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EBT SAND AND M-ONE INJECTION SYSTEM UPGRADE AT UNITED STEEL (KUWAIT). - MORE | Innovation in Steelmaking

EBT SAND AND M-ONE INJECTION SYSTEM UPGRADE AT UNITED STEEL (KUWAIT). - MORE | Innovation in Steelmaking: United Steel Industrial Company is a private Kuwaiti Closed Shareholding Industrial and Commercial Joint Venture Company that was established in 1996 through a joint partnership between Kuwaiti investors and ASCOTEC of Germany. United Steel Industrial Company is the sole producer of steel rebar and billets in Kuwait. Since 2011, their 150t EAF operates with a complete MORE sidewall injection system (oxygen, carbon and lime injection) with excellent results with 100% DRI/HBI charge. Main EAF data: Furnace type DANIELI EAF EBT Nominal steel capacity 125 t /  138 st Shell diameter 6,9 m /  22 ft Transformer 163 MVA +10% Charge mix From 100% DRI to 100% scrap Hot heel 40 t / 44 st To have the possibility to charge more scrap according to market conditions, in 2015 United Steel contacted MORE to upgrade the sidewall injection system. Moreover, as operators’ safety  is always one of the top priority of the company, United Steel also requested an automatic system to sand and inspect the EBT tap hole after tapping thus avoiding any manual operation on the EBT sump panel. During the beginning of 2016, both companies agreed on the final injectors lay-out design in order to have the possibility to run the EAF charging from 100% DRI/HBI to 100% scrap.   MORE scope of supply included: three (3) M-ONE injectors for the combined supersonic oxygen and carbon injection, two JET burners, one (1) LIMEJET for pneumatic lime injection, the valve stands upgrade  and one (1) EBT SAND for the automatic inspection and sand filling of the EBT tap hole.                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            The M-ONE injectors have been installed into CNC copper bulged blocks; the front panels are equipped with FLASH STOP system to avoid damages caused by back fires Since October, excellent results have been achieved. Thanks to the availability of better injection tools, EAF operations have improved both in terms of productivity and overall process control. With the installation of the EBT-SAND, just replacing the manual inspection and sanding operation with an automatic cycle, the power-off time was reduced by 1,5 minutes per heat therefore it was possible to gain 1 heat per day. Moreover, a better distribution of the supersonic oxygen injection with highly coherent supersonic streams has generated a better bath penetration for C oxidation and other oxidizing reactions in the steel/slag interface Main EAF results: Parameter Before After Difference Charging 2,5 min 2,5 min 0.0 Power-on time 43 min 37 min 6 min* Tap-to-Tap 60 min 51,5 8,5 min Power off 17 14,5 2,5 Electrical energy consumption 530 kwh/t 510 kwh/t 20 kwh/t* Number of heats per day 24 28 4 *with the injectors upgrade the customer replaced also the EAF transformer with a bigger one. Steelmaking, Innovation, chemical energy, auxiliary equipment, water cooled elements, Electric Arc Furnace

 

EBT SAND AND M-ONE INJECTION SYSTEM UPGRADE AT UNITED STEEL (KUWAIT).

31.01.2017
United Steel Industrial Company is a private Kuwaiti Closed Shareholding Industrial and Commercial Joint Venture Company that was established in 1996 through a joint partnership between Kuwaiti investors and ASCOTEC of Germany. United Steel Industrial Company is the sole producer of steel rebar and billets in Kuwait.
Since 2011, their 150t EAF operates with a complete MORE sidewall injection system (oxygen, carbon and lime injection) with excellent results with 100% DRI/HBI charge.
Main EAF data:

Furnace type

DANIELI EAF EBT

Nominal steel capacity

125 t /  138 st

Shell diameter

6,9 m /  22 ft

Transformer

163 MVA +10%

Charge mix

From 100% DRI to 100% scrap

Hot heel

40 t / 44 st

To have the possibility to charge more scrap according to market conditions, in 2015 United Steel contacted MORE to upgrade the sidewall injection system. Moreover, as operators’ safety  is always one of the top priority of the company, United Steel also requested an automatic system to sand and inspect the EBT tap hole after tapping thus avoiding any manual operation on the EBT sump panel.
During the beginning of 2016, both companies agreed on the final injectors lay-out design in order to have the possibility to run the EAF charging from 100% DRI/HBI to 100% scrap.  
MORE scope of supply included: three (3) M-ONE injectors for the combined supersonic oxygen and carbon injection, two JET burners, one (1) LIMEJET for pneumatic lime injection, the valve stands upgrade  and one (1) EBT SAND for the automatic inspection and sand filling of the EBT tap hole.                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                            The M-ONE injectors have been installed into CNC copper bulged blocks; the front panels are equipped with FLASH STOP system to avoid damages caused by back fires
Since October, excellent results have been achieved. Thanks to the availability of better injection tools, EAF operations have improved both in terms of productivity and overall process control.
With the installation of the EBT-SAND, just replacing the manual inspection and sanding operation with an automatic cycle, the power-off time was reduced by 1,5 minutes per heat therefore it was possible to gain 1 heat per day.
Moreover, a better distribution of the supersonic oxygen injection with highly coherent supersonic streams has generated a better bath penetration for C oxidation and other oxidizing reactions in the steel/slag interface

Main EAF results:

Parameter

Before

After

Difference

Charging

2,5 min

2,5 min

0.0

Power-on time

43 min

37 min

6 min*

Tap-to-Tap

60 min

51,5

8,5 min

Power off

17

14,5

2,5

Electrical energy consumption

530 kwh/t

510 kwh/t

20 kwh/t*

Number of heats per day

24

28

4

*with the injectors upgrade the customer replaced also the EAF transformer with a bigger one