DRI and HBI Production Research Papers (original) (raw)

2025, ABM Proceedings

O trabalho está baseado na análise de dados de perto de 200 fornos elétricos a arco de diferente design: convencional, de corrente contínua, de carcaças gémeas, com preaquecimento de sucata no transportador ou em shaft, etc. Incluem-se fornos que processam principalmente sucata, e fornos com carregamento parcial de gusa sólido ou líquido, ferro briquetado a quente (HBI) ou ferro esponja (DRI) a frio ou a quente. São avaliados os consumos de energia elétrica, oxigênio, gás natural e materiais carbonosos; os tempos entre vazamentos, com forno ligado e com forno desligado, assim como a produtividade horária. Com os dados obtidos, se analisa a influência dos metálicos (e seu estado térmico ao momento do carregamento), e o design do forno, sobre os consumos específicos mencionados e a produtividade.

2025, Anais do Seminário de Aciaria, Fundição e Metalurgia de Não-Ferrosos

After almost half a century of experience in using DRI/HBI in electric arc furnaces (EAFs), and taking into account the decrease of natural gas cost in the USA, it is interesting to revisit some trends and controversial issues around this alternative iron source. This paper reviews aspects like the evolution of iron ore quality and its influence on EAF operation; DRI stockpiling and transport, regarding the risk for selfcombustion; optimum charge design; cold DRI/HBI charging (fifth hole, bucket, transporter); hot charging (ways and results); carbon content, metallization and silica in DRI/HBI, and its influence on EAF operation and performance; oxygen / carbon balance; chemical energy and DRI/HBI charge.

2024, Scandinavian Journal of Metallurgy

Commercially-produced hot briquetted iron (HBI) contains considerably more phosphorus than scrap. This raises the question of how much dephosphorisation can be achieved when using HBI in an electric arc furnace (EAF), or in oxygen steelmaking, and what the cost of this dephosphorisation will be. A commonly held misconception amongst EAF operators who do not currently use HBI, is that the relatively high level of phosphorus in HBI will make dephosphorisation difficult, if not impossible. The experience of EAF operators who do currently use HBI is that dephosphorisation is easily achieved, with no cost penalty, when a conventional flush slag practice is employed. The production of low 286 phosphorus steel from a high phosphorus HBI charge, with no associated cost penalty, has been demonstrated by trials conducted at BHP's Sydney Steel Mill and routine practice at CASI-MA in Venezuela and other EAF operators.

2024

The history of electric steelmaking is quite short-only little over 100 years from the first trials to melt steel by utilizing electric power. During that period, great advancements have been attained both in furnace equipment and technology, melting practice, raw materials, and products. In this chapter, a short introduction to most significant progresses, features, and phenomena in electric steelmaking are presented. 1.5.1.1. Short History of Electric Steelmaking Until Today The electric arc furnace applied in steelmaking was invented in 1889 by Paul Héroult [1]. Emerging new technology started in the beginning of the twentieth century when wideranging generation of relatively cheap electric energy started at that time. First-generation furnaces had a capacity in between 1 and 15 t. The EAF had Bessemer/Thomas converters and Siemens Martin furnaces as strong competitors, initially. But its niche was the production of special steels requiring high temperature, ferroalloy melting, and long refining times. In the 1960s, with the advent of billet casting, the EAF occupied another niche: it was the melting unit of choice for the so-called minimills, feeding billet casters for the production of rebar and wire rod. In the following two decades, to better support the short tap-to-tap time required by the billet casters, the EAF reinvented itself as a melting-only unit. Steel refining was left for the recently introduced ladle furnace. Large transformers were introduced; ultrahigh-power furnaces developed, which were made possible by adopting foaming slag practice. This way, tap-to-tap time became close to casting time. By 1985, a new niche for electric steelmaking began to be taken: flat products, through thin slab casting and direct rolling. Also this process route has achieved a significant role in world steel production. Altogether, the basic argument is that most of the ferrous scrap worldwide is recycled and refined to special steels just via electric furnaces. EAFs are versatile, charging everything from all sorts of scrap to hot briquetted iron (HBI), direct reduced iron (DRI), pig iron, hot metal. EAFs may produce all type of steels: long and flat, carbon and alloyed, for

2024, ABM Proceedings

Resumo O trabalho está baseado na análise de dados de perto de 200 fornos elétricos a arco de diferente design: convencional, de corrente contínua, de carcaças gémeas, com preaquecimento de sucata no transportador ou em shaft, etc. Incluem-se fornos que processam principalmente sucata, e fornos com carregamento parcial de gusa sólido ou líquido, ferro briquetado a quente (HBI) ou ferro esponja (DRI) a frio ou a quente. São avaliados os consumos de energia elétrica, oxigênio, gás natural e materiais carbonosos; os tempos entre vazamentos, com forno ligado e com forno desligado, assim como a produtividade horária. Com os dados obtidos, se analisa a influência dos metálicos (e seu estado térmico ao momento do carregamento), e o design do forno, sobre os consumos específicos mencionados e a produtividade. Palavras-chave: Forno eléctrico a arco; Metálicos; Benchmarking; Preaquecimento de sucata; Consumo de energia; Produtividade.

2023, ABM Proceedings

2023

2023, Revue de métallurgie

and the author. * Les projections sont présentées à l'indicatif et non pas au conditionnel. La Revue de Métallurgie-CIT Novembre 2000 1349 * In the French language, these possible futures (FUTURs possIBLES) are called "futuribles".

2023

The present paper highlights the main differences between Consteel® and conventional EAF technologies regarding scheduled and unscheduled maintenance practices. The study has been made on the basis of data collected in plants with high maintenance standards and more than 10 years of operational experience. These data have been analyzed and organized in a comparison table where they have been associated with the relevant maintenance costs. The comparison shows that the Consteel® technology achieves a significant reduction in the overall maintenance costs compared to a conventional EAF.

2023, Archives of Metallurgy and Materials

One of the main problem of steel melting in EAF technology are excessive contents of nitrogen in a semi steel products. This concerns in peculiarity these grade of steels from which the good plasticity was required or steels designed to production of the wire rod for welding electrode. The object of investigations was the range of changes of the nitrogen concentrations in the liquid steel immediately before tapping from the UHP – EAF’s (105 MVA) in dependence of the kind of metallic charge (scrap and other iron sources). Then the changes of nitrogen content were qualified during steel treatment in a ladle furnace and pick up of nitrogen content during continuous casting of rectangular billets was established. The theoretical description of nitrogen absorption during steel tapping and continuous casting was applied. The dependence among the nitrogen concentration in liquid metal and quantity of the carbon oxidized during oxygen injection was determined. The influence of electric para...

2023, Energy

A model of the EAF energy efficiency was developed based on a closed mass and energy balance of the EAF melting process. This model was applied to industrial EAFs in steel industry charged with scrap or with mixes of scrap and DRI. Complex mass and energy conversion in the EAF was simplified with the introduction of mass and energy conversion efficiencies for the conversion of oxygen and the energy conversion of electrical energy in the electric arcs, chemical energy from the oxidation reactions in the melt and energy from the combustion of burner gas. It turned out that close agreement with observed process parameters from 16 EAFs is obtained by slight variations of the efficiency values. Especially the sensitivity of the steel temperature from the energy conversion efficiency of the electric arc energy indicates the importance of efficient foaming slag operation in EAF steel making. Characteristics and process parameters of DRI charged EAFs are discussed. Model results for a series of case studies illustrate the correlations between DRI chemical composition, DRI portion, oxygen consumption, etc. with electrical energy demand in order to indentify cost-effective EAF process conditions.

2023, Scandinavian Journal of Metallurgy

2023, Heliyon

A study of energy optimization derived from simulation software has been done for the high-intensity energy of an Electric Arc Furnace (EAF), hot metal charging within the cooler duct dedusting system. The present work aims to develop a dynamic model of the EAF operation based on mass and energy balances integrated with simulation of the dedusting system with hot metal charging system using MATLAB ® and Computational Fluid Dynamics (CFD). The effect of various percentages of hot metal charging on EAF performance and the dedusting system was simulated and validated from the real EAF data plant from one of the steel manufacturer companies in Indonesia. Three cases for the EAF with various hot metal (HM), sponge iron, and scrap iron charging compositions and four cases for the EAF with post-combustion CO have been developed. Careful observation shows that the electric arc power consumption can be reduced down to 72.9 MWh from 87.4 MWh (ca. 16% more efficient) while at the same time increasing the HM charging temperature at the endpoint of the duct dedusting system up to 900 • C from 540 • C (app. 65% higher). Additionally, advanced simulation of an EAF with post-combustion CO shows that power consumption can be decreased to 59.9 MWh (ca. 30% more efficient).

2023, Natural Gas Markets in India

2022, Anais do Seminário de Aciaria, Fundição e Metalurgia de Não-Ferrosos

2022

booklet 2 European Academic Symposium on EAF Steelmaking, 12-13 May 2016, Aachen, Germany 2 Optical emission spectrum measurement in on-line analysis of scrap melting in electric arc furnaces Matti Aula, Mikko Jokinen, Timo Fabritius 1 University of Oulu, Process Metallurgy Research Group P. O. Box 4300, 90014 University of Oulu, Finland 2 Luxmet Oy, Oulu, Finland Matti.aula@oulu.fi

2022, Journal of Iron and Steel Research International

2022

Electric arc furnace (EAF) is an energy intensive process and one of major routes of steelmaking. EAF productivity and steel production cost are major concern for EAF technology development. ABB developed electromagnetic products for EAFs over 70 years ago. Over 150 units were installed worldwide with increased productivity, improved steel quality and operation safety. Since 2009, ABB has committed to the technology and product development of ArcSave, a new generation of electromagnetic stirrer for EAF application. ArcSave has been investigated through numerical simulation [1], EAF water model experiments [2] and plant test with ABB previous electromagnetic stirrer [3]. ArcSave product was released in 2014 and first was installed in a 90 ton Arc furnace. Hot test results show a significant iron yield increase and other process benefits which have been presented in the AISTech 2015 conference [4].

2022

2022, Anais do Seminário de Aciaria, Fundição e Metalurgia de Não-Ferrosos

2022

This article presents Romanian steel industry production and environmental efforts in view to achieve the EU environmental standards and regulation and remain profitable. BSE – Badische Stahl Engineering “off gas” concept means “High... more

2022, Anais do Seminário de Aciaria, Fundição e Metalurgia de Não-Ferrosos

The introduction of the EAF Quantum furnace by Primetals Technologies represents an important milestone in the field of electric steelmaking during the last 15 years. In this process the latent and chemical heat of the off-gas generated during a melting process in an EAF is used to pre-heat scrap in an integrated shaft prior the melting of the scrap in the vessel. Combining proven own technologies, Primetals EAF Quantum enables nearly continuous process, cutting down idle times and enhancing availability for production. The essential benefits will be shown in this Paper.

2022, ABM Proceedings

Gerdau Monroe has installed and commissioned the Tallman Supersonic Carbon Injection system (TSCi™) for use in their 135-ton Electric Arc Furnace (EAF) located in Monroe, MI. TSCi™ is an innovative injection system with the primary aim of improving injection carbon delivery to the steel bath by increasing efficiency. It is proven technology with installations at numerous steelmaking facilities all over the world. Results from installation and commissioning of TSCi™ at Gerdau Monroe will be reported as well as on-going trials and optimization efforts. Standard injection systems deliver carbonaceous material from a vessel to the EAF using air where it is injected through a lance pipe or oxy-fuel burner. Using this method, material delivery to the EAF is limited by the pressure and velocity of the transport air. Loss of efficiency can be observed by looking at the quality of the injection carbon stream during operation or by measuring loss on ignition of EAF slag or off-gas system dust. TSCi™ uses a patented design and proprietary technology to improve delivery of carbonaceous material to the EAF. Using this method, savings at Gerdau Monroe were realized by reducing the amount of carbon used in each heat while maintaining or improving upon existing foamy slag practice. As well, significant savings were achieved as a result of reduced FeO content in the slag and improved recovery of iron. Additional savings can be realized by using a smaller mesh material to take advantage of lower material cost and higher injected surface area. Other inherent benefits to improved injection carbon include lower energy and electrode consumption, reduced refractory wear and reduced maintenance cost.

2022

A theoretical overview about the slag structure, their compatibility with the refractories and their foaming behavior has been realized. Such a theoretical background is the basis for the performed experimental trials focused on the use of crude MgCO3 injected within the slag. This raw material can develop the gaseous phases (CO2) needed for the slag foaming and it can provide the MgO useful to make the slag compatible with the refractories. The experimentation has been performed through the injection of different specific quantities of MgCO3 and the obtained results pointed out a significant decrease of refractory wear, a saving of the specific electric energy, a decrease of the lime injection and of the anthracite powder needed to induce the foaming effect.

2021, Anais do Seminário de Aciaria, Fundição e Metalurgia de Não-Ferrosos

One of the most important factors in successful electric steelmaking is the continuous observation of the process and the reaction to it. Traditional electric arc furnace control uses mainly direct controls which are based on the electric power input. Not considering the furnace conditions will necessarily lead to suboptimal operation in terms of energy consumption and productivity not fully utilized. The ARCCESS X-PACT® FEOS Furnace Energy Optimization System includes the simultaneous control of the transformer tap, impedance operating point, reactor tap, burner and carbon injection, DRI charging control, post combustion-oxygen injectors, as well as a reproduction and simulation of process scenarios for the purpose of making offline studies and for system optimization. FEOS has proven in practical operation benefits of high melting yields, no interruptions through switch offs in borderline temperature area, rapid reaction, reproducible and efficient electrical energy input and short tapto-tap times [1]. (1).

2021

With an increasing demand for steel world-wide, scrap metal has become a critical resource, where scrap consumption has been growing at 12% per annum in steel industry. The major environmental benefits of using recycled steel or scrap is shown in the fact that the production of one tone of steel through the EAF routes consumes only 9 - 12.5 Gj/tcs, whereas the BOF steel consumes 28 - 31 Gj/tcs, this significant saving in energy means in addition to saving in energy costs, minimizing CO2 emissions, reducing the solid waste of steel and reducing the consumption of stockpile. But the increased use of scrap metal in the steelmaking process results in rising the content of some residual elements in the recycled materials. It is also agreed that the behaviour of copper and tin in the reheating step during the hot working of steel is the main reason for the appearance of hot shortness, in which during continuous casting or hot rolling, the liquid copper-rich phase weakens grain boundaries ...

2020, Transactions of the Indian Institute of Metals

Deoxidation was carried out by addition of ferrosilicon and ferromanganese. Temperature, chemical composition, concentration of dissolved oxygen, total oxygen content of bath and composition of deoxidation products were collected. Temperature and bath composition data taken after 5-10 minutes were used to thermodynamically calculate the dissolved wt. pct. oxygen and inclusion composition. Stirring is essential for speedy attainment of equilibria for SiO//2 and MnO reactions. The variation in total oxygen as a function of time after addition of deoxidizer was in conformity with literature findings.

2020, Architect

The most common materials are often presumed to have reached technological maturation-meaning that further advances are either not achievable or economically feasible. However, breakthroughs continue to occur, even with familiar material technologies. Bainitic High Strength Steel (BHSS) is one such recent innovation. Developed by Detroit entrepreneur Gary Cola, the so-called "Flash Bainite" process renders a material seven percent stronger and 30 percent more ductile than existing high-strength steel. The key is the use of higher temperature ovens for a much shorter amount of time-1,100 C versus 900, and for 10 seconds as opposed to several hours. Researchers at Ohio State University have corroborated Cola's invention. "We think that, because this new process is so fast with rapid heating and cooling, the carbides don't get a chance to dissolve completely within austenite at high temperature, so they remain in the steel and make this unique microstructure containing bainite, martensite and carbides." Flash Bainite steel will likely find its first application in automobiles, and will eventually be used in high-performance buildings. Its high strength and ability to be lengthened and thinned beyond other steels will allow the design of lighter, more efficient, and less energy-intensive structures.

2018

There is an important variation in scrap quality and alternative iron sources depending on country and region. esides, a variety of furnace designs are available. This paper looks at the innuence of metallics type and AA design on specific consumption of energy, ooygen and other inputs, as well as on some productivity indicators, based on a survey of published figures of AAs around the world. The results obtained are analysed in detail.

2016

After almost half a century of experience in using DRI/HBI in electric arc furnaces (EAFs), and taking into account the decrease of natural gas cost in the USA, it is interesting to revisit some trends and controversial issues around this alternative iron source. This paper reviews aspects like the evolution of iron ore quality and its influence on EAF operation; DRI stockpiling and transport, regarding the risk for self-combustion; optimum charge design; cold DRI/HBI charging (fifth hole, bucket, transporter); hot charging (ways and results); carbon content, metallization and silica in DRI/HBI, and its influence on EAF operation and performance; oxygen / carbon balance; chemical energy and DRI/HBI charge.

2016

After almost half a century of experience in using DRI/HBI in electric arc furnaces (EAFs), and taking into account the decrease of natural gas cost in the USA, it is interesting to revisit some trends and controversial issues around this alternative iron source. This paper reviews aspects like the evolution of iron ore quality and its influence on EAF operation; DRI stockpiling and transport, regarding the risk for self-combustion; optimum charge design; cold DRI/HBI charging (fifth hole, bucket, transporter); hot charging (ways and results); carbon content, metallization and silica in DRI/HBI, and its influence on EAF operation and performance; oxygen / carbon balance; chemical energy and DRI/HBI charge.

2016

This paper reviews aspects of DRI/HBI use and production, like the evolution of iron ore quality and its influence on EAF operation; DRI stockpiling and transport, regarding the risk for self-combustion; optimum charge design; cold DRI/HBI charging (fifth hole, bucket, transporter); hot charging (ways and results); carbon content, metallization and silica in DRI/ HBI, and its influence on EAF operation and performance; oxygen/carbon balance; chemical energy and DRI/HBI charge. Authors Sara Hornby (top row, left) principal,

2016

The paper discusses the evolution of electric steelmaking technology in South America, Central America and Caribbean countries, on the basis of raw material utilization, electric energy and alternative energy use, start-ups, retrofitting... more

2016

DR Tech and DRG were formed with the core knowledge base of the most important and oldest Direct Reduction group in Venezuela, the leading country in this industry. In 2015 DRG presented a new project development for a 2.0 MTPY HBI plant... more

2016

DRI/HBI – exploding the myths Half a century of DRI/HBI electric arc furnace (EAF) use, coupled with low-cost American natural gas (NG) suggests a needed review of trends and controversial issues surrounding this alternative iron source (AIS). Aspects such as iron ore quality and operational influence; DRI stockpiling and transportation auto-ignition; optimum charge design, temperature and mechanism; compositional impact on EAF operation and performance; oxygen/carbon balance; and chemical energy need to be addressed.

2016

This paper reviews aspects of DRI/HBI use and production,
like the evolution of iron ore quality and its influence on EAF
operation; DRI stockpiling and transport, regarding the risk
for self-combustion; optimum charge design; cold DRI/HBI
charging (fifth hole, bucket, transporter); hot charging (ways
and results); carbon content, metallization and silica in DRI/
HBI, and its influence on EAF operation and performance;
oxygen/carbon balance; chemical energy and DRI/HBI charge.

2015

Developed in Brazil for replacing small open hearth furnaces, the EOF technology has grown and is now striving to occupy its position in the iron and steel world, disputing with the established processes of Electric Arc Furnace (EAF) and the oxygen converter (BOF or LD). Notwithstanding its 24 years of successful operation at the GERDAU Divinopolis plant in Brazil, delivering more than 42 heats per day and about 600.000 t/y liquid steel, and the three efficient units operating in India, the EOF is still little known. This paper endeavors to present the technology with its latest achievements and developments.