Steelmaking and Casting at The New Minimill of Abinsky Electrometal Works LLC

CVS MAKNA
NAAT SAN. ve TC. A..
theMill for Minimills STEELMAKING AND CASTING AT THE NEW MINIMILL OF ABINSKY ELECTROMETAL WORKS LLC F.BOZDEMR Project and Contracting Department CVS Makina D.ERTAS Project and Contracting Department CVS Makina A. TUNABOYLU Project and Contracting Department CVS Makina Located in the South Part of Russia, near to NOVOROSSIYSK sea port, in KRASNODAR Region, the new minimill complex of ABINSKY ELECTROMETAL WORKS LLC, named AEMZ, is designed to produce 1,30 million ton/year of square billets. Design, manufacture, erection and commissioning of steelmaking and billet caster is performed by a Turkish engineering/manufacturing company, CVS.
Introduction Today, investors worldwide are looking and waiting for new signals from steel market to understand where to direct and dedicate their money, energy and resources for possible alternative business. Because of uncertainty in the market, steelmakers are looking for more flexible operation to catch the changing market demands. AEMZ LLC is the new investment project of the Russian businessmen beginning the activity since 1996 as suppliers and exporters of scrap metal. In due course from the small enterprise the largest in Southern federal district base on processing of scrap metal with capacity of 500 thousand tons per year has been created. In 2002 the "Novorosmetall" Ltd. Meltshop with capacity of 120 thousand tone of square billets per year has been started in operation for the purpose of producing of higher-value-added product. From April, 2005 till February, 2006 plant has been reconstructed, designed capacity has made 360 thousand tons of square billet per year. Now "Novorosmetall" is the group of companies uniting the enterprises of scrap processing, vehicle depots, the procuring and serving companies. In 2010 owners of "Novorosmetall" Ltd. have started-up the first stage of Metallurgycal Complex small-section mill 350-1 with productivity of 500 thousand tons per year in Abinsk, Krasnodar territory, with firm SMS MEER equipment. And same year the contract with firm CVS on realization of the second stage of a Metallurgycal Complex steel melting shop - has been concluded. According to
Dilovas Organize Sanayi Blgesi 3. Ksm Muallimky Cad. No:21 Gebze 41400 Kocaeli / TRKYE Tel. +90 262 759 1505 Fax. +90 262 759 1880 info@cvs.com.tr www.cvs.com.tr
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theMill for Minimills the time schedule plant is planned to start-up in 2012. Thanks to the good cooperation and organization between CVSs and AEMZs team, work on the project moves ahead under the schedule and within the limits of mutual support. This is one of the most modern, competitive and flexible minimills for the production of billets. The meltshop composes an 130 ton AC-EAF and a Ladle Furnace as secondary metallurgy station and one CCM to produce square billets. The complex is designed to guarantee a productivity of 1,3 Miotpy of commercial quality, low carbon steel, medium carbon steel and low alloy steel. Future installation of Vacuum Degasser and adaptation of electromagnetic mould stirring system to CCM are also considered. The mission of AEMZ is not only to create big plant to serve the international market but also to keep the environment clean around of the plant. The CVS supply is not only meltshop equipment but also Fume Treatment Plant, Material Handling System, Cranes for meltshop. All units are connected by a special design Level 1,5 system easily adaptable to Level 2 automation system. Plant Concept The plant is designed according to the latest technology in the field of steel plant machinery and equipment. The layout takes full advantage of the rationality of material handling in the plant in order to obtain the following results: Minimum amount of areas occupied Optimization of personnel required Optimization of production time and costs. Best scrap handling Future Extension consideration of plant
The choice of the various systems making up the plant is strictly related to the achievement of the following high-priority objectives, namely: Limited investment costs High quality products High productivity Maximum simplicity of operation P a g e | 2 of 15
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theMill for Minimills Operation reliability Maximum flexibility to meet various market demands.
The technological solutions were selected with the objectives in mind to use most innovative systems and achieve highest quality levels by a compact plant configuration. To achieve the required production rate of 177 ton/h, furnace tapto-tap time has to be shortened 44 minutes. With this in mind, the single heavy bay lay-out was chosen. As a matter of fact, this configuration allows an easy and smooth process route of liquid steel tapped from EAF, through the in-line ladle furnace refining station to the billet caster. Scrap cars and cranes are considered as remote controlled. Crane operators can easily co-ordinate scrap car movements by watching screens in contol pulpit.
Fume Treatment Plant The FTP is designed to collect, suck and treat the primary and secondary emissions generated by the EAF during melting, tapping and charging conditions, the primary emission generated by the LF during heating/refining operation and the emissions generated by the Material Handling System. The dedusting plant consists of a set of fume collection points, a set of ducting lines (water-cooled or radiant type), a bag filter of pulse-jet and negative pressure type, a set of exhausting main fans, a booster fan for LF line and for additive suction line and a final stack for discharging the cleaned emissions into the atmosphere. Besides, a dedicated handling and storage system is foreseen to collect the dust generated in the bag filter and to transfer them into a storage in an appropriate area. Main design values for fume treatment plant is designed as follows: Suction Point EAF Primary Emission (melting) EAF Secondary Emission (Charging) EAF Secondary Emission (Melting) Ladle Furnace Material Handling System Fume Suction Capacity 250.000 Nm3/h 1.580.000 Nm3/h 680.000 Nm3/h 80.000 Nm3/h 50.000 Nm3/h Maximum Temperature 1.200 C 80 C 50 C 150 C 50 C
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theMill for Minimills This huge flowrate calls for pulse ject filter which are suction-type filters, equipped with compressed air automatic bag cleaning system. The filter itself is composed of 2 parallel lines, made up of several compartments containing a fixed number of bags. The filter casing is made of welded steel structures with external reinforced walls. It is subdivided into parallel compartments in such a way that each compartment can be separated from the gas stream during cleaning cycle (off line cleaning design). Each compartment consists of a raw gas chamber below and a clean gas chamber above divided by the bag supporting plate. The lower chamber composes the filter body, contains the filtering bags and the dust collecting hoppers. The upper chamber contains the injectors for the compressed air distribution to the bags for cleaning purpose. The two chambers are connected to the central collector respectively to the gas inlet and outlet by means of separation dampers. Dampers for lower chambers are manually actuated, being utilized in closed position as an additional safety in the event of maintenance or inspection; the dampers of the upper chambers, instead, are provided with pneumatic actuators, being automatically closed while performing maintenance and bag cleaning in OFF-LINE mode. The filter is completed with the supporting structures, made of steel profiles, the filter roofing and the dust conveying system, which continuously remove the dust collected at the filter hoppers. The normal maintenance operation of the filter does not imply to enter into the dirty section, since all the necessary operations can be performed from above the filter head in the clean chamber. This guarantees better working conditions for the personnel, while a manhole is foreseen in each hopper only for inspection purposes. The cleaning system of the filtering bags is located inside the clean gas chamber. It is composed of one distributor per row of bags, completed with compressed air feeder to each bag. There are 8 distributors (shooting pipes) per compartment, each shooting pipe having 11 nozzles and blowing in 12 bags. The air blown by each nozzle is amplified by a Venturi, thus causing an air pulse to flow through the filter bag (inside to outside). This pulse shakes the bag and dislodges the dust accumulated on the external surface of the bag allowing the dust to fall to the bottom of the filter into the collecting hopper.
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theMill for Minimills The OFF-LINE cleaning cycle allows to reach high efficiency cleaning, because, as the compartment is excluded, there is no upward gas velocity, thus allowing the dust to fall into the hopper without being drawn again to the surface of bags. This technology allows to reach high efficiency cleaning with a little air consumption. The small amount of compressed air utilized for bags cleaning does not effect the overall flow rate treated by the filter. The cleaning cycle is automatically controlled via PLC, where either a differential pressure controlled cycle or a time dependent cycle can be chosen. Bag fitler is designed for 1.060.000 Nm3/h suction capacity at 105 C during melting and 1.710.000 Nm3/h capacity at 80 C during charging/tapping. To respect the guaranteed dust content of 10 mg/Nm3 at the stack, net filtering surface of 22.300 m2 is obtained by 24 compartments. The chain conveyors discharges the dust into the storage bin. The storage bin is cylindrically shaped and is designed in order to facilitate the internal flow of dust and to prevent internal dust bridge formation. Extraction of dust from the bin is performed by means of a vibrating extractor below the lower cone of the bin itself. A manually operated emergency discharge vane is located at the centre tip of the silo hopper. Dust silo is equipped with three dust level indicators (LSL, LSH, LSHH) connected to the automation system that stops the operation of the dust conveying system whenever the silo is full. The dust separated by the filter is collected in the hoppers below and then removed via a chain conveying system. The conveying system by booster fan collect the dust from the respective hoppers and transfer it to the storage silo. The dust discharge from a silo is made by means of a telescopic pipe directly in the bulk-cement transport unit type truck. Operation of complete dedusting system is syncronised by automation system. Distribution of flow to primary and secondary section of EAF is controlled by two dampers located on the lines actuated automatically by automation. Damper position and main fan speeds according to 5 main modes of furnace operation can be changed by HMI in FTP control room. Additionally, fan speed is adjusted during melting phase according to the value coming from pressure transmitter measuring the pressure inside combustion chamber. Electric Arc Furnace EAF is designed for nominal 130 (150 t max) tapping weight with 177 ton/hour Production capacity. Features of the furnace is given in the following table: Type of Furnace AC-ful platform P a g e | 5 of 15
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theMill for Minimills W.C. Panels Diameter Diameter of inner bottom shell Tapped Steel Hot heel Total Volume of EAF Volume of scrap bucket Type of Tapping Electrode Arms Electrode Diameter 7.200 mm 7.400 mm 130 ton 20 ton 178,7 m3 162,5 m3 EBT Cu-conductive 660 mm
The EAF is designed as an AC furnace fed by a single transformer power of 130 MVA as rated power, with an allowable overload of 20 %. Thanks to the EAF transformer tap changer, it is possible to work with high flexibility and select to work with high flexibility and select the proper working point according to required process phase. The main feature of the EAF is its extremely high available power. Considering the nominal tapped weight of 130 ton, specific available power of the furnace is 1,2 MVA/t, which is much higher than the Standard values used for EAF design. Furnace is charged in 2 bucket sequence with 100 % scrap practice. Furnace roof is considered with 5th hole for lime and/or dololime feeding by fully automated by MHS and 6th hole for future consideration of continuous feding of DRI and/or HBI up to 30 %.
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theMill for Minimills Electrode movements of EAF are controlled by EARS electrode regulation system which allows a constant ratio between electrode voltage and current to be maintained. Together with the hydraulic system of electrode movement control, system acts on arc voltage to maximise the efficiency of melting process. Using special algorithm following benefits can be obtained: Fast adjustment of arc length, Fast response and fast and stable control, Minimizing of power consumption, Minimizing of flicker effects due to regulation quality, Minimizing of electrode and refractory consumption.
EAF also employs supplementary chemical energy to save electrical power and thereby reduces conversion cost through improved EAF productivity. Chemical energy is supplied through special design CVS-Combined burner system providing carbon and oxygen injection. (5+1)x5 MW burners having each 2.500 Nm3/h average oxygen flow are installed around the furnace mounted on shell panels. Burners are distributed for the aim to cancel cold spot areas and also to obtain good foamy slag. In other words, the configuration was selected in order to have an as homogenous as possible supply of chemical energy to the bath. The module philosophy follows the target of efficient management of electrical and chemical energy, combining efficient dynamic control of the electric arc with a balanced injection of oxygen and carbon in order to increase EAF productivity. The oxygen jets supply the necessary oxygen amount for boosting the chemical reactions with both elements in the bath and also injected and/or charged carbon. The injectors, designed as laval nozzle, provide a highly coherent and efficient flow. Moreover, they make an important contribution to bath stirring leading to chemical and thermal homogenisation. The evolution in electric arc furnace technology has progresively led to the utilisation of alternative energy contributing to the heat balance, optimising the consumption of electrical energy and increasing productivity. A further effect of the correct adoption of this practice is the formation of a high level of foaming slag, with all the benefits arising from the resulting arc coverage. To obtain better slag foaming, additional slag door manipulator with two oxygen and one carbon lance is installed which yields faster operation. The carbon injectors provide the possibility to control the bath conditions by regulating the flowrate and promoting slag foaming. This slag condition has many
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theMill for Minimills advantages in terms of furnace wall protection, more efficient power utilisation and reduced maintenance. Ladle Furnace The final quality of the steel is obtained by means of a powerful ladle furnace capable of operating in accordance with the required short tap-to-tap times. The furnace is conceived for reheating the steel in the ladle placed on a ladle car and is designed and built according to the most modern techniques in the field and is in particular provided with: Water cooled ladle roof equipped with indirect fume collecting hood to reduce steel oxidation. Roof lifting mechanism, with hydraulic cylinder. Electrode arms with reduced electrode pitch diameter. Water cooled secondary circuit and water cooled flexible cables. Electro-hydraulic electrode regulation.
Transformer is chosen as 25 MVA for maximum heating rate of 4,5 /min. By considering 130 ton nominal weight of steel, average time for ladle furnace is 35 minutes. The steel is continuously stirred through one porous plag inserted in the bottom of ladle to assure good metal bath stirring to homogenise steel chemically and thermally. Continuous Casting Machine The caster is a 6-strand, 9-meter-radius machine with two unbending points. Generel features are given below: Machine type Number of strands Machine radius Unbending radius Strand distance Metallurgical length Casting section range Outfit sections Ladle capacity (nominal) CVS-CC-6-9 6 9m 17 m 1.200 mm Minimum 32 meter 100x100 to 215x215 mm 130x130, 150x150 mm 130 ton P a g e | 8 of 15
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theMill for Minimills Ladle support Tundish support Mould tube Oscillating unit Withdrawal speed range Billet cutting Cutting length Liftable-independent arm ladle turret Liftable tundish cars Curved 1.000 mm long Hydraulic type 0,6 6 m/min Oxy-gas torches 6 to 12 m
Layout foresees that the new CCM shall be located parallel to the EAF and LF axis. The ladle turret of the CCM is located in the melting bay and has the purpose to transfer the full ladle coming from loading position in the melting bay to the casting position in the melting bay. In this bay the cooling chamber, the main technological equipment of the new CCM and discharge area up to cross transfer area are also placed, while the following bay (billet bay) is foreseen for housing the cross transfer equipment of the CCM. The main hydraulic system and the main control desk are located in the melting bay, as well as the maintenance areas for moulds.
CCM is designed for the Production of structural, low-carbon and Si-killed grades. Billets up to 200 mm square can be cast from the machine whereas the outfit sections of 130, and 150 mm square billets are chosen for the start-up.
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theMill for Minimills The cast sections, as well as the maximum casting speeds and Production rates for the six strands are given below: Parameters Casting Speed Metric Weight Strand productivity CCM max productivity m/min Kg t/h t/h Billets - Casting sections (mm) 130x130 160x160 180x180 4,2 2,8 2,1 129 195 246 32,5 32,7 30,9 195 196,2 185,4
In the below table are shown the calculated casting times required to empty one full ladle of 130 tons with 1 casting strand at the above mentioned nominal casting speeds.
Parameters Casting Speed Emptying time with 1 strand Emptying time with 6 strands m/min Min Min
Billets - Casting sections (mm) 130x130 160x160 180x180 4,2 2,8 2,1 239 39 238 40 252 42
All the steel grades are cast in open stream, using the fast nozzle changing device for long casting sequences in order to reach very good productivity and reliability levels. The design is also suitable to submerged casting for quality steel grades for future extension. The continuous Casting concept is made possible by rotating ladle turret and large capacity tundish that acts as a buffer during ladle changes. The ladle turret with independent arms is liftable design to make ladle shroud positioning easier for the operator. Each arm on the ladle turret is also equipped with a ladle weighing system via load-cells. T-shaped tundish design with 30 ton nominal capacity promotes inclusion removal, assuring a stable steel flow, increasing steel residence time and homogenization for temperature patterns between strands. The use of pool type impact pad also helps in creating a good steel flow pattern and an even temperature through the tundish. The temperature difference between hot nad cold spots is designed to be less than 10C. The flow between ladle and tundish is with an automatically controlled slide gate system. Weight cells on cantilever type tundish car measure the weight of liquid
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theMill for Minimills steel in the tundish and automatically open or close the ladle slide gate to maintain the depth of steel required.
Tundish Nozzle Changer system is used to change nozzle quicker and safer, to replace damaged nozzle during casting resulting longer sequence casting ratio, to close strand automatically automatic in case of emergency condition, to adjust casting speed by changing nozzle with different nozzle diameter. Mould technology with long copper mould and tapered design yields for high casting speed by increasing heat transfer equally all around the mould. Thanks to the multi-tapered design, the air gap that is formed inside the mould is reducing. Air gap is normally formed because of in the lower part of the mould by billet shrinkage and in the upper part by the difference in heat Exchange between the faces and corners. Quick and safe mould changing is achieved by cartridge type mould yielding preassembled and self-centering design, together with self-sealing connections for cooling water supply. Foot Roll design underneath the mould helps to overcome bulging of semi-product. The mould is supplied with possibility for application of external type Electromagnetic Stirrers (EMS) to help improve the internal structure of the billet. This is an important tool when casting high quality steels to help in the formation of the cast structure (equaxial zone), and to avoid deposits of non-metallic or gaseous inclusions in the sub-surface area of the solidified shell. These inclusions may lead to serious defects during the successive processes downstream of the caster. The project of all system is developed ready to the future installation of EMS system. Co60 Radioactive source is used for Automatic Mould Level Control System. It controls the liquid steel level in the by adjusting the speed of withdrawal and straightening unit variably for open casting. Control system is not effected by the vibrations created by steel stream impact into the tundish and by the vibration of the casting platform. It allows flying tundish change, fly nozzle change without
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theMill for Minimills casting stop. The source and detector are located on the mould body so that the location of detector and its cable are well protected to steel splashes, over flow. Thanks to the system having high accuracy with quick response features, for precise control of meniscus level in the mould, surface quality problems arising especially from oscillation marks are cancelled . The oscillating table is of heavy-duty design and is sized to support the mould housings. It is designed to permit mould oscillation along the casting radius with adjustable stroke, frequency and negative strip time. The real oscillating curve overlaps the ideal one with strict tolerances and is stable during machine life in order to insure quality of the billet and a longer mould life by reducing friction between steel and copper tube. The oscillating motion is generated by a hydraulic cylinder that takes the stroke and form variations of the wave during the casting. The mould oscillation system is designed to maintain surface quality, limiting oscillation marks depth and cracks generation, to allow an adequate lubrication of the solidifying shell, to obtain good heat transfer in mould, to get shallow oscillation mark by short stroke and high frequency values. The secondary cooling is devided into four zones, each having its own regulation loops. The cooling for all zones is with water by correctly balanced flowrates and pressures. Sprayer designs of this multi zone secondary cooling system is arranged to reach the goal to avoid reheating of strand surface and to promote the continuation of shell growth, which has very ig influence on the internal quality of end product. Additionally, to decrease the risk of break-out and avoiding internal crack, secondary cooling system is automatically controlled in accordance with section size and casting speed. Each strand of the caster is equipped with a withdrawal and straightening module to carry out dummy-bar insertion and withdrawal of the billet. The module consists of totally five rolls, three of them are electrically driven. A hydraulic cylinder lifts and lowers the top roll and applies the required pressure on the dummy bar or the billet. The pressure of the rolls on the billet is adjusted highly enough to avoid skidding on the billet surface.
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The billets are cut-to-length automatically by a single torch oxycutting car according to length measurement from encoder installed on withdrawal motor. As the billet reaches the length required, the oxycutting car automatically clamps to the side of the billet and start to cut. Clamping action enables the car to travel forward with the same speed of the strand. After cutting operation is finalised, clamps are opened and car returns back to park position. After cutting, billet is transported along the run-out roller table up to billet transfer zone and lifted by hydraulic cylinder. After completion of one billet lifted for each strand, transfer car moves them sideways to the walking beam cooling bed. Along this unit, billet is transported by 90 rotation for even cooling. At the end of the bed, billets are off-loaded by magnet crane and stockpiled. Material Handling System Material Handling System is designed to reduce manual work and to avoid losing time-demanding material handling and automatic operation. The main operations are the storage into bins, extraction, weighing, transport and charging of ferroalloy, additives and fluxes into scrap bucket, into the ladle in tapping position and to the ladle refining station. All plant functions, specifically from storage bins up to loading to the final users, are controlled automatically. The dosage is carried out with high accuracy to obtain maximum technical results and, at the same time, to use additives and fluxes in the best possible way to minimize expenses. Suitable interlocks are to guarantee the right positioning of the devices. On the customers request in this project MHS is divided on two separate groups: Material feeding system to the EAF/LADLE/LF and Lime and carbon feeding system scrap baskets. Automation All meltshop is equipped with sophisticated automation system based on Local Area Network supporting the PLC Unit, operator workstations. Each phase of the process is automatically controlled and constantly monitored to help making the
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theMill for Minimills various phases of the process repeatable to guarantee the overall production cycle. Through the MMIs, the operator has an immediate overview of the process. They incorporate easy-to-read graphics and user-friendly systems for rapid access and control of all phases. Alarms and diagnostics are displayed on the screen to enable quick corrections to be carried out when necessary. The whole meltshop is connected by Level 1,5 automation system so that each point can be visualised from only one computer. Level 1,5 is a computer system combined with software tools, providing the operators with user interfaces on computer screens offering visual tools to enable access to process control parameters, acknowledging the alarm messages in alarm history, monitoring the machine conditions, simple tasks for recipe management, data exchange among local HMI stations and reading analysis report from spectral analysis laboratuary computer. Thanks to open architecture of SQL database, parameters can be accessed not only by the operator but also a higher level computer system which is called Level 2. It is able to built a Level 2 hardware & software on Level 1,5 substructure. The user access to Level 1,5 can also be classified into several authorization levels, such as operator access level, meltshop chief access level, etc. Main aim in designing user interfaces is to create a virtual bridge between user and machine. User interface pages on HMI screens are designed by using Siemens WinCC HMI software which offers screens with rich graphical objects displaying process variables, such as temperature, pressure, flow, animated graphics and status of machine. User screens can also be used to monitor machine conditions for maintenance purposes, for instance, monitoring the total working hours of motors, temperature variation graphics versus time, etc. Conclusion The steelmaking plant of the new minimill is basically made up of one 130 ton full-platform split-shell AC-EAF, one 130 ton inert roof ladle furnace, one 6strands 9 m radius CCM, one material handling system, one fume treatment plant and other auxiliaries like cranes, etc. The project has successfully passed a stage of basic and detail engineering and now it is at a stage of manufacture of the equipment. Equipment deliveries are planned for autumn-winter, 2011. at full speed there is a Preparation of the foundations for the equipment which installation will be carried out since spring of 2012 at plant AEMZ are well under way. The process of project realization goes smoothly thanks to many years
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theMill for Minimills experience of CVS in this field and good co-operation/co-ordination between CVS and AEMZ teams.
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Steelmaking and Casting at The New Minimill of Abinsky Electrometal Works LLC

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Steelmaking and Casting at The New Minimill of Abinsky Electrometal Works LLC

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theMill for Minimills

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