HBI Use in EAF For Slag Control

Hot Briquetted Iron (HBI) Seminar
October 21, 2008

Swissôtel The Bosphorus
Istanbul, Turkey
HBI Use in EAF

for Slag Control
Atilio Lares
Technical Support Manager
Orinoco Iron
www.hbia.org
Slag Control Using HBI
Based On
¾ Sidetur - Casima experience using 80% HBI in
the EAF
¾ “Foamy Slag Fundamentals and Their
Practical Application to Electric Furnace
Steelmaking”
Eugene B. Pretorius & Robert C. Carlisle(1998)
HBIA Istanbul Seminar - HBI Use in EAF (Slag Control)

2
Furnace Characteristics
¾ 1 Voest Alpine AC-EAF (EBT)
¾ Nominal capacity 75 MT/heat
(Actual 83 MT/heat)
¾ Diameter 5.9 m
¾ Transformer capacity 70 MVA
¾ Primary voltage 23 KV
¾ Secondary voltage 276 – 831 V
¾ Electrode size 600 mm
¾ Pitch circle diameter 1100 mm
¾ Equipped with a lance
manipulator for oxygen and coal
injection (BSW)
3
Continuous Charging Considerations
¾Charge Distribution
9Bucket charging
9Continuous feeding
¾Melting Practices
¾Slag Control
9What is the proper slag
9Slag control in continuous feeding

4
Charge Distribution
Recommendations to charge HBI should
be based on the number of buckets per
heat, scrap quality, bucket shape, hot heel
practices, and percentage of HBI used.

5
Charge Distribution
¾Up to 30% HBI can be charged in buckets
9Avoid HBI agglomeration on the bottom of
the furnace
9Avoid mix of HBI and fluxes on the
bottom of the furnace
9Try to mix HBI with medium scrap in the
charge bucket
¾Consider continuous feeding if it is available
9More than 30%, continuous feeding is
recommended

6
Charge Distribution
Bucket Layering
Light Scrap (turnings/bushelings)

Medium Scrap (blend/shredded)
HBI
Heavy Scrap /bundles
Fluxes / Coal
¾Up to 15% HBI can be placed on heavy scrap

¾Higher than 15%, alternative layering of HBI and
medium scrap is recommended
7
Casima Charge Distribution

8
Process Steps
600 1680 T (oC)
First Melting 1640
Period
500 1620
1580
1540
POWER OFF TIME
400
1500
SCRAP BORE DOWN
1460
KWH/TC
300 MAXIMUN POWER AFTER 1 min 57 Mw
START CONTINUOUS FEEDING AT 320 Kwh/Tc
200 AT LOW RATES (60 MT/hr)

INCREASE CONTINUOUS FEEDING TO 80 MT/hr
AFTER 430 Kwh/Tc
100 INCREASE TEMPERATURE UNTIL 1550° C
1550 oC - 1570 oC
0
0 10 20 30 40 50 60 70
t (min)
9
Process Steps
600 1680 T (oC)
First Melting Melting & Refining 1640
Period T=Constant
500 1620
1580
1540
POWER OFF TIME
400
KEEP MAXIMUM POWER INPUT 1500
INCREASE THE BATH VOLUME 1460
KWH/TC
300 CONSTANT TEMPERATURE

MELTING AND REFINING TAKE PLACE
200 PHOSPHORUS REMOVAL

TEMPERATURE IS BETWEEN 1550 and 1570 oC
-
MAXIMUM FEED RATE IS REACHED (120 MT/hr)
100 35 Kg/Mw.min
FLUX ADDITIONS (7MT/hr)
0
0 10 20 30 40 50 60 70
t (min)
10
Process Steps
600 1680 T (oC)
First Melting Melting & Refining Heating 1640
Period T=Constant
500 1620
1580
1540
POWER OFF TIME
400
1500
DECREASE CONTINUOUS FEEDING TO 60MT/hr 1460
TAPPING
KWH/TC
300
TAPPING TEMPERATURE IS REACHED
TENDENCY OF FOAMY SLAG TO COLLAPSE IN

200
IN THE LAST 4 MINUTES (T>1610 oC)
DESLAGGING TAKES PLACE
100 SOME PHOSPHORUS RECOVERY MAY OCCUR
0
0 10 20 30 40 50 60 70
t (min)
11
Electrical, Feeding and Oxygen Injection Procedures
550 Kwh/TC
First MeltingAverage Power 57 Mw
12 Period
470 Kwh/TC 480 Kwh/TC 140
11
Charging Rate (MT/hr)

10
430 Kwh/TC
35 Kg/min Mw
120
POWER OFF TIME
9
Power Level
8 100
320 Kwh/TC
TAPPING
7
23 Kg/min Mw
6 80
5
17 Kg/min Mw
4 60
3
40
2 Oxygen Injection 1400 m3/hr
1 20
Dolo-lime 7 Mt/hr
0 10 20 30 40 50 60 70
t (min)
12
Why do we need good slag control?

What are the characteristics of a good slag?
How can we produce it?
13
Exposed Arc Arc Submerged in Foamy Slag
Energy Losses
Gases
CO
Refractory
Damage
CO
C+O=CO C+O=CO

14
¾To help stabilize the arc and improve
power quality (reduced flicker and
harmonics).
¾To reduce the amount of noise

generated.
¾To reduce absorption of harmful

gases (nitrogen, hydrogen) from the
atmosphere to the bath in the arc
region.
¾Good foaming slag reduces the

amount of slag required to cover the
arc, resulting in cost reductions in
fluxes, slag handling, and electrical
energy by reducing the heat loss to
slag.

15
Uncovered Arc Covered Arc

16
¾ Protects refractory and reduces gunning

¾ Reduces power consumption
¾ Utilizes long arc and the maximum power
available
¾ Reduces nitrogen pick up
¾ Removes phosphorus
¾ Increases iron recovery
¾ Optimizes flux consumption

17
¾ Slag must be liquid enough to react with

metal
¾ Slag must be saturated with MgO in order to
avoid chemical effect on the furnace lining
¾ Slag must have the proper proportion
between liquid phase and solid precipitant in
order to reach the proper viscosity for
foaming

18
Optimum Over-
Slag Saturated:
Too much
solid particles
Foaming Index (Σ)
Liquid Liquid to Creamy Creamy to Crusty
θ=0 θ>0
Effective Viscosity (ηe)
Ŋe=ŋ(1-1.35θ) -5/2
19
CaO
Isothermal Solubility Diagram (ISD) B3 =
(SiO2+Al2O3)
18
16
MW + L
14
12 C2S + MW
% MgO
10 +L
8
6 L
4
2 C2S + L
0
0 5 10 15 20 25 30 35 40 45 50 55
% FeO
20
Isothermal Solubility Diagram (ISD) B3 = 1,5 T= 1600 0 C
18
16
MW + L
14
12 C2S + MW
% MgO
10 +L
8 X
X1 X2
6 L
4
2 C2S + L
0
0 5 10 15 20 25 30 35 40 45 50 55
% FeO
21
18
16
MW + L
14 Y1
Y
Y2
12 C2S + MW
% MgO
10 +L
8
6 L
4
2 C2S + L
0
0 5 10 15 20 25 30 35 40 45 50 55
% FeO
22
18
Z1
16 Z
Z2 MW + L
14
12 C2S + MW
% MgO
10 +L
8
6 L
4
2 C2S + L
0
0 5 10 15 20 25 30 35 40 45 50 55
% FeO
23
Isothermal Solubility Diagram (ISD)
18
16
MW + L
14
12 C2S + MW
% MgO
10 +L
6 L
4 B3 = 1.5
C2S + L
2 T = 1600oC
0
0 5 10 15 20 25 30 35 40 45 50 55
% FeO
24
18
16
MW + L
14
12 C2S + MW
% MgO
10 +L
6 L
4 B3 = 1.8
C2S + L
2 T = 1600oC
0
0 5 10 15 20 25 30 35 40 45 50 55
% FeO
HBIA Istanbul Seminar - HBI
) Use in EAF (Slag Control)
25
18
16
14
12 MW + L
% MgO
10
8
C2S + MW
+L
6
4 L B3 = 2
C2S + L
2 T = 1600oC
0
0 5 10 15 20 25 30 35 40 45 50 55
% FeO
26
B3 = 1,5 B3 = 2 B3 = 2,5
% MgO = 12,7 % MgO = 9,3 % MgO = 7,6
Foaming Index (Σ)
% FeO

27
SLAG COMPOSITION (S1)
CaO (%) 33.03

SiO2 (%) 14.02
Al2 O3 (%) 5.11
MgO (%) 10.1
FeO (%) 34.0
MnO (%) 1.9
P2 O5 (%) 0.9
IB2 2.35
IB3 1.73
IB4 2.25
Slag Volume 12.5 T

28
18
16
MW + L
14
12 C2S + MW
% MgO
10 +L S1
8
6 L
4 B3 = 1.8
C2S + L
2 T = 1600oC
0
0 5 10 15 20 25 30 35 40 45 50 55
% FeO
29
Good foamy slag can be controlled by HBI

charging
¾High CO generation
9FeO and Fe3C contained in HBI react,
producing CO during continuous feeding,
which favors foamy slag formation

30

charging
¾FeO content reduces the viscosity

9During continuous feeding of HBI, the FeO
content in slag can be increased if the HBI
has low carbon and if there is not a balance
between carbon and oxygen in the heat
9Carbon injection and carbon additions
during continuous feeding are recommended

31
18
16
MW + L
14
12 C2S + MW
% MgO
10 +L S1
S2
8
6 L
4 B3 = 1.8
C2S + L
2 T = 1600oC
0
0 5 10 15 20 25 30 35 40 45 50 55
% FeO
32
18
16
MW + L
14
12 C2S + MW
% MgO
10 +L
6 L
S1
S2
4 B3 = 1.8
C2S + L
2 T = 1600oC
0
0 5 10 15 20 25 30 35 40 45 50 55
% FeO
33

continuous feeding
¾Other acid oxides such as SiO2 and Al2O3
reduce viscosity and affect foamy slag
9During continuous feeding of HBI, there
are important increments of SiO2 and Al2O3
in slag
9The procedure must consider the addition
of fluxes during continuous feeding in order
to keep the same oxide proportions in the
slag
34
18
16
MW + L
14
12 C2S + MW
% MgO
10 +L S1
8
6 L
4 B3 = 1.8
C2S + L
2 T = 1600oC
0
0 5 10 15 20 25 30 35 40 45 50 55
% FeO
35
18
16
MW + L
14
12 C2S + MW
% MgO
10 +L S1
8
6 L
4 B3 = 1.5
C2S + L
2 T = 1600oC
0
0 5 10 15 20 25 30 35 40 45 50 55
% FeO
36

continuous feeding
¾Basic oxides such as CaO and MgO increase
the viscosity, which affects the foamy slag
9The amount of fluxes charged in bucket
must be calculated to avoid high CaO and
MgO concentrations during the first melting
and the first step of continuous feeding
9The addition of fluxes during continuous
feeding must be in balance with the
increments in acid oxides
37
18
16
MW + L
14
12 C2S + MW
% MgO
10 +L S1
8
6 L
4 B3 = 1.8
C2S + L
2 T = 1600oC
0
0 5 10 15 20 25 30 35 40 45 50 55
% FeO
38
18
16
14
12 MW + L
% MgO
10 S1
8
C2S + MW
+L
6
4 L B3 = 2
C2S + L
2 T = 1600oC
0
0 5 10 15 20 25 30 35 40 45 50 55
% FeO
39

continuous feeding
¾Temperature decreases the viscosity
9The feeding rate has to be calculated in
order to avoid overheating because the
temperature has to be constant during the
major part of continuous feeding
9It also aids in phosphorus removal

40
18
16
MW + L
14
12 C2S + MW
% MgO
10 +L S1
8
6 L
4 B3 = 1.8
C2S + L
2 T = 1600oC
0
0 5 10 15 20 25 30 35 40 45 50 55
% FeO
41
18
16
MW + L
14
12 C2S + MW
% MgO
10 +L S1
8
6 L
4 B3 = 1.8
C2S + L
2 T = 1650oC
0
0 5 10 15 20 25 30 35 40 45 50 55
% FeO
42

43

44
CONCLUSION
Slag control is the key factor in the continuous

charging procedure because it allows use of
the maximum power available and an increase
in the feeding rate.

45
HBI Use in EAF
for Slag Control
Thank you for your attention
www.hbia.org

46

HBI Use in EAF For Slag Control

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Hot Briquetted Iron (HBI) Seminar

October 21, 2008

HBI Use in EAF

HBIA Istanbul Seminar - HBI Use in EAF (Slag Control)

Continuous Charging Considerations

HBIA Istanbul Seminar - HBI Use in EAF (Slag Control)

HBIA Istanbul Seminar - HBI Use in EAF (Slag Control)

HBIA Istanbul Seminar - HBI Use in EAF (Slag Control)

Light Scrap (turnings/bushelings)

Heavy Scrap /bundles

¾Up to 15% HBI can be placed on heavy scrap

HBIA Istanbul Seminar - HBI Use in EAF (Slag Control)

300 MAXIMUN POWER AFTER 1 min 57 Mw

START CONTINUOUS FEEDING AT 320 Kwh/Tc

200 AT LOW RATES (60 MT/hr)

300 CONSTANT TEMPERATURE

200 PHOSPHORUS REMOVAL

TENDENCY OF FOAMY SLAG TO COLLAPSE IN

Charging Rate (MT/hr)

Why do we need good slag control?

HBIA Istanbul Seminar - HBI Use in EAF (Slag Control)

¾To reduce the amount of noise

¾To reduce absorption of harmful

¾Good foaming slag reduces the

HBIA Istanbul Seminar - HBI Use in EAF (Slag Control)

Uncovered Arc Covered Arc

HBIA Istanbul Seminar - HBI Use in EAF (Slag Control)

¾ Protects refractory and reduces gunning

HBIA Istanbul Seminar - HBI Use in EAF (Slag Control)

¾ Slag must be liquid enough to react with

HBIA Istanbul Seminar - HBI Use in EAF (Slag Control)

Liquid Liquid to Creamy Creamy to Crusty

Effective Viscosity (ηe)

Isothermal Solubility Diagram (ISD) B3 = 1,5 T= 1600 0 C

HBIA Istanbul Seminar - HBI Use in EAF (Slag Control)

SLAG COMPOSITION (S1)

CaO (%) 33.03

Slag Volume 12.5 T

HBIA Istanbul Seminar - HBI Use in EAF (Slag Control)

Good foamy slag can be controlled by HBI

HBIA Istanbul Seminar - HBI Use in EAF (Slag Control)

Good foamy slag can be controlled by HBI

¾FeO content reduces the viscosity

HBIA Istanbul Seminar - HBI Use in EAF (Slag Control)

Good foamy slag can be controlled by HBI

Good foamy slag can be controlled by HBI

Good foamy slag can be controlled by HBI

HBIA Istanbul Seminar - HBI Use in EAF (Slag Control)

HBIA Istanbul Seminar - HBI Use in EAF (Slag Control)

HBIA Istanbul Seminar - HBI Use in EAF (Slag Control)

Slag control is the key factor in the continuous

HBIA Istanbul Seminar - HBI Use in EAF (Slag Control)

HBIA Istanbul Seminar - HBI Use in EAF (Slag Control)

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