lining thickness:
Lateral at sill level 475 mm
Bottom 750 mm
Qty of thermocouples 9 approx.
Total weight of bottom shell 188 Tn (refractory included)
Lifting lugs for Centering pins for Lower
Lower Shell handling and Upper shell union
with crane
Lower shell supporting

surfaces (to be resting
on the tilting frame)
EAF lower shell.

Design and details

The lower shell is composed of:
Base frame
Lower shell in welded steel construction with EBT-balcony to accommodate the bottom tapping
system. Ribs and required stiffeners are incorporated into the design to provide integrity and
long operational life to the fabrication.
Refractory moisture and gas evacuation holes are considered in the lower shell design.
Lower shell will rest on the Tilting frame in 9 surfaces. Such Tilting frame surfaces will be
provided along with centering plates and stoppers, and will provide the required attachment. Our
design, although ridged for integrity, also allows the required freedom to the Lower shell for
expansion and contraction; properly distributing tensions generated on the lower shell, thus
avoiding cracks and deformations on the lower shell.
Lifting lugs are welded to both shells for ease of handling with crane for maintenance operations.
Bottom shell, upper shell centering pins

A connecting flange will be provided around the top perimeter of the lower shell, including the
upper shell centering pins.
These centering pins guarantee the union between Lower and Upper shells while also allowing
for quick replacement. Locking wedges will be installed in order ensure the proper union
between Lower and Upper shell assemblies.
Bottom shell temperature monitoring thermocouples

The spun dished bottom is equipped with sockets to accommodate thermocouples, for bottom
temperature monitoring from the Main desk.
Refractory lining will be done according to Customer specifications.
Cable routing and Junction Box on-board

On-board cable routing from the thermocouples to the junction box, fixed and covered against
heat radiation and environmental conditions, to the lateral of the bottom shell base frame.

1.4.2 EBT Tap hole opening system

Function
To accurately open and close the EAF tap hole.
Technical data
Tapping hole 180 mm
Tap hole slide gate system
Design and details

The tap hole slide gate assembly is bolted to the furnace shell EBT balcony and is utilized to open
the tap hole. Actuation of the slide gate movement is by means of a direct pull pneumatic
cylinder installed in a water-cooled housing with air curtain.
Housing equipped with slag holders to provide refractory splash protection.

1.4.3 Upper shell- Cage type

Function
Upper part of the shell, designed to contain the raw materials.
Location
Mounted on the lower shell
Technical data
Design Cage type
Cage type EAF Upper shell workshop assembly
Parts
The upper shell is composed by:
Support structure
Upper shell part in cage construction, designed for the accommodation of the water cooled
panels.
The structure also acts as the water distribution for the water cooled panels and all other water
cooled components fixed to the furnace shell.
Union between Lower shell and Upper shell will be made by the centering pins placed on the
lower shell flange with corresponding centering holes in the upper shell portion, facilitating the
shell exchange process. Locking wedges will be installed in order ensure the proper attachment
between Lower and Upper shell assemblies.
Lifting lugs will be provided welded to the Upper shell for an easy handling with crane for
maintenance operations.
Upper shell water cooled panels
Function
Cooling of the Upper shell.
Technical data
Distance to steel level 700 mm
Wall panels types Steel in the upper part, copper in the lower
part.
Distance to sill level approx. 600 mm
Water cooled panel
EBT Panel (Cu)

Design and details

Set of water cooled panels in tubular design, consisting of:
− Wall panels in steel / copper design with independent water circuits
− 1 Door steel tunnel
− 1 Door
− 1 EBT balcony panel in copper-tube design, with steel support water cooled panel

Slag door
Function
To allow the opening of EAF for deslagging and clearing operation.
Location
Attached to the upper shell.
Technical data
Opening width 1,200 mm
Opening height 1,000 mm
Opening actuation 1xHydraulic cylinder
Slag door
Design and details

Slag/working door, hydraulically operated, and consisting of:
− Water cooled door equipped with tubular steel panel
− Chain, sprockets, drive shaft and bearing seats
− Water cooled hydraulic cylinder for door movement

On board interconnection piping
Function
Connect the water cooled panels with the upper shell headers.
Design and details

Set of on-board piping for cooling water, arranged between the main header of the upper shell
and the following components:
− Wall cooling elements
− EBT balcony panel
− Door cooling tunnel
− Slag door
− Slide gate system
− Oxygen injectors
Tap hole filling bin
Function
Allow a precise tap-hole fill using sand.
Location
Over the EBT balcony panel.
Design and details

Tap hole filling device, swivel mounted to balcony platform to allow tap hole filling.
EBT tap hole filling.

1.5 Roof assembly

1.5.1 Water-cooled roof - Cage type
Function
Upper enclosure of the EAF.
Location
On the upper shell supported by lifting/lowering system.
Technical data
Roof panels internal diameter 6.900 mm
Design Cage type
EAF Roof

Parts
The roof is composed of:
Support structure
The roof features a cage-type structure (roof ring) with a bushing where the lift arm is attached
to the roof.
This structure also has the necessary internal connections for the water-cooled parts mounted
onto it.
The roof structure is featured with access platforms for the electrode arms and the electrodes.
A set of safety railing installed in the top part of the roof structure which allows to make safely
the maintenance works in the top of the roof.
Water cooled panels

The water-cooled panels (tubular design, steel) are attached to this structure, and they are easy
to replace.
Set of water-cooled elements in tubular design, consisting of:
− Roof panels in steel design with independent water circuits
− Roof center piece in steel design with 1 or 2 circuits
− Off-gas elbow adaptor ring in cooper
Water cooled off-gas elbow

The furnace off-gas elbow, which is also water-cooled, is connected to the roof by the roof elbow
adaptor ring. The elbow is made of tube to tube steel pipe design.
On-board interconnection piping for all the cooled parts

Set of internal interconnection piping for all water-cooled parts. Fixed pipe work for all cooled
parts except the ones which are subject to high wear.
The cooling water circuits of both roof and elbow are connected in series.
Sand storage hopper

The sand storage hopper will be installed on the roof, close to the EBT area.
5th hole addition hopper

For the continuous addition of ferroalloys, DRI, a dedicated 5th hole addition hopper is installed
close to the elbow.

1.5.2 EAF Centrepiece Template

Function
Template to allow the construction of the roof centrepiece.
Design and details

Steel sheet construction with pipes on the electrode positions.
The EAF centerpiece template allows construction the refractory for the centerpiece, using for it
the watercooled heart (centerpiece). Once the refractory is done and dry, refractory and
watercooled centerpiece, could be moved and erected together to the roof structure.
Centerpiece template

1.6 Maintenance platforms

Function
To allow safety maintenance to various parts of the furnace.
Design and detail

All the metallic parts such as platforms, catwalks, landing places and hand railings, as well as
those for accessing the stairs are made of a mix of steel tube and plate.
1.6.1 Roof access platform

Function
To allow safety maintenance to the gantry and to access the roof.
Gantry and roof access stains and platform.
1.6.2 EBT balcony access

Function
To allow safety maintenance and to access the EBT balcony area.
EBT Area maintenance platform and stairs.

1.6.3 EBT hole access retractable platform

Function
Retractable type access platform to allow safety maintenance and to access the ETB area.
EBT Area maintenance platform and stairs
Parts
The platform is composed of:
Fix frame
Movable frame
Gear motor and chain
Safety railing
The retractable platform is placed under the furnace in a safe position and it is actuated by an
electric motor.

1.7 Grounding network

Function
To provide common grounding for all the parts of the furnace up to a pike inserted into the floor.
1.7.1 Copper braid joining each cooling circuit of water-cooled

panels to the upper shell structure
Function
To provide common grounding for all the parts of the furnace up to a pike inserted into the floor.
1.7.2 Copper braids from the upper shell to the lower shell
Function
To provide grounding between upper shell and lower shell.
1.7.3 Connection from the lower shell to the fixed pike

inserted into the floor
Function
To provide grounding between the furnace up to a pike inserted into the floor.
1.7.4 Copper braid connecting the roof and the gantry

Function
To provide grounding between the roof and the gantry.
1.7.5 Copper braid joining the moving part of the gantry to the
fixed part of the tilting platform
Function
To provide grounding between the top part (gantry) and bottom part (tilting platform) of the
bearing, protecting the bearing from currents passing through it

1.7.6 Copper braids between the centre piece and the roof
structure
Function
To provide grounding between the roof center piece and the roof structure.
1.7.7 Copper braid joining the tilting frame is joined to the

fixed pike fixed located into the floor
Function
To provide grounding between tilting platform and the pike inserted into the floor.

2 EAF Media distribution

2.1 Cooling Water system
2.1.1 Equipment for control and regulation
Function
To cool down EAF components exposed to heat during operation with indirect cooling water.
Location
From TOP to each water user.
Technical Data
Water requirements to each user within the furnace will be optimized to provide long
operational life and reduced maintenance issues caused by excessive water piping.
Design and details

The following circuits are foreseen:
− General distribution piping consisting of:
Pressure gauges, pressure transmitters and temperature transmitter (PT100 or US
equivalent) for the primary supply and discharge lines feeding:
− Furnace shell supply and return piping
− Furnace roof supply and return piping
− Transformer wall supply and return piping
Individual supply lines will be equipped with:
− Manual On/Off valve
Individual return lines will be equipped with:
− Electromagnetic flow meter (in the Arms, shell and roof circuits)
− Electromagnetic flow switches (for high temp. cable circuits)
− Resistance temperature detector (PT100)
− Furnace Shell distribution:
The general shell supply and return lines will consist of:
− Flexible hoses from fixed part to tilting platform, for supply and return lines, installed
under the tilting platform and composed of:
− Wafer type valve at each end of the flexible hose per each line
− Flexible hoses finished in flanges DIN 2633
− Tilting platform water distribution consists of rigid piping channeled under the platform
through predefined paths to the users on the operating side of the platform. Connection
to the user is made by means of two supply and two return lines composed of:
− Stainless steel flexible hoses
− Butterfly wafer type valve at each end of the flexible hose per line
− Roof distribution:
Roof supply and return is accomplished from the transformer wall and it consists of:
− Flexible hoses, for supply and return lines. Installed to avoid interferences between their
bends in any situation, from roof down and closed to roof up and open, consisting of:
− Butterfly wafer type valve at each end of the flexible hose per line
− Rotary flanges on both ends of the flexible hose
− Flexible hoses finished in flanges DIN 2633 or US equivalent
− Transformer wall distribution:
Supply and return lines fabricated from stainless steel tubing to avoid magnetic effects
generated by the transformer. The piping for the users on the transformer wall consists of:
− Current conductive arms; per arm:
− Flexible hoses, 1 supply and 1 return
− Hose for electrode cooling
The cooling of clamps, contact segments and upper part of the columns is
accomplished by internal partitions inside the conductor arm. This arrangement
significantly reduces the number of flexible hoses to be installed between the
transformer wall and arm
− The arms cooling feeding circuit is composed of:
− Manual On/Off valves
Return from arms will be made up of:
− Electromagnetic flow meters
Electrode cooling will consist of:
− Remote controlled On/Off valves for Air and Water
− Flow switch to monitor water flow
− Remote controlled On/Off valve for each electrode
− Flexible hoses with quick-connect fittings at its ends

− High current cables:
Cooling circuit of the high current cables connected in series
Supply / return of cables consists of:
− Manual On/Off valves (feeding line)
− Flexible hoses finished in quick-connecting devices (feeding line)
− Cooled cables
− Bridges between two cables for serial connection made by a flexible hose with quick-
connecting device at its ends
− Cooled cables
− Flexible hoses with quick-connect fittings at its ends (return line)
− Resistance temperature detector (PT100) (return line)
− Flow switch (return line)
− Manual On/Off valves (return line).
− High current system:
The Busbar assembly cooling supply line will consist of:
− Flexible hose with quick-connecting device at its ends
The Busbar assembly cooling return line consists of:
− Flow switch
− Flexible hose with quick-connect fittings at its ends
Transformer:
For the transformer cooling circuit there will be supply / returns lines, consisting of:
− Manual On/Off valve (inlet line)
− Flexible hose
− Manual On/Off valve (outlet line)
Hydraulic Unit:
The hydraulic Unit Cooling supply / returns lines consists of:
− Manual On/Off valve (inlet line)
− Flexible hose
− Manual On/Off valve (outlet line)
The hydraulic Fluid Cooling is accomplished with a Heat Exchanger

2.1.2 Interconnection Piping

Necessary interconnecting piping from unit TOP to each consumer, including:
Rigid piping( including reductions, bends,Manometers, flanges and connection elements,
joints,...)
Flexible hoses
Supporting and installation material
Technical data
Carbon steel (except in some transformer wall
Pipe material
areas, where SS pipes are required)
Cooling water diagram

2.2 Hydraulic system

Function
Hydraulic system to feed the hydraulic users and related equipment composed of fixed piping
and flexible hoses.
Location
Inside hydraulic Room.
Technical data
Equipment Adequately sized according to the installation requirements and customer
requests
Pipes Adequately sized according to the installation requirements
Pipe material Carbon steel (except in some transformer wall areas where SS pipes are
required)
Flexible hoses Adequately sized according to the installation requirements
Design and Details

Hydraulic System equipment will include:
− 1 Tank
− 4 Motor-pump units (3 working + 1 stand-by)
− 1 Recirculation motor-pump unit
− 3 Accumulator unit (piston type)
− 1 Operational control desk
− 1 Emergency valve stand
The following hydraulic users will be fed by the Hydraulic system:
− 2 Double acting tilting cylinder
− 2 Double acting tilting interlocking cylinders
− 1 Double acting gantry swiveling cylinder
− 1 Double acting gantry swiveling interlocking cylinder
− 1 Double acting roof lifting cylinder
− 3 Single acting electrode regulation cylinders
− 1 Single acting slag door cylinder (water cooled)
− 3 Single acting electrode clamping cylinders


Function
Hydraulic equipment that comprises the system to feed the hydraulic users.
Location
Inside the hydraulic room.
Technical data
Tank capacity 4000 l
Accumulator Unit data Accumulator Nitrogen bottles
- Quantity 3 8
- Capacity (each) 275 l 75 l
- Working Pressure 100 - 160 bar
- Pressure Safety valve 170 bar
Pump data Main Recirculation

- Quantity 3 (working) + 1 1
(stand-by)
- Power (each) 45 kW 4 kW
- Flow rate (each) 145 l/min 200 l/min
- Pressure (each) 160 bar 10 bar
Operating pressure 100 to 160 bar

Design pressure 180 bar
Fluid Organic Ester

Design and Details

Hydraulic system equipment includes:
− Steel Tank, equipped with:
− Inside Partition for separation of suction and return lines
− Air filters
− Oil level visual indicator
− Inspection door
− 1 Temperature sensor
− 2 Electrical oil levels controlling the low and very low levels
− Motor-pump equipment installed on a dedicated frame
− Tank draining cock
− Fluid conditioning:
− Offline cooling circuit with plate type heat exchanger. The water circuit is designed with
two shut-off valves to isolate the cooling circuit in the event of a failure
− Fluid filtering is installed on the tank in order to allow maintenance operations, such as
replacing cartridge filter or cleaning the exchanger. Operations which can be performed
without requiring to stop the hydraulic unit
− Oil recirculation system with two filters, 1 working + 1 as stand-by
− Tank filling:
− Carried out by means of quick-connecting device through return filters to prevent the
introduction of undesirable elements into the unit.
− Motor-Pump Unit, equipped with:
− Pumps located on a separate frame at a lower level than the fluid tank
− Suction line provided with built-in shut-off cock with limit switch, preventing the electric
motor from starting if it is not de-energized
− Remote control start-up procedure. The procedure allows the pumps to start at a low
pressure. Once a defined time has elapsed the pump reaches the working pressure by
means of a solenoid-operated valve
− Accumulator Unit (Piston type):
− The piston accumulator consists of a fluid section and a gas section, with the piston acting
as a gas-proof screen. The gas section is pre-charged with Nitrogen gas.
− The fluid section is connected to the hydraulic circuit so that the piston accumulator draws
in fluid inside the piston accumulator when the pressure increases, thus compressing the
gas. When the circuit pressure drops, the compressed gas expands, displacing the piston
and forcing the stored fluid into the circuit.

− Operation Control desk, equipped with:

− 3 Servo Proportional valves in the operation control desk controlling the electrode
movements, as well as the proportional valves controlling the Tilting, Roof lifting and
Portal Swivelling motions.
− The Check valves allowing the Roof lifting motion to be carried out by the pumps are in the
same block, whereas the electrode lifting and roof swivelling are performed using the
accumulators.
− The fluid supply for piloting is filtered at 10 microns in order to protect the components.
− 2 Pressure Filters are installed for this filtering, one of them as backup. The unit allows
selecting the cartridges and is designed to allow the replacement of each filter with the
unit running (no shut-down required)..
− Manual Emergency operations:
In case of main power failure, a manually operated Emergency Valve stand is provided
(located in the Working platform, exact location to be agreed according to customer
preferences) to ensure the following movements:
− Furnace tilting
− Tilting locking (gantry side cylinder)
− Column lifting
− Gantry unlocking
− Roof lifting
− Gantry swivelling movements
− Roof lifting cylinder:
− The cylinder has a built-in control block with non-return devices, which guarantees the
roof position.
− Electrode cylinders:
− Each electrode cylinder has a control block, to guarantee the electrode position.
− A Pressure Transducer is installed in the supply line of the electrode cylinders, to monitor
its working pressure.
− Tilting cylinders and gantry swiveling cylinder:
− Cylinders have built-in control block with check valves, to protect the cylinder in case of
pressure peaks. All the blocks have built-in pressure testing points.

Pump unit
Proportional valves diagram

Directional valve diagram


Necessary piping from hydraulic unit to each consumer, including:
Rigid piping (including reductions, Manometers, flanges and connection elements, joints, ...)
Flexible hoses
Technical data
Pipes Adequately sized according to the installation
requirements
Pipes material Carbon steel (except in some transformer wall
areas, where SS pipes are required)
Flexible hoses Adequately sized according to the installation
requirements
Flexible hoses material With External SS Braiding and Fire Protection
(DIN EN 856 4SP)

2.3 Lubrication
Function
Lubrication of EAF moving parts.
Location
Automatically operated central lubrication system located inside the hydraulic room.
Interconnection piping from central lubrication system to each lubricated part.
Technical Data
Equipment Adequately sized according to the installation
requirements and customer requests
Pipes Seamless pipes adequately sized as per
installation requirements
Pipes material Stainless steel
Design and Details

The following elements of the furnace are automatically lubricated:
− Electrode guiding rollers
− Roof lifting system
For other furnace parts lubrication, manual grease connection nipples are considered.
Automatic lubrication system configuration to be agreed with Customer.
Lubrication cycles to be done according to such configuration.
System will detect the grease requirement per cycle and line according to the measured line
pressure.
The following pieces of equipment compose the central automatic lubrication system:
− Motor-pump (electrically actuated)
− Pressure valves
− Grease distributors
− Safety alarms
− Level switches
− Pressure switches

2.3.2 Interconnection piping

Technical Data
Pipes Seamless pipes adequately sized as per
Pipes material Stainless steel
Design and Details

Necessary piping from Central Lubrication unit to each consumer, including:
Rigid piping (including reductions, Manometers, flanges and connection elements, joints...)
Flexible hoses
Lubrication diagram

2.4 Compressed air system

Function
To supply compressed air to the pneumatically driven actuators and control elements in the
conditions required by the installation.
Location
Valve stands to be located in safe areas during operation, and in suitable areas for handling them
with visibility of the consumables.
Technical Data
Equipment Valve stands with instrumentation adequately
sized as per installation requirements
Pipes Adequately sized according to the installation
requirements
Pipes material Carbon steel (except in some transformer wall
areas where SS pipes are required)
Flexible hoses Adequately sized according to the installation
requirements
Design and Details

Foreseen circuits:
− EBT slide gate
− Additive stand
− Electrode spray cooling system
− Water valves (pneumatically actuated)
− Other Control elements regulation
Separate Valve stands containing the following control elements are considered:
− Filter + Regulator units at the inlet of the valve stands (to ensure that compressed air is
supplied to each element in proper moisture and pressure conditions)
− Shut-off valves
− Pressure gauges
− Pressure indicators
− Electro valves and silencer


Design
Necessary piping from TOP points to each consumer, including:
Rigid piping (including reductions, bends, Manometers, flanges and connection elements,
joints...)
Flexible hoses
Location
From TOP to each consumer, passing through valve stands.
Pipe routing will be engineered to protect pipes from heat radiation and other possible damages.
Technical data
Pipes Seamless pipes adequately sized according to
Pipes material Carbon steel
Flexible hoses Adequately sized according to installation
requirements
Flexible hoses material With external fiberglass coating

Compressed air diagram

2.5 Oxygen
Oxygen distribution details are specified in Section 3 – Item 3.1 of the present document.
2.6 Fuel gas

Fuel gas distribution details are specified in Section 3 – Item 3.1 of the present document

3 Chemical package
equipment
Function
Chemical package equipment is composed of:
− Oxygen and Gas injection equipment, including wall panels
− Carbon injection equipment
− Lime/Dololime injection equipment
3.1 Oxygen and gas injection equipment

3.1.1 Oxygen – Gas injector
Function
Oxygen - gas injector internally water-cooled and equipped with a copper head. To lower
electricity consumption during melting.
Technical data
Number of injectors As per Scope of supply
Gas type Natural gas
Max. flow O2 1,800 Nm3/h per injector
Max. flow Gas 310 Nm3/h per injector
Design and details

Injectors are composed of a water cooled body and a De Laval type copper nozzle.
Each injector is designed to work in different ways:
− Burner mode, with a large flame, during the first charge melting stage
− Lance mode, during the final melting stage and during superheating stage
− Blower mode when the EAF is in power-off phase

Oxygen-gas injector
3.1.2 High Speed Panel (Water box)

Function
To support and protect the front of the Injectors (be it gas, lime or carbon injectors) against scrap
obstructions during scrap charging or melting phases.
Location
In the upper Shell wall, in between the water cooled panels.
High speed panel
Design and Details

The high speed panel (HSP) structure is made of copper, it also has the water Inlet / Outlet
connections.
Inside the high-speed water cooled copper panels holding the injectors, the water circuit is
designed to have a high flow rate, thus optimizing the heat exchange.

A back-fire protection system, which consists of thermocouples installed in the internal part of
the copper plate, is installed in order to detect any back-fire caused by the reflection of the
burner flame or the oxygen lance jet caused by heavy scrap pieces, slowly melting pieces or non-
conductive materials placed in front of the injectors.
Furthermore, a special mechanical sealing is installed in order to avoid any flame coming out of
the furnace shell, which could damage the flexible hoses or the instrumentation. The wiring is
installed outside the shell.
HSP are fixed to the upper shell panels with two support plates in the lower part and two
shaft/wedge/washer systems in the upper part. It allows a quick replacement of the HSP, should
it be required.
High speed panel

3.1.3 Oxygen - Gas valve stand

Function
To control and regulate the Oxygen – gas to be injected inside the furnace according to the
different melting stages.
Location
Valve stand to be located in a safe area, and in suitable areas for handling them with visibility of
the injectors.
Pipe routing to be done to protect pipes from heat radiation and other possible damage.
Design and Details

Oxygen and gas regulation will be done by separate valve stands. The valve stands will comprise
all the instrumentation required to individually control each injector (valves, flowmeters,
pressure transducers, etc.).
Each stand has its own pneumatic and electrical boards.
Valve stand

Oxygen/gas injection diagram

3.1.4 Interconnection piping

Function
Transportation of the oxygen and gas from each valve stand up to the Oxygen – gas injectors or
the oxygen lances.
Design and details

Different piping lines are required:
− Oxygen line for the lance oxygen supply
− Oxygen line for the burner oxygen supply
− Gas line for the burner gas supply
All the Oxygen interconnection line elements will be made of stainless steel and have to be
completely degreased.
All the fuel gas interconnection line elements will be made of carbon steel.
The interconnection piping will include:
Rigid piping (including reductions, Manometers, flanges and connection elements, joints,...)
Flexible hoses

3.2 Carbon injection equipment

Function
Distribution and injection of Carbon inside the furnace.
Carbon injection reference diagram

3.2.1 Carbon storage silo

Function
Reception and storage of carbon.
Technical data
Storage silo volume 60 m3
Carbon grain size Dry, 1 to 4 mm
Design and Details

The Carbon silo is composed by:
Carbon storage silo
The silo is a welded plate construction vessel. It is designed to be filled using big bags of carbon.
On top of the silo a filter is foreseen to clean the transportation air, and also a maintenance
inspection door.
Support structure, maintenance platforms, handrails and stairs
The silo is installed in a dedicated structure erected on ground level. The silo structure is
completed with maintenance platforms, intermediate platforms, stairs and handrails.
Silo instrumentation
The silo is fitted with level detectors and fluidization equipment on the bottom part.
The lower part of the silo is connected to the dispenser hopper.
Carbon
storage Silo
Carbon
Dispenser
Storage silo

3.2.2 Carbon dispenser

Function
Pressurized vessel used for dosing of injected material.
Technical data
Number of dispensers 2
Dispenser volume To be defined
Injection lines 2 per dispenser
Injection flow rate 50 Kg/min (each line) approx.
Design and details

The dispenser is designed so that it can hold the volume of carbon necessary for a single heat.
A weighing system is installed to verify the amount of charged carbon and dedicated filling valves
are used for the charging sequence.
The dispenser is fitted with a fluidization system to reduce the risk of clogging and pressure
control equipment for the transportation air.
Carbon dispenser.

3.2.3 Carbon transportation

Function
The transportation of carbon from dispensers up to the carbon injectors.
Design and Details

The conveying line is designed to convey the carbon from the dispenser to the carbon injectors
installed in the furnace shell.
Pressure transmitters will be installed in each conveying line for continuously monitor each line’s
pressure, in order to prevent any clogging problems.
Special wear resistant elbows are featured due to the high erosion generated by the carbon
during transportation.
Transportation line will be composed by:

Rigid piping ( including reductions, Manometers, flanges and connection elements, joints,
special wear resistant elbows...)
Flexible piping
Supporting and installation elements
3.2.4 Carbon injection pipe

Function
Injection of carbon inside the furnace.
Location
Installed in the high speed panel (water boxes), next to the oxygen – gas injectors
Technical data
Number of carbon injectors As per Scope of supply
Injection pipe diameter 40 to 60 mm

3.3 Lime injection equipment

Function
Distribution and injection of Lime inside the furnace.
3.3.1 Lime storage silo

Function
Receiving and storage of lime.
Technical data
Lime grain size Dry, 2 to 6 mm
Design and Details

The lime silo is composed by:
Lime storage silo
The silo is a welded plate construction vessel. It is designed to be filled using big bags of lime. On
top of the silo a filter is foreseen to clean the transportation air, and also a maintenance
inspection door.
Support structure, maintenance platforms, handrail, stairs

3.3.2 Lime Dispenser

Function
Technical data
Design and Details

The dispenser is designed so that it can hold enough lime volume for a single heat.
A weighing system is installed to verify the amount of lime charged and dedicated filling valves
are use d for the charging sequence.

3.3.3 Lime transportation

Function
Transportation of lime from dispensers up to the lime injectors
Design and Details

The conveying line is designed to convey the lime from the dispenser to the lime injectors
installed in the furnace shell.
Pressure transmitters will be installed in each conveying line for continuously monitoring each
line’s pressure, in order to prevent any clogging problems.
Flexible piping

3.3.4 Lime injection pipe

Function
Injection of lime inside the furnace.
Location
Installed in the High speed panel (water boxes), next to the oxygen – gas injectors
Technical data
Number of lime injectors As per Scope of supply

3.4 Dololime injection equipment

Function
Distribution and injection of Dololime inside the furnace.
3.4.1 Dololime storage silo

Function
Receiving and storage of dololime.
Technical data
Dololime grain size Dry, 2 to 6 mm
Design and Details

The Dololime silo is composed by:
Dololime storage silo
The silo is a welded plate construction vessel. It is designed to be filled using big bags of dololime.
On top of the silo a filter is foreseen to clean the transportation air, and also a maintenance
inspection door.
Support structure, maintenance platforms, handrail stairs

3.4.2 Dololime Dispenser

Function
Technical data
Design and Details

The dispenser is designed so that it can hold enough dololime volume for a single heat.
A weighing system is installed to verify the amount of dololime charged and dedicated filling
valves are use d for the charging sequence.

3.4.3 Dololime transportation

Function
Transportation of dololime from dispensers up to the carbon injectors
Design and Details

The conveying line is designed to convey the dololime from the dispenser to the dololime
injectors installed in the furnace shell.
Pressure transmitters will be installed in each conveying line for continuously monitoring each
line’s pressure, in order to prevent any clogging problems.
Flexible piping

3.4.4 Dololime injection pipe

Function
Injection of dololime inside the furnace.
Location
Installed in the High speed panel (water boxes), next to the oxygen – gas injectors
Technical data
Number of dololime injectors As per Scope of supply

4 Auxiliary equipment
4.1 Electrode nippling stand
Function
Stand necessary for nippling the electrodes required to create the necessary working column.
Technical data
Electrode diameter 610 mm - 24"
Positions 3 storage and 1 jointing
Actuation type Manual (storage) / Hydraulic (jointing)
Jointing stand
Design and Details

Nippling stand made of welded structural steel and integrated into the main operating platform.
The electrode is positioned into the guide hopper by means of the auxiliary crane.
The electrode nippling stand is composed by:
4.1.1 Manual clamping mechanism

The manual clamping mechanism (for the 3 storage positions) presses the electrode against the
fixed shells, where its own weight holds it in place.

4.1.2 Hydraulic clamping mechanism

The hydraulic clamping mechanism is actuated by a hydraulic cylinder (for releasing), and
clamping is done by Belleville type springs.
4.1.3 Hydraulic unit

A dedicated hydraulic unit installed to actuate the hydraulic clamping mechanism.

4.2 EAF automatic electrode jointer

Function
To allow electrode jointing directly on the furnace or on the electrode jointing stand
Design and Details

Jointing stand which enables to joint electrodes either on the furnace or on the maintenance
jointing stand.
Automatic electrode jointer is provided with:
− Electric motor
− Hydraulic pump
− Hydraulic motor
− Hydraulic cylinders
− Electrode-valves
− Hydraulic-electric plants
− Pressure switches
− Proximity switches
− UPS Battery system with display to show the battery level
− PLC inserted in the electric box on-board, for the control of the automatic and manual
sequences
− Radio transmitter for the control of the Jointer
− Power box to be located on the ground floor to connect the jointer
Automatic electrode jointer allows:

− Time saving (reduction of furnace down-time during jointing)
− Elimination of thermal shock
− Reduction of electrode oxidation
− Reduction of heat loss (electrode columns are not removed)
− Safety
EAF Automatic electrode jointer - For Reference Only

4.2.1 EAF Electrode deposit and hoisting station

Function
Move the electrodes to the vertical position without using the lifting plugs
Design and Details

Hydraulic machine that houses the electrodes to be jointed and moves them to the vertical
position
without lifting plug. This station is necessary when using the electrode jointer or working without
lifting plugs. It could even be useful to avoid stresses to the electrode while lifting from the
horizontal position or to screw the half-nipple on the standing electrode.
The equipment is provided with:
• Hydraulic unit
• Electric control box ( on-board)
EAF Electrode deposit and hoisting station - For Reference Only

4.3 EAF Automatic temperature and sampling

robot - Optional
Function
Temperature and sample acquisition of the molten steel inside the furnace.
Location
Installed on the EAF working platform, beside the slag door
Technical data
Temperature measuring range 1,450 to 1,750 °C
Temperature precision 0,1% of displayed value
Oxygen measuring range 50 – 1,000 ppm
Automatic
Probes unloading cartridge Robot tools
station dispenser warehouse 6axis Robot
Automatic temperature and sampling robot

Design and Details

The EAF automatic temperature and sampling robot is composed of:
4.3.1 6 axis robot

The proposed system is an Anthropomorphic Robot, which is able to perform movements similar
to the ones performed by the operators.
The robot arm is to be introduced into the furnace trough the Slag door. The robot movements
are predefined so that they are easily replicated whenever it is required.
The Robot is installed such that it is not exposed to radiation heat. The home position also makes
the robot accessible to operators so that the consumable lances can be replaced.
4.3.2 Consumable lances

Consumable lances are connected to the tip of the robot by mean of a quick exchangeable
connectors.
Consumable lance exchange is made automatically (common practice) by means of automatic
cartridge dispenser or manually by the operators, in case of emergency or any unexpected
problem.
Different Robot positions will be defined (Home position, lance exchange position, working
position, etc.)
4.3.3 Protection equipment

Function
To protect the Robot from radiant heat, splashes and dust.
Design and Details

Covers manufactured in stainless steel, internally insulated by fireproof material.
4.3.4 Robot tools warehouse

Location
Close to the robot, in a safe and clean area

Design and Details

The robot tools (sample and temperature lance or camera) will be stored in a specially designed
warehouse.
The rack is equipped, with a metal sheet cover, which prevents the deterioration of the tools due
to aggressive environment of the dog-house.
Automatic temperature and sampling robot
4.3.5 Automatic cartridges dispenser

Function
Storage of different typologies of cartridges: Sample, Temperature and Oxygen.
Technical data
Cartridge storage capacity 60
Dimensions 2200x600x1800mm approx.

Automatic cartridge dispenser
4.3.6 Probes unloading station

Design and Details
Once the cartridge is put it out from the EAF, the cartridge is unloaded automatically in a
dedicated station using a V-shaped fork installed in the device.
Probes unloading station

4.3.7 Jumper point

Function
Provide the information of the lance alignment status.
Design and Details

The lance, before the automatic connection of the cartridge, touch the jumper sensor to verify if
the lance is bended or not. The robot/lance allows working with a bended lance in case of being
into defined tolerances.
4.3.8 Sample probe tip cutting unit

After the sampling picking and the jumper point, the robot moves the lance in a dedicated station
where the sample cartridge tip, containing the sample, is cut (before the robot continues the
cycle and unload the reaming part of the cartridge in the dedicated station). The operator can
pick up the sample tip from the extractable drawer on the station back.
Sample probe tipo cutting unit

4.3.9 Safety barriers and interlock

Design and Details
In order to guarantee the human presence and mainly due to the safety of the operators, safety
barriers installed around the robot and its auxiliary devices.
Automatic robot safety barriers

4.4 Manual sampling and temperature

equipment - Optional
Function
Temperature and sampling acquisition of the molten steel inside the furnace.
Location
Close to the slag door
Technical data
Temperature measuring range 1,450 to 1,750 °C
Temperature precision 0.1% of displayed value
Oxygen measuring range 50 – 1,000 ppm
Design and Details

Manual lance introduced into the furnace trough the slag door. Automatic measurement
selection depending on the inserted probe.
Disposable samplers used with the hand-held lance produce “lollipop-shape” samples that can be
sent directly to the chemical laboratory without any previous processing in the steel plant. Once
in the laboratory, only the grinding or milling of one face is required before performing a
spectrometric analysis. Therefore, this sampling method enables a quicker analysis than
conventional “spoon-and-copper-mould” samples.
Spare handheld lances can easily be produced by the Customer. The measured temperature is
displayed in a common display in the working platform area, so that the result is immediately
known to the operators.The peripheral unit has optical and acoustic signals to tell the operator
about the status of the measurement:
− Ready to measure
− Measuring
− Stop measuring
The manual sampling equipment comprises:
− 1 sampling lance for “lollipop-type” probes
− 1 sampling lance for temperature and oxygen probes
− 2 cables for measuring lance
− 1 set of permanent connection cable
− 1 measuring instrument for temperature and oxygen

4.5 Other auxiliaries

4.5.1 Furnace lifting beam
Function
The EAF lifting beam is a device designed to lift the shell with the overhead crane and to
transport it to the maintenance area.
Technical data
Load capacity 250 t approx.
Parts
The lifting device includes:
EAF lifting beam
1 set of wire rope slings
4.5.2 Shell relining and debricking stand

Function
To allow the maintenance of the shell.
Location
In the EAF maintenance area.

5 Technological auxiliaries
5.1 Automatic EBT Sand feeding
Function
To automatically feed sand into the EBT hole.
Location
On the EAF roof, above the EBT hole area.
Technical data
Hopper volume 1,5 m³
Hopper opening Pneumatic cylinder
Hopper sand feeding With Big-bags (or belt conveyors), including a
knife system to open big bags.
Monitoring Water-cooled tele-camera.
Parts
The system is composed of:
Sand storage hopper installed on the EAF roof (EBT hole area)
Guide chute
Automatic opnening gate of the EBT (including pneumatic cylinder)
CCTV Camera ( including covers, air blowing...)
Sand is charged inside the hopper by means of big-bags or directly by means of belt conveyors.
Design and details

After each tapping, the furnace is tilted backwards (-3º approx.) to allow feeding sand to the EBT
hole. With the water-cooled tele-camera installed in the hopper, the operator will monitor the
EBT hole status in a dedicated screen from the EAF Control room, and will actuate on the hopper
opening cylinder. Once the EBT has been successfully filled, the hopper is closed and the furnace
will be ready for the next heat.

Automatic EBT sand filling system

5.2 EBT opening robot - Optional

Function
Safe and automatic solution for opening the EBT in case of failure to open during tapping.
Location
Attached to the bottom part of the furnace Tilting platform.
Technical data
Robot type Anthropomorphic – 6 axes movements
Load Capacity 150 kg
Reach 2.200 mm
Protection Degree IP 67
Design and details

The EBT opening robot device is composed of:
5.2.1 6 axis robot
The proposed system is an Anthropomorphic Robot, which is able to perform movements similar
to the ones performed by the operators.
During tapping operations, in case the EBT is clogged, it will be unclogged by means of an oxygen
lance connected to the robot. The unclogging operations is remotely operated with a dedicated
control desk installed on the Tilting Room or Control Room (with the assistance of dedicated
camera installed to see the EBT area).
The Robot is installed such that it is not exposed to radiation heat. The home position of the
Robot is such that collisions are avoided when furnace tilts. The home position also makes the
robot accessible to operators so that the oxygen lance can be replaced.
5.2.2 Oxygen lances

Oxygen lances are connected to the tip of the robot by mean of a quick exhangable connectors.
Oxygen lance exchange is made by the operators.
Different Robot positions will be defined (Home position, lance exchange position, working
position, etc.).

Robot in working position
Robot in lance exchange position

5.2.3 Protection equipment

Function
To protect the Robot from radiant heat, splashes and dust.
Design and details

The Robot will be protected using stainless steel shields.
Additionally, compressed air is blown inside the protections, helping with the equipment cooling
and creating a positive pressure inside the protections and around the robot, which prevents
dust from getting to the robot.
5.2.4 Oxygen system

Equipment for control and regulation
Function
To provide the required oxygen flow to the oxygen lance in the conditions required by the
equipment.
Technical data
Operating pressure 16 bar / 232 psi
Design and details

Necessary instrumentation and valves to control the oxygen injection for the EBT opening
system. All the required instrumentation will be installed in a dedicated valve stand.

Interconnection piping
Function
To connect the oxygen lance to the valve stand and oxygen supply.
Technical data
Pipe material Stainless steel
Design and details

The pipe routing has into consideration protecting the pipes from heat radiation and other
hazards. The necessary piping from the oxygen valve stand to the oxygen lance includes:
− Rigid pipes
− Flexible hoses
− Rotary joints
− Elbows
− Reducers
− Flanges and related connections
− Gaskets
− Support and installation materials
5.2.5 Pneumatic system

Function
The compressed air is used for cooling the robot and dust protection.
Equipment for control and regulation
Function
To supply compressed air to the pneumatic users in the conditions required by the equipment.
Design and details

A dedicated valve stand featuring the following control elements is considered:
− Filter and regulator units at the inlet of the valve stand, to ensure that the compressed air is
supplied to each user with the right moisture and pressure
− Shut-off valves
− Pressure gauges
− Pressure indicators
− Electro-valves
− Silencers
Interconnection piping
Function
To connect each user to the valve stand and compressed air supply.
Technical data
Pipe material Carbon steel
Design and details

The pipe routing has into consideration protecting the pipes from heat radiation and other
hazards.

5.3 EBT inspection camera

Function
To check EBT area and tapped steel level into ladle.
Design and details

Rugged design camera, prepared for hard environment conditions. Main advantages of the
system are described as follows:
− Control of the steel level of the ladle until pre-defined level
− Enables the auto-tapping system
5.4 Slag detection camera

Function
To minimize the amount of slag poured to the ladle during tapping.
Location
Located in a safe area, suitable for handling them with visibility of the EBT.
Design and details

Camera with rugged design, prepared for tough environments. The main advantages of the
system are described as follows:
− Uniform quality of steel due to the slag content reduction in the ladle
− A smaller amount of slag in the ladle also entails a smaller amount of metal oxides: FeO and
MnO
− With less oxides, refractory life is extended
− Fewer additives required in the LF
− Less time in the LF

5.5 EAF internal inspection camera

Function
To inspect the internal part of the EAF.
Location
The 360o camera is fixed to the end effector of the temperature and sampling robot.
Design and Details

It includes a specific lance, equipped with 360o cameras, which are able to enter inside the
furnace and inspect the state of the panels, refractory, high speed panels and injectors.

Unit 3 – Liquid Steel Handling (LSH)
Chapter 3
Unit 3
Liquid Steel Handling (LSH)

File name: 3.3-Technological equipment-LSH-19338-R1 Page 0 of 25
Content
1 Liquid Steel Handling ....................................... 3

Ladle assembly .................................................................... 3
1.1.1 Ladle .............................................................................................................................. 3
1.1.2 Slide gate ....................................................................................................................... 4
1.1.3 Automatic coupling – FEMALE - Mobile part on-board ladle ........................................ 5
1.1.4 On-board piping ............................................................................................................ 6
Ladle cover .......................................................................... 6

EAF Ladle transfer car assembly ......................................... 7
1.3.1 EAF Ladle transfer car ................................................................................................... 7
1.3.2 Automatic coupling – MALE – Fix part on-board car..................................................... 8
1.3.3 Power and Inert gas supply ......................................................................................... 10
1.3.4 Weighing system ......................................................................................................... 11
1.3.5 Rails, end stops and installation material.................................................................... 11
1.3.6 Position control laser detectors .................................................................................. 11
1.3.7 Presence sensing device ............................................................................................. 12
LF Ladle transfer car assembly .......................................... 13

1.4.1 LF Ladle transfer car .................................................................................................... 13
1.4.2 Automatic coupling – MALE – Fix part on-board car................................................... 14
1.4.3 Power and Inert gas supply ......................................................................................... 16
1.4.4 Rails, end stops and installation material.................................................................... 16
1.4.5 Position control laser detectors .................................................................................. 16
1.4.6 Presence sensing device ............................................................................................. 17
Ladle relining/maintenance area ...................................... 18

1.5.1 Vertical ladle preheater / dryer................................................................................... 18
1.5.2 Last minute preheater................................................................................................. 19
1.5.3 Horizontal ladle preheater .......................................................................................... 19
1.5.4 Ladle debricking stand ................................................................................................ 21
1.5.5 Ladle Deslagging - Area provision ............................................................................... 21
1.5.6 Ladle relining stand ..................................................................................................... 22
1.5.7 Slide gate maintenance area ....................................................................................... 22

1.5.8 Horizontal ladle support.............................................................................................. 22
1.5.9 Vertical stand for empty ladle ..................................................................................... 23
1.5.10 Vertical stand for full ladle .......................................................................................... 23
LADLE SLIDE GATE SANDING ............................................. 24

Slag pot .............................................................................. 25
Slag pot carrier .................................................................. 25

1 Liquid Steel Handling

This chapter describes the main equipment composing the Liquid steel handling, also here called
LSH.
All the included drawings and images are for reference only. The final configuration and final
details of the equipment are defined only after the detailed engineering is completed.
Ladle assembly
1.1.1 Ladle
Function
Liquid steel containment from tapping at EAF to casting at CCM.
Technical data
For detailed dimensions, refer to Chapter 2 – Section 1.4.1 of the present Technical Specification.
Design and details

The ladles will be cylindrical design with dished bottom and equipped with trunnions.
The bottom part of the ladle is designed with openings for the teeming nozzle and for 2 porous
plugs.
On the ladle side the piping required for the connection of the inert gas is installed.
The ladles are designed to provide enough clearance under the ladle bottom not to damage the
nozzle or porous plugs when the ladle is laid down on the ground. Full ladles must be supported
on the trunnions.

Ladle drawing and 3D sketch
1.1.2 Slide gate

Function
Hydraulically actuated control of outlet steel flow.
Design and details

The slide gate system is hydraulically actuated from:
− Service hydraulic unit at the preheating station
− Control hydraulic unit is used at the caster for opening and closing the slide gates
The hydraulic unit consists of a motor and a pump with an oil tank, equipped with level gauge
with alarm, pressure reducers, regulators and hoses and cylinders for slide gate actuation.

1.1.3 Automatic coupling – FEMALE - Mobile part on-board ladle

Function
Coupling the inert gas system to provide the gas to the liquid steel.
Technical data
Quantity 2 each ladle ( 1 per porous plug)
Fix part - MALE

(on-board ladle car)
Mobile part - FEMALE

(on-board ladle)
Automatic coupling
Design and details

The automatic coupling permits the connection of inert gas directly to the porous plugs of the
ladle directly from the ladle car only by positioning the ladle on the car, without the necessity of
the operators to connect the flexible hoses.
The car Fix part is equipped with spring-loaded pins, in all directions, which enable the unit to
compensate for possible misaligned of the mobile and fix sections.

1.1.4 On-board piping

Function
Rigid piping to the ladle porous plug.
Technical data
Pipes material Carbon steel
Design and details

Piping includes:
− Check valves
− Rigid pipes and flexible hoses
− Bends
− Reducers
− Flanges and related connection
− Gaskets
− Supporting and installation material
Ladle cover
Function
Covering the ladle
Technical data
Diameter as per ladle size
Design and Details

Refractory-lined steel cover, provided with anchors to facilitate the attachment of refractory
material.

EAF Ladle transfer car assembly

1.3.1 EAF Ladle transfer car
Function
Ladle transfer car, complete with weighing system, to transport the ladle from deposit/pick-up
position to tapping position below the EAF.
Technical data
Car drive Electrically by motor
Number of wheels 4
Power and inert gas supply Drum or cable chain
Ladle car
Design and details

Close car with in heavy box construction, with wheels powered by electrical motors fed by
frequency converter.
Control of the car by means of a dedicated control desk at the tapping area.
The car is mainly composed of:

a 1 Main car lower frame, welded steel construction
b 1 Top frame in heavy box construction for ladle support
c 2 Units of idle wheels with rail cleaning device
d 2 Units of driven wheels with rail cleaning device
e 2 Gear motors with brake directly connected to the wheels
f 1 Set of heat protection. Guards are provided with anchor for refractory lining
g 1 Drum for electrical power and inert gas supply
h 2 Set of mechanical bumpers
i 1 Set of electrical devices for movement signalization
j Refractory lining
1.3.2 Automatic coupling – MALE – Fix part on-board car

Function
Fixed part of the automatic coupling system to be installed on the car/support.
Technical data
Sealing type Metal / metal
Design and details

The system allows the coupling of inert gas stirring automatically and without the need of any
personnel being the connection between the lower and upper section done when a ladle is
placed onto the ladle.
The car fixed section is equipped with spring-loaded pins, in all directions, which enable the unit
to compensate for possible misaligned of the mobile and fix sections.

Sarralle argon automatic coupling system
The argon automatic coupling system is basically composed by a fixed part mounted on the ladle
car and mobile part mounted on the ladle. While the ladle is release on the car, a special set of
guides allows the perfect connection of the two parts.
Sarrlle argon automatic coupling system details

In case of deformations or misalignment, the fixed part is designed in order to allow the
connection even in the presence of an offset up to 50 mm.
Sarralle automatic coupling system.
1.3.3 Power and Inert gas supply

Function
To supply electrical power for the ladle car movements.
To supply inert gas up to the ladle car to connect it to the ladle bottom porous plugs.
Technical data
Power & Inert gas supply Drum
Design and details

A drum type device is considered for power, communication and inert gas supply.

1.3.4 Weighing system

Design and detail
EAF ladle car is equipped with a weighing system to detect the weight of the tapped steel. The
system is designed to reduce the risk of lateral stress to the load cells when the ladle is loaded on
the support platform.
The weight signal is continuously detected, conditioned and transferred to the PLC to allow the
correct tapping practice.
Technical data
Weighing system Four (4) load cells
Total weighing cell load capacity sufficient for a full ladle, plus impact
Capacity
and asimmetric lowering factor

Function
Rails and related installation material to guide the car.
Technical data
Rails type A120
Stroke limitators Stoppers on each rail end


Deflector
Car
Deflector

Ladle Car laser detectors - For Reference Only


LF Ladle transfer car assembly

1.4.1 LF Ladle transfer car
Function
Ladle transfer car, to transport the ladle from deposit/pick-up position to tapping position below
the LF.
Technical data
Car drive Electrically by motor
Number of wheels 4
Power and inert gas supply Drum or cable chain
Carrying capacity 230 ton approx.
Design and details

Close car with in heavy box construction, with wheels powered by electrical motors fed by
frequency converter.
Control of the car by means of a dedicated control desk at LF area.
The car is mainly composed of:
a 1 Main car lower frame, welded steel construction
b 2 Units of idle wheels with rail cleaning device
c 2 Units of driven wheels with rail cleaning device
d 2 Gear motors with brake directly connected to the wheels
e 1 Set of heat protection. Guards are provided with anchor for refractory lining
f 1 Drum for electrical power and inert gas supply
g 2 Set of mechanical bumpers
h 1 Set of electrical devices for movement signalization
i Refractory lining

1.4.2 Automatic coupling – MALE – Fix part on-board car

Function
Fixed part of the automatic coupling system to be installed on the car/support.
Technical data
Sealing type Metal / metal
Design and details

The system allows the coupling of inert gas stirring automatically and without the need of any
personnel being the connection between the lower and upper section done when a ladle is
placed onto the ladle.
The car fixed section is equipped with spring-loaded pins, in all directions, which enable the unit
to compensate for possible misaligned of the mobile and fix sections.
Sarralle argon automatic coupling system
The argon automatic coupling system is basically composed by a fixed part mounted on the ladle
car and mobile part mounted on the ladle. While the ladle is release on the car, a special set of
guides allows the perfect connection of the two parts.

Sarrlle argon automatic coupling system details
In case of deformations or misalignment, the fixed part is designed in order ot allow the
connection even in the presence of an offset up to 50 mm.
Sarralle automatic coupling system.

1.4.3 Power and Inert gas supply

Function
To supply electrical power for the ladle car movements.
To supply inert gas up to the ladle car to connect it to the ladle bottom porous plugs.
Technical data
Power & Inert gas supply Drum
Design and details

A drum type device is considered for power, communication and inert gas supply.

Function
Rails and related installation material to guide the car.
Technical data
Rails type A120
Stroke limitators Stoppers on each rail end


Deflector
Car
Ladle Car laser detectors - For Reference Only Deflector


Ladle relining/maintenance area

1.5.1 Vertical ladle preheater / dryer
Function
Heat up the ladle refractory before tapping.
Location
At ladle maintenance area.
Technical data
Gas Type Oxygen / Natural gas.
Flowrate 240 Nm³/h
Burner rating (dryer) 900.000 Kcal/h
Burner rating (preheater) 1.100.000 Kcal/h
Cover movement Vertical
Design and details

The vertical ladle preheater consists of a circular, concave lid with a burner in the center. The
burner generates a high-velocity, extended flame which brings the thermal energy down to the
ladle bottom. The lid is lined with refractory fibers capable of withstanding temperatures up to
1300 °C.
The burner lid describes a tilting and vertical movement when approaching the ladle brim to
enable a close fitting to the ladle without causing damages to lid or ladle.
The hydraulic power for lid movements is provided by an independent hydraulic power pack.
The burner is directly ignited by means of a high voltage equipment after an automatic purging of
the combustion chamber.
The ladle preheater has automatic temperature control. It is fitted with all filters, valves, pressure
switches, safety devices etc. required for normal operation.

1.5.2 Last minute preheater

Function
Heat up the ladle refractory before tapping.
1.5.3 Horizontal ladle preheater

Function
Maintain the refractory temperature of the ladle during maintenance.
Location
At ladle refractory maintenance area.
Technical data
Gas Type Oxygen/ Natural gas.
Flowrate 240 Nm³/h
Burner rating 900.000 Kcal/h
Cover movement Horizontal
Design and details

The horizontal ladle preheater consists of a circular, concave lid with a centrally located burner.
The burner generates a high-velocity, extended flame which brings the thermal energy down to
the ladle bottom. The lid is lined with refractory fibres capable of withstanding temperatures up
to 1300 °C.
The burner lid describes a longitudinal movement made by means of a pneumatic cylinder so as
enable a close fitting to the ladle without causing damages to lid or ladle.
After a pre-ventilation start is released, the burner is directly ignited by means of a high voltage
equipment.
The ladle preheater has automatic temperature control. It is fitted with all filters, valves, pressure
switches, safety devices etc. required for normal operation.
Ladles will rest on concrete supports.

Ladle horizoantal preheater - For Reference Only

1.5.4 Ladle debricking stand

Function
Dedicated area for ladle lining demolition.
Design and details

The ladle will rest in horizontal position at dedicated supports at the ladle debricking area.
Steel frames bolted to the foundations with steel guiding plates for the ladle braces and the
cylindrical body.
The debricking machine is used for lining demolition.
a Ladle support
Function
To support the ladle the ladle in horizontal position during debricking.
Design and details

cylindrical body.
b Debricking machine
Function
To remove the refractory from the ladle.
1.5.5 Ladle Deslagging - Area provision

Function
Dedicated area for ladle slag removal.
Design and details

A dedicated space is considered for the removal of the slag remaining inside the ladles after
casting.
A dedicated box is placed, where the removed slag is placed.

1.5.6 Ladle relining stand

Function
Dedicated area for ladle relining.
Design and details

The ladle will rest in vertical position at dedicated supports at the ladle relining area.
Steel frames bolted to the foundations with steel guiding plates.
Monorail hoist is considered for refractory material handling.
1.5.7 Slide gate maintenance area

Function
To allow safety cleaning of the ladle slide gate after casting.
Design and details

Steel frames bolted to the foundations with steel made guiding plates for the ladle braces and
the cylindrical body resting.
1.5.8 Horizontal ladle support

Function
To safely support the ladle in the horizontal preheating area and the ladle debricking area during
lining demolition.
Design and details

cylindrical body.

1.5.9 Vertical stand for empty ladle

Function
To allow the maintenance or resting of the Ladles in vertical position.
Design and details

Concrete support with steel guiding plates for the ladle braces.
1.5.10 Vertical stand for full ladle

Function
To support a full ladle during waiting time.
Design and details

Concrete support with steel guiding plates for the ladle braces.


19338-Technical Specification - R1 (001-250)

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Complete Steel Melting Plant

ArcelorMittal Jubail - Saudi Arabia

Technical specification n° 19338

File name: 0-Cover and foreword-19338-R1 Page 0 of 4

Technical specification content

Chapter 3 Technological equipment √

Chapter 5 Civil and buildings √

Chapter 6 Electrical and automation √

Chapter 7 Options and alternatives -

Chapter 9 Advisory service √

Chapter 12 Project time schedule √

Chapter 14 Performance and guarantees -

Date: 11/08/2022 Technical specification n° 19338 Revision 1

Date: 11/08/2022 Technical specification n° 19338 Revision 1

Address Al Jubail 35738, Arabia Saudí

Date: 11/08/2022 Technical specification n° 19338 Revision 1

Sarralle project team

Date: 11/08/2022 Technical specification n° 19338 Revision 1

Date: 11/08/2022 Technical specification n° 19338 Revision 1

Date: 11/08/2022 Technical specification n° 19338 Revision 1

Date: 05/08/2022 Technical Specification n°19338 Revision 1

1 Meltshop Process .......................................... 6

1.2 Scrap Yard........................................................................ 11

1.4 LADLE Main Features ...................................................... 21

1.5 Ladle Furnace- Twin LF Main Features ........................... 27

1.6 Vacuum Degasser – VD Main Features ........................... 33

Date: 05/08/2022 Technical Specification n°19338 Revision 1

1.6.2 VD Equipment Configuration ...................................................................................35

1.7 Material Handling System - MHS .................................... 50

1.8 Fumes Exhaust System – FES .......................................... 53

1.9 EAF Process Calculations ................................................. 58

1.10 LF + VD Process Calculations ........................................... 75

2 Billet caster process ..................................... 79

2.1.3 Production calculation .............................................................................................85

2.2 CCM Design ..................................................................... 92

2.3 CCM specific consumption figures ................................ 109

Date: 05/08/2022 Technical Specification n°19338 Revision 1

Date: 05/08/2022 Technical Specification n°19338 Revision 1

1.1.1 Main Facility Description

AC / EAF / 6900 approx.

Vacuum Degasser-– VD / 120 155.000 m3/h pumping

Material Handling System – M H S Total No. of bins:

Fumes Extraction System – FES maximum capacity:

Date: 05/08/2022 Technical Specification n°19338 Revision 1

Continuous Casting Machine – approx.

1.1.2 Steel Grades

1.1.3 CCM Cast Products

1.1.4 Process Routes

Date: 05/08/2022 Technical Specification n°19338 Revision 1

1.1.5 Raw Materials (estimated analysis)

MgO [%] 1,5

SiO2 [%] 2,0

Ferro alloys & other additives:

Regular quality for production of considered steel qualities.

Date: 05/08/2022 Technical Specification n°19338 Revision 1

1.1.6 Productivity Data (estimated)

30% SCRAP - 70% CDRI (BASE CASE)

Available Working Time:

Net available working hours h 7.200

EAF Production Target:

EAF average tapping weight (t) 120

Productivity [t/hour] 135,8