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Mass and energy balances of stainless steel EAF

Conference Paper · May 2002

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 MASS AND ENERGY BALANCES OF STAINLESS STEEL EAF

M. Kirschen 1, H. Pfeifer 1, F.-J. Wahlers 2

1
Institute for Industrial Furnaces and Heat Engineering in Metallurgy, RWTH Aachen, Germany
2
ThyssenKrupp Nirosta, Bochum, Germany

Key Words: Electric arc furnace, Stainless steel, Off-gas measurements, Mass balance, Energy
efficiency, Off-gas extraction

ABSTRACT

Off-gas measurements were performed at two EAFs of ThyssenKrupp Nirosta in order to set-up precise
mass and energy balances. Results show that, with similar production parameters as steel type, scrap
and slag former input, coal addition, cooling system, tap-to-tap times, the use of fuel burners and
dedusting system operation drastically affects the measured off-gas composition and amount of air
infiltration into the furnace vessel. A high degree of air infiltration may result in decreasing the
chemical energy load (H2 and CO content) but increasing the total off-gas enthalpy. On the other hand,
without additional oxygen input for post-combustion, H2 and CO off-gas concentrations may achieve
considerable values. Mass and energy balances for austenitic heats are presented for two TKN steel
mills at Bochum and Krefeld.

INTRODUCTION

During the last 25 years the EAF steel productivity increased with decreasing number of production
sites in Germany. Today, 13.406.000 tons per year or 29 % of total crude steel is produced in Germany
by scrap melting using the EAF. The capacity of TKN steel mills located at Bochum and Krefeld of
1.280.000 tons per year stainless steel (ferritic and austenitic grades) yields about 10 % of total EAF
steel production in Germany (Fig. 1).

Martensite 3%
Bochum Krefeld

Austenite
with Mo
Austenite 28 %
44 %
Ferrite
51 % Austenite
72 %

Austenite with Mo 2 %

Fig. 1: EAF steel production mix at ThyssenKrupp Nirosta steel mills [1]
TKN operates two EAFs in the steel mills of Bochum and Krefeld. Technical data for both furnaces are
summarized in table 1. The Bochum EAF is characterized by an UHP transformer with an apparent
electrical power of 135 MVA. Energy recovery has been optimized by use of a shell cooling system
based on steam cooling at a pressure of 23 bars and a temperature of 220 °C [2]. The Roof is
conventionally water cooled at the Bochum EAF. At the Krefeld EAF, both, shell and roof are steam
cooled. The dedusting systems lack a rough separator but yield a lowered furnace pressure via the
elbow by buoyancy effects in the vertical hot gas line. This construction grants a restricted off-gas
extraction and steel production even in the case of breakdown of the dedusting system fans. A further
optimization of the energy efficiency and the influence of off-gas extraction on the energy balance is
subject of the present comparing study. Special focus is set on the off-gas enthalpy because (1) total
enthalpy increases with the mass of infiltrated air during melting and (2) shifting chemical to sensible
heat load by CO post combustion improves the possibility of energy recovery from the exhaust gas and
consequently higher energy efficiency.

Table 1: Technical data of the ThyssenKrupp Nirosta EAF’s at Bochum and Krefeld

Bochum Krefeld
Start up date 1982 1985
Transformer apparent power [MVA] 135 70
Primary voltage [kV] 33 25
Secondary voltage [V] 700 - 1200 455 - 802
Current [kA] 62-84 50-52
Mean tapping weight [t] 145 75
Annual productivity [t/y] 720000 530000
Shell diameter [m] 6.9 5.9
Electrode diameter [mm] 650 550
Wall cooling system Steam cooling Steam cooling
Roof cooling system Water cooling Steam cooling
Number of wall cooling panels 14 11
Gas burner no yes
Primary off-gas extraction [Nm3/h] 165.000 60.000
Secondary off-gas extraction [Nm3/h] 660.000 400.000
Tapping system Skimmer Runner
Tapping temperature [°C] 1550 1550-1600
Additional equipment: Current conducting
electrode arms
Digital electrode control system
Oxygen lance manipulator
Process control computer

MASS AND ENERGY BALANCES

In order to assess and optimize yield and energy efficiency of the EAF melting process, mass and
energy balances are widely used working tools (Fig. 2). However, the energy balance is based on a
reliable mass balance, since, e.g., the calculation of chemical energy depends on the masses of oxidized
elements C, Si, Al, Mn, Ni, Cr and Fe. Some important parameters for mass balances are commonly not
logged at the melt shop. As steel weight and composition is generally precisely determined after
tapping, the slag weight and composition is not. Scrap composition is often estimated, dust composition
and yield, specific refractory and gun mass consumption are statistical averages. The off-gas volume
flow at the elbow and the volume flow of infiltrated air is usually unknown. However, these unknowns
can be determined from element mass balances, e.g. the total slag weight from the CaO balance using
the slag chemical analysis and the amounts of CaO input from refractories and gun materials.
Scrap/Alloys
1050 - 1100 kg
Electrodes
1 - 3 kg
Lime/Dolomite
Oxygen 25 - 50 kg
15 - 50 kg Dust
Coal 15 - 20 kg
5 - 15 kg Off-gas
Fuel (N2,O2,CO,CO2,H2)
5 - 10 kg 150 - 250 kg

Infiltrated air
100 - 200 kg

Slag Refractories Steel

100 - 200 kg 3 - 12 kg 1000 kg

Fig. 2: Ranges of specific values for EAF mass balances [3]

E.g., the slag weight is determined by the CaO mass balance:

x CaO, LimemLime + x CaO,RefractoriesmRefractories = x CaO,SlagmSlag + x CaO,Dust mDust (1)

where x denotes the CaO amount in weight % and m the total mass. Dashed symbol denotes statistical
average. In the case of high amounts of recycled material, e.g. for austenitic heats, CaO input from
skulls has to be taken into account. The usually unknown amount of off-gas can be determined from the
C balance assuming carbon output solely by steel and off-gas:

x C,Scrap m Scrap + x C,Limestone m Limestone + x C,Coal m Coal + x C,Electrodes m Electrodes =

(2)
x C,Steel m Steel + åòx
i= CO, CO2
C,i
 off -gas dt
m

where xCO and xCO2 are measured off-gas mass concentrations. The amount of infiltrated air can be
estimated from the N2 mass balance assuming that all N2 of the off-gas is from infiltrated air.
Therefore, measurements of off-gas composition, temperature and volume flow at the elbow yield
valuable information in order to set up and improve EAF mass and energy balances.

EAF OFF-GAS MEASUREMENTS OF AUSTENITIC HEATS

At the Krefeld EAF, off-gas temperature, composition and volume flow were measured in the exhaust
duct of the dedusting system. In addition, chemical composition of the primary EAF off-gas was
measured on the roof (Fig. 3). With this set-up, the volume flow of infiltrated air at the gap between
furnace elbow and exhaust duct is determined by C mass balance.
Fig. 3: Two off-gas sampling points in the dedusting system (75t-EAF)

At the Bochum EAF, off-gas measurements were conducted using water cooled lances in the gap
between the EAF elbow and the exhaust duct of the dedusting system (Fig. 4).

Fig. 4: EAF off-gas and infitrated air volume flows at the elbow
 Gas Sampling Filter
Detector
Sample CO2,CO,
Preparation O2,H2,CH4
Heater
Cooling 4...20 mA
Water
Compressed Air Data
Acquisition
Temperature
Pt/Rh6 - Pt/Rh30 4...20 mA

0 ... 1820 °C
Cooling Signal
Water Converter

Compressed Air

Volume Flow
4...20 mA

Cooling Signal
Water Converter

Fig. 5: Instrumentation for off-gas measurements

The gas sample is filtered, cleaned, cooled and dried (Fig. 5). The CO, CO2 and CH4 concentrations are
determined using an infrared analyzer. H2 and O2 concentrations are measured by thermal conductivity
and diamagnetism of the oxygen molecule, respectively. Temperature measurements are done with
shielded Pt/Rh6-Pt/Rh30 and Ni/Cr-Ni thermocouples, respectively. The volume flow is determined by
measuring the mean dynamical pressure of the gas flow which is proportional to the gas velocity.

RESULTS

Measured amounts of off-gas components for austenitic heats at are plotted in Fig. 6 (145t-EAF) and
Fig. 7 (75t-EAF). H2O content is calculated to few vol.-% assuming water gas equilibrium (CO + H2O
= CO2 + H2) at measured off-gas temperature.

80

70 CO CO2 Oxygen Lancing

H2 O2
Off-gas composition [Vol.-%]

60 H2O calc
50 Tapping
st nd rd
1 Bucket 2 Bucket 3 Bucket
40

30

20

10

0
0 10 20 30 40 50 60 70
Time [min]

Fig. 6: Measured amounts of off-gas components vs. time (145t-EAF, austenitic heat)
It is clearly shown, that during melting periods without oxygen blowing the off-gas consists mainly of
heated air infiltrating the furnace through various leakages, e.g. slag door, gap between vessel and roof,
electrode holes. CO2 content does rarely exceed 10 % (calcination of limestone). With oxygen blowing
the amount of CO and CO2 increases up to 60 % and 25 %, respectively. The amount of post-
combusted CO2 remains essentially constant at about 20 % due to limited infiltrated air volume flow
into the vessel. A rather distinct off-gas pattern is measured at the 75t-EAF (Fig. 7), where a fuel gas
burner is active during the first period of melting. H2 from fuel gas is detected up to 30%, CO2 ranges
from 10 % to 15 %. CO in excess during the complete heat period indicates a rather limit amount of
infiltrated air.
80
nd
2 Bucket CO CO2
70 H2 O2
st
1 Bucket
60
Off-gas composition [vol%]

50

40

30

20

10

0
0 10 20 30 40 50
Time [min]

Fig. 7: Measured amounts of off-gas components vs. time (75t-EAF, austenitic heat)

The temperature of the off-gas increases from about 1000 °C to 1200°C during melting of the scrap
with the electric arc up to 1600 °C during decarburization by oxygen blowing and partial post-
combustion of CO (145t-EAF). The volume flow of the off-gas remains essentially constant during
various periods of melting due to constant fan power of the dedusting system. During swinging out the
roof for charging the volume flow at the elbow is reduced by opening an air damper. The normalized
off-gas volume flow and mass flow slightly decreases with increasing gas temperature at the elbow
(Fig. 8).
500 20
2000

400 1600
16
Volume flow per ton [Nm /h t]
3

Temperature [°C]

300 1200
12

200 8800

100 4400

0 0
0 10 20 30 40 50 60 70 80
Time [min]

Fig. 8: Measured off-gas volume flow and temperature (145t-EAF, austenitic heat)
With known data of off-gas composition, temperature and volume flow, the off-gas enthalpy at the
elbow is easily determined (Fig. 9, 145t-EAF). As the sensible heat load of the off-gas is more or less
constant over heating time, the total power significantly varies from 10 to 50 MW due to varying
amounts of H2 and CO. On the other hand, the amounts of CO and H2 determine the minimum amounts
of oxygen for complete combustion, either from infiltrated air or from oxygen injection. CO
combustion in the furnace further increases energy efficiency by decreasing the off-gas chemical heat
[4]. However, with increasing gas and shell temperatures due to complete CO and H2 combustion
sensible gas enthalpy and heat flux to the cooling system may increase.

20000 80000
Total Enthalpy Sensible Portion
Total Enthalpy Flow Sensible Portion
15000 60000

Enthalpy Flow [kW]

Enthalpy [kWh]

10000 40000

5000 20000

0 0
0 10 20 30 40 50 60 70 80
Time [min]

Fig. 9: Total off-gas enthalpy for an austenitic heat (145t-EAF)

After having determined the off-gas energy of a heat the complete energy balance is easily set up.
Average of numerous heats erases incertitude from formation of heel to mass balances. Chemical
energy includes exothermic oxidation of Si, Mn, Cr, Ni, Fe and endothermic calcination of limestone
(Fig. 10). Masses of oxidized Si, Mn, Cr, Ni and Fe were calculated from the oxides with chemical
analysis of slag, slag formers, refractories and dust. C oxidation comprises energy release from
combustion of coal, electrode and scrap carbon. For the Krefeld EAF the energy from fuel gas burners
is separately noted (Fig. 11).
Off-gas enthalpies were integrated from measured volume flow, temperature and composition. Cooling
includes the enthalpy of steam which is recovered in part at TKN Bochum and Krefeld. However,
precise calculation of the enthalpy sink by steam cooling solely from volume flow and temperature of
the cooling medium is difficult. Instead, enthalpy of steam is estimated from the measured energy flux
to water cooled roof assuming equal flux to roof and wall in the case of Bochum EAF. For the Krefeld
EAF the contribution of the cooling system is estimated by difference. From the resulting value (218
kWh/t), an average heat flux of < 239 kW/m2 is estimated for the Krefeld EAF, which compares to the
measured value of 197 kW/m2 at the roof of the Bochum EAF. Reference weight for the mass and
energy balances in table 2 and Figs. 10 and 11, respectively, is the AOD input weight after deslagging.
Fig. 10: Averaged energy balance for 7 heats (austenitic grades, 145t-EAF)

Fig. 11: Averaged energy balance for 24 heats (austenitic grades, 75t-EAF)

The energy balance of the 75t-EAF Krefeld shows lower total energy input (754 kWh/t) and specific
electric energy (494 kWh/t) than Bochum (781 kWh/t and 510 kWh/t, respectively). The enthalpies of
austenitic melts differ slightly due to lower tapping temperatures of the heats considered in this study
(75t-EAF: 1584°C, 145t-EAF: 1543°C). The energy balances and corresponding mass balances are
given in table 2. Specific average slag mass and enthalpy as the chemical energy contribution from
alloy elements oxidation is lower for the 75t-EAF due to lower oxygen lancing (see table 2).
Table 2. Mass- and energy balances for two EAF’s of ThyssenKrupp Nirosta

145t-EAF 75t-EAF
Scrap and Alloys [kg/t] 1106 1057
Lime, Dolomite, Limestone [kg/t] 44 41
Fuel Gas [kg/t] - 1.1
Coal [kg/t] 17.2 12.2
Mean Electrode Consumption [kg/t] 2.5 2.6
Mean Refractory Consumption [kg/t] 0.9 0.9
Mean Dust Emission [kg/t] 11.0 11.0
Oxygen Consumption (Lance and Oxy-fuel Burner) [kg/t] 7.8 7.8 1
Infiltrated Air [kg/t] 267 118
Off-gas [kg/t] 293 123
Slag Production [kg/t] 79 64
Electrical Energy [kWh/t] 510 494
Chemical Energy from Carbon Oxidation [kWh/t] 128 169
Chemical Energy from Fe, Si, Cr, Ni, Mn Oxidation [kWh/t] 120 79
Oxy - fuel Burner [kWh/t] - 12
Enthalpy Steel [kWh/t] 391 383
Enthalpy Slag and Dust [kWh/t] 36 30
Enthalpy Off-gas [kWh/t] 121 79
Furnace Cooling [kWh/t] 179 218
Radiation and Convection [kWh/t] 49 33
Total Energy [kWh/t] 781 754
1: 2.9 kg/t is oxygen of the gas fuel burner; reference weight is EAF tapping weight after deslagging

High amounts of off-gas (293 kg/t) and infiltrated air (267 kg/t) are obvious for the 145t-EAF resulting
in a higher average off-gas enthalpy (121 kWh/t) when compared to the 75t-EAF (123 kg/t, 118 kg/t,
79 kWh/t, respectively). As illustrated in Fig. 6 mainly CO-bearing off gas is produced by oxygen
blowing during the second period of heat. However, Fig. 8 demonstrates that continuous off-gas
extraction through the elbow of the furnace leads to a more or less constant off-gas mass flow during
the complete melting period. Therefore, large amounts of air are infiltrated at low temperature and
heated during the first period of scrap melting for the 145t-EAF. However, during oxygen blowing the
amount of infiltrated air is insufficient for complete CO combustion in the furnace shell. The amount of
energy recovery from CO post-combustion within in the steam cooled hot gas line is not considered for
the 145t-EAF, but it is included in the energy balance of the 75t-EAF. A reduced off-gas extraction
during the first melting period is suggested for further minimization of the off-gas enthalpy for the
145t-EAF. Due to the buoyancy effect of the vertical hot gas line and mixing with secondary off-gas
primary off-gas extraction at the elbow is controlled by the infiltrated air damper and the variable gap
between elbow and exhaust duct rather than the fan power. Following this hypothesis tests of different
furnace operations are on the way.

SUMMARY

Measurements of exhaust gas mass flow and composition at EAF elbow yield valuable information
about various process parameters and energy efficiency of stainless steel making, e.g.: the amount of
air infiltration due to furnace and dedusting system operation. These data permit the refinement of
estimates about the off-gas enthalpy in order to set up precise mass and energy balances of the EAF.
For two furnaces of stainless steel production sites measured off-gas compositions are significantly
different due to use of fuel gas burners. In absence of fuel gas combustion the amount of infiltrated air
increases and affects the energy balance of the furnace. Consequently, off-gas extraction should be
adapted to different types of EAF operation and even melting periods in order to optimize (1)
infiltration of air into the furnace vessel, (2) energy efficiency of the melting process, and (3)
homogeneous temperature distribution in the furnace shell.

REFERENCES

[1] F.-J. WAHLERS, M. WALTER, H. ZÖRCHER, Stahl und Eisen, 118, (1998), No. 9, pp. 95-98.
[2] H. BROD, F. KEMPKENS, H. STROHSCHEIN, Stahl und Eisen, 109, (1989), No. 5, pp. 229-238.
[3] H. PFEIFER, in: K.-H. Heinen (Ed.), "Elektrostahlerzeugung," Verlag Stahleisen, Düsseldorf,
(1997), pp. 112-127
[4] E.J. EVENSON, H.D. GOODFELLOW, M.J. KEMPE, Proc. ISS 58th Electric Furnace Conference,
Orlando, (2000), pp. 39-48.
[5] M. KIRSCHEN, H. PFEIFER, F.-J. WAHLERS, H. MEES, Proc. ISS 59th Electric Furnace
Conference, Phoenix, (2001), pp. 737-745.

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