ELECTRIC ARC FURNACE

Advantages of using DRI Known chemical composition which helps in improving EAF efficiency Low impurities as Sulphur/Phosphorus Absence of tramp elements, any sort of quality steel can be produced Easy Handling and storage Higher density in the basket Possibility of feeding continuously without opening roof, hence avoiding energy losses, Stable and predictable steel bath Less chances of electrode breakages

Disadvantages Higher power consumption Higher refractory consumption in comparison to scrap

Why DRI? The quality of DRI produced depends mainly upon the iron ore source and the proper selection of raw materials to be fed to the pelletizing plant or directly into the Direct Reduction Reactors. The slag weight depends mainly on the content and composition of the gangue in the DRI and the basicity of the slag. One of the main concerns for the EAF steel maker is the reduction in yield and increase in power consumption by increasing the amount of DRI. Liquid Yield is based on the DRI metallization, Gangue content, Carbon content, Size distribution and Oxygen practices in EAF. Higher the metallization, higher the metallic iron in DRI and lower the FeO. The FeO and gangue content decide the foamy slag practice and Yield. As much of the FeO as possible should be reduced in the EAF to avoid iron losses to the slag. To recover the iron, the addition of coke and graphite is required. But in Al-Tuwairqi DRI, the required carbon comes mainly from the DRI.

The quasi-equilibrium reached by the liquid steel-slag system before tapping determines the iron oxide content in the slag. The slag generation depends on the DRI and scrap quality, carbon-oxygen equilibrium in the bath, gangue content and nonferrous oxide distribution in the gangue. In Al-Tuwairqi, the metallization degree shows a great consistency in the short period of time. National Steel co. Ltd. has seen strong positive impact on production. The average %FeO in the slag is about 28%, The FeO content in the slag of the EAF not only measures the amount of iron lost directly in the slag, but it also controls the amount of slag generated . The advantages with this high carbon content are: Foaming slag formation takes place through all the heat, allowing a good protection of the EAF lining from the arc radiation and also promoting the reduction of the FeO in the slag, decreasing the coke and graphite addition. Submergence of the arc in slag favors heat transfer to the bath enhancing the thermal efficiency of the reactor, additionally, arc stability is also increased. DRI size distribution is a special matter that requires a lot of attention because influences directly in the metallic yield. The smaller sizes lead to direct loss in slag. In other case, as it is direct reduction process, core may not be as reduced as surface. There are mainly two methods of using DRI 1. Bucket route with scrap 2. Continuous feeding thru belt conveyors

Bucket route with scrap The bucket route with scrap should operate with established and tried parameters for basket loading in scrap yard, the amount of DRI in each layer and amount of fluxes to be used based on the amount of hot heel, power input and melting profile.

The standard process should follow EAF - higher amount of hot heel (Which is better for scrap meting too),

Bucket practice : 1. light scrap (5-10%) to be loaded initially in the first basket followed by (5-10% ) of DRI and then rest of scrap as per normal practice. The lime/Dololime should be loaded at the bottom of the bucket to protect hearth. 2. Second Basket can also follow the same trend, the amount of lime/Dololime (target B3 ratio 1.8) should be added further to protect side wall. Bath temperature should be maintained within 1570-1600 C

Subsequent Baskets may or may not use DRI based upon the melting profile. Continuous feeding thru belt conveyors a) Usual range for feed rate is 28-35 kg/min/MW depending on DRI composition. The fluxes are also fed continuously fed thru conveyor based on composition and gangue of DRI. b) If temperature is too low reduce the feed rate to 10kg/min/MW or stop DRI, recheck the temperature and start again.

Prepared by

M. Noman Bari Technical Sales Engineer DRI Sales & Marketing