518023, 12:43AM Use of Direct Reduced Iron in Electric Are Furnace —IspatGura Use of Direct Reduced Iron in Electric Arc Furnace Sab ndra_Mas 4. Comment EAE, Feed Rate, Metallization, Scrap, Slag, Slag Foaming, Total Use of Direct Reduced Iron in Electric Arc Furnace Steelmaking by the electric arc furnace (EAF) has very good flexi ty with respect to the selection of charge materi EAF process has been 100 percent cold scrap but as the issues regarding scrap such as its availability and quality, imposed by scrap in making some steel grades due to residual elements and nitrogen level etc, have increased, EA\ alternative iron containing charge materials. Direct reduced iron (DRI) like pig iron and hot metal is one of the alternative iron charge material which has been us steelmaking process. DRI usage can have distinct effects on the melting process. Energy consumption, productivity percentage of DRI used in the scrap mix and operating practices. DRI is utilized as a scrap replacement in the EAF melting profile with DRI in the charge mix in a 150 ton EAF. Fig 1 Typical melting profile with DRI in the charge mix in a 150 ton E: The normal advantages associated with the use of DRI in the EAF steelmaking process are (i) constant size and din absence of tramp elements, (iv) purity, or the absence of non-metallic substances leading to better productivity and « EAF, since DRI can be charged into an EAF along with scrap, using buckets or by the continuous feeding, (vi) better scrap, (vii) availability of the associated carbon content which yield energy during the steelmaking process, (vii) eas) in case of the use of hot DRI with hot DRI reducing the energy consumption by as much as 16 % to 20 % by making nelemperatures higher than 600 deg C, (vill) easy handling and storage with the possibility of feeding without opening | system resulting into stable steel bath surface which reduces the risk of electrode breakages. (ix) possi518023, 12:43AM Use of Direct Reduced Iron in Electric Are Furnace —IspatGura EAF operations have improved considerably since late 1970s — early 1080s. Steelmaking in EAFs has been benefit increasing further the use of chemical energy, and with the use of the DRI in a proper way. The practices developed demonstrated that DRI use can improve energy consumption, yields, productivity, and above all the operating costs. allows the EAF steelmaking to reap substantial financial and technical benefits. The use of high carbon, hot DRI can coupled with the cost effective productivity. The main parameters affecting the operation of EAF are composition of raw materials (% gangue / chemistry, metall energy content), operating practices (power profiles, foamy slag, and melting practices), and furnace design (heel, 0 metallics coming with DRI (usually in case of DRI produced by rotary kiln) also has adverse effect on EAF steelmaki DRI in the EAF steelmaking can have adverse impact on the operating parameters of the EAF. DRI is the product which is produced by the direct reduction of iron ore or other iron bearing materials in the solid ste Processes which produce DRI by reduction of iron ore below the melting point of the iron are normally known as the agents are carbon monoxide (CO) and hydrogen (H2), coming from reformed natural gas, syngas, or coal. Iron ore i Oxygen (02) is removed from the iron ore by chemical reactions based on H2 and CO for the production of highly m In the direct reduction process, the solid metallic iron (Fe) is obtained directly from solid iron ore without subjecting t reduction can be defined as reduction in the solid state at 02 potentials which allow reduction of iron oxides, but not etc.), to the corresponding elements, Since reduction is in the solid state, there is very little chance of these element in the reduced iron, so the oxides which are more stable than iron remain essentially unreduced. DRI has a porous « DRI is produced in many forms. These are lump, pellets, hot briquetted iron (HBI), fines, and cold briquetted iron (CE When DRI is discharged from the fumace in cold condition (temperature around 50 deg C) then the product is know! discharged in hot condition (temperature around 650 deg C) for use in hot condition in steelmaking then the product Iron content in the DRI is in two forms. One is in metallic form which is known as metallic iron, Fe (M), and the secor iron oxides, Fe (0). The total iron, Fe (T), in DRI is the sum of these two iron components. Metallic iron is the aggre¢ with carbon (as cementite) present in DRI. The chemical and physical properties of DRI produced by the different pr The quality of the DRI is important since it impacts parameters of steelmaking such as yield, flux consumption, slag | oxygen and raw material feeding rates. The quality of DRI is dependent upon (i) quality of input materials mainly iror determines the gangue materials/impurities in the DRI, (i) production process which determines the carbon content which determines the metallization of the DRI. A low degree of metallization means more FeO has to be reduced in the EAF. On the other hand, a high metallizatio lower bath agitation in the EAF, which in turn reduces the heat transfer efficiency and accordingly increases the fur: mare obtained when metallization of DRI lies between 94 % and 96 %5118/23, 1243 AM Use of Direct Reduced Iron in Elect Are Furnace —IspatGuru Also with the increase of the DRI percent in the charge mix, nitrogen levels show a similar reduction with proper slac EAFs to produce many special steels, Further, DRI is also used for economic high quality steel production with very DRI has high bulk density, which is greater than that of the most types of the steel scrap. Its density is higher than th facilitates its melting at the slag / metal interface. The remaining FeO in the DRI reacts with the carbon in the liquid r which shields the refractory from the electric arc. However, DRI feeding rate is an important parameter of the EAF pi optimum feeding rate depends on the DRI chemical composition, the bath temperature, and the stirring energy provi bottom stirring plugs. DRI feeding rates in most of the DRI charged furnaces are in the range of 27 kg/min MW to 35 The carbon content of the DRI is important with respect to its use in the EAF steelmaking. Carbon in DRI can be pre as a combination of both the elemental as well as in the bonded form, The bonded form of carbon in DRI is iron cart iron and carbon. Normally around two-thirds of the carbon contained in DRI is present as iron carbide, and the balar the carbon is in the bonded form then there is no loss of the not-bonded C due to its combustion in the EAF atmosp! based DRI. Tab 1 Typical specification of gas based DRI Basis- Fe in iron ores / pellet - 65.5 % to 68 % SI. No. Parameter Unit 1 Metallization % 2 Fe (Total) % 3 Fe (Metallic) % 4 Carbon % 5 Sulphur % 6 Phosphorus as P205 % 7 Gangue % 8 Typical size mm 9 Apparent density tons/eum, 10 Bulk density tons/cum Note: Residuals are unreduced oxides such as silica, manganese oxide, alumina, lime, and magnesia Itis normally seen that in the gas based DRI, the carbon content of the DRI is generally more than the stoichiometric content remaining in the DRI product. The excess carbon has significant impact on the FeO content of the slag and efficient EAF steelmaking process. In case of negative excess carbon, the necessary addition of anthracite coal for F steelmaking process. However, not all the FeO is reduced into Fe since a portion of the FeO does always exist in the amount of excess carbon of DRI which is available for combustion in the EAF steel bath is more than the excess car is called combustible carbon and defined by the equation ‘Combustible carbon = carbon in DRI — stoichiometric carb niThe combustible carbon reacts with the oxygen injected to the EAF steel bath to release heat in the steel bath and a With increasing camhietible carhon in the EAE the nitranen content of the tanned steel alen decreases Eyrece carl518023, 12:43AM Use of Direct Reduced Iron in Electric Are Furnace —IspatGura Electric power consumption Electric power consumption (kWh per ton of liquid steel) during EAF steeImaking increases when there is an increas As per the thumb rule, with every increase of 10 % in DRI percent leads to an increase in electric power consumptio certain conditions. Many factors tend to increase the electric energy consumption when using DRI in the EAF steelmaking, With good s scrap and without other energy inputs typically consumes energy in the range of around 400 kWhiton to 435 kWh! tc an EAF having a charge mix consisting of 98.2 % DRI with very good slag foaming has achieved an average energy steel. DRI metallization affects energy consumption. The lower metallization level of DRI means higher FeO level. Chemic reaction. Reduction of one ton of FeO to Fe needs around 800 kWh at steelmaking temperatures. Increasing levels | power requirements. SiO2 needs the addition of lime to maintain the basicity ratio. Melting one ton of slag needs arc amounts of SiO2 need increasing amounts of CaO to maintain the basicity ratio, Both the SiO2 in the DRI and calcin process. Fig 2 shows the relationship between the gangue content of DRI and the energy consumption per ton of liq of additional factors which affect the steelmaking process. These include yield, lime requirements, and the oxygen a Effect of gangue content on energy requirement per ton of liquid steel 700 c ‘Slag basicity =2 Curve 1 - Basicity of gangue=0 ? FeOin slog = 20% Carve 2 Bascty of gengue =O i farbon content in OR = 1.2% Bn wieu dice tt i Metalzation of RI ; Sex ie =n 3 — 56 5 seo 3 0 4 0 3 F 2 8 4 +5 6 7 8 Gangue content of DRI ig 2 Effect of gangue content on energy requirement per ton of liq Phosphorous and sulphur contents can have a negative effect on energy consumption due to lime requirements. Th from the bath. If the EAF is being operated at a constant FeO percentage then the only way to remove more phosph the amount of ime results in increased energy consumption and Fe yield loss. Efficient sulphur removal needs the u operate with a basic oxidizing slag. While it is possible to remove some sulphur from the EAF by increasing the amo energy consumption and is not very effective. Carburized DRI has a positive effect on the energy consumption if high volume oxygen is available to inject into the by 2 KWhIN cum to 4 KWh/N cum of oxygen, if is injected with the correct amount of carbon and a good foaming sl Iitpsmwispatguru.comluse-oFdrect-reducedror-in-elecinicarcfurnace! 465118/23, 1243 AM Use of Direct Reduced Irn in Elect Are Furnace —IspatGura metallization goes down, it has negative influence on all the parameters. Fig 3 shows typical relationship of metallize experienced in an EAF. ‘Typical relationship of metallization with yield and power consumption 5 om ea Prana nara vrata roa is 3 i Merton in Maatilaation in Fig 3 Typical relationship of metall Effect of DRI percent in the charge mix on lime and total flux DRI normally contains silica as the main gangue constituent together with low levels of other impurities such as sulp concentrations of these components in the DRI and the proportion of DRI in the metallic charge, varying quantities 0 slag the silica and remove the sulphur and phosphorus to the allowable levels of these elements for the grade of the The total lime consumption increases with the increase in the DRI percent in the EAF charge mix. As per thumb rule by 2.6 kg/ton of liquid steel with every 10 % increase of DRI in the charge mix. The thumb rule equation for calculati liquid steel) is ‘Flux consumption (kg /t) = 45.31 + 0.2416 x DRI percent, Charging methodology With the increased use of DRI in EAF steelmaking, charging methods have changed. With a captive DRI plant, the p high such plants. In such plants, direct supply to the EAF is done through a continuous charging system to a fifth hol storage bins or large warehouses to accept DRI supply when the EAF shop is down for maintenance or delays or wh shutdowns. Fig 4 shows different charging practices being followed with DRI usage in EAF steelmaking. Charging practice of DRI in EAF steel making SSS Light sera Hor Continuous Feeding | "| ee i Wear Mined 2 otal wlth Set] = cau sera ; |*—sarcletone | Comiaeus feeding le 4 ° 25 35 35700 Percent DRI in EAF charge Bucket charging es bi Fig 4 Different charging pra \g followed with DRI usage in EAF ste Continuous feeding is usually employed above 25 % to facilitate matching feeding rate to power and chemical energ 'ferroberg’ formation. Prevention of ferrobergs is determined in part by the feed rate and the power input available.5118/23, 1243 AM Use of Direct Reduced Iron in Elect Are Furnace —IspatGura have been many different hot charging methods. One method is hot charging by transporting the DRI from the DRI method uses a pneumatic system conveyor with gravity feed through the fifth hole, Several plants make use of conv study based on published data from 150 EAFs shows that some of the EAFs charging HDRI are matching the energ hitps:wzispatguru.comluse-of direct reduced-iromin-lectrc-arcfuacel 86