SIMETAL Ultimate Leading EAF technology from a single source – powerful, flexible, environmentally compatible

Metals Technologies

www.siemens-vai.com

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Searching for the ultimate high-performance EAF

Your challenge:The global demand for steel continues to grow – and if you intend to be part of this boom, you will have to boost the throughput and production volume of your plant.

What you need now is an electric arc furnace that’s totally top-of-the-line. That combines high capacity with maximum availability. That flexibly processes differ-ent charge materials. And that can pro-duce a range of steel types – without long preparation times that slow down production.

At the same time, it’s crucial to reduce costs both when investing and dur ing ongoing operations. To do this, you need simple, consistent operation, compo-nents with a long service life, ease of maintenance, and reduced personnel requirements.

And naturally, you also need to limit the impact your plant has on the environ-ment – to ensure that you can comply with all regulations into the future and to fulfill your responsibility for ensuring a clean environment.

Is there one solution that meets all these needs?

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Ultimate 120-t EAF

K Productivity 1.8 million tons per year• at 320 net production days/year

K 1-bucket charge• scrap bucket 185 m3

• furnace volume 210 m3

• w/c panel height up to 3.4 m

K Transformer design up to 1,500 kVA/t• 180 MVA for 120 tons tapping

weight• secondary voltage up to 1,500 V

K Utilization of chemical energy• 3 oxygen gas burners • 5 refining combined burners (RCB) • 4 carbon injectors • 4 postcombustion injectors

Conventional 120-t EAF

K Productivity 1.2 million tons per year• at 320 net production days/year

K 2-bucket charge• scrap bucket 130 m3

• furnace volume 145 m3

• w/c panel height up to 2.8 m

K Transformer design up to 1,000 kVA/t• 120 MVA for 120 tons tapping

weight• secondary voltage up to 1,200 V

K Utilization of chemical energy• 3 oxygen gas burners • 3 refining combined burners (RCB) • 2 carbon injectors

Standard is not Ultimate – comparing two types of EAF

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Ultimate EAF at start-up

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SIMETAL Ultimate – the best from 40 years of experience

Our solution:SIMETAL Ultimate bundles over 40 years of experience and innovative strength from Siemens VAI in the field of electric arc furnaces. Just about everything is “ultimate” in this new generation. State-of-the-art electric steel production technology and design features deliver maximum furnace performance – in terms of both quantity and quality.

Productivity: more energy input, greater performance Extremely high energy input rates of up to 1,500 kVA/t liquid, innovative RCB technology to boost performance, and an enlarged furnace for single-bucket charging – only SIMETAL Ultimate offers all of these features in this combination.

The result is extremely short tap-to-tap times – and therefore a real boost in pro-ductivity. At a capacity of 120 tons, for example, SIMETAL Ultimate delivers the same productivity as a 180-t standard EAF – or 50% more productivity at the same tapping weight.

Flexibility: it processes everything Whether you’re working with 100 per-cent scrap or any combination of scrap, sponge iron, and/or hot metal – the charging materials can be loaded as desired in the required proportions. This extreme flexibility provides a solid basis for high throughput as well as reduced operating costs, because SIMETAL Ultimate cost-effectively pro-cesses whatever is available on the spot markets.

Availability: top resultsSIMETAL automation enables simple, reliable operation. The use of well-designed, high-quality components ensures maximum availability. And all components, from hydraulics to elec-trode control, have power reserves.

Investment: down with costs, up with earningsWhat does top performance mean in terms of investment costs? It means that SIMETAL Ultimate delivers 50% more pro-ductivity compared with standard EAFs – with the same building, crane, and ladle furnaces, and therefore significantly reduced investment costs.

Advantages of SIMETAL Ultimate

K Cost savings – low investment and conversion costs thanks to highly efficient use of space, energy, raw material, and personnel

K Highest production output – 50 percent more productivity compared with standard EAFs

K Maximum throughput – due to extreme flexibility with raw materials and finished products

K Highest availability – through simple and reliable operation with sophisticated automation and sturdy mechanical components

K Environmental compliance – thanks to the efficient use of energy and application of environmental technologies

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Smart operations: the automationThe automation in SIMETAL Ultimate supports efficient operation, slows down mechanical wear, and helps ensure top quality for the produced steel – for exam-ple, with optional infrared slag detection and robot-controlled cleaning.

An overview:�K Optional slag door pusher and clean-

ing robot – for efficient operation and maintenance

�K Tapping from the main pulpit – for safe and easy operation

�K Automatic scrap bucket positioning, controlled by main pulpit – for highest precision and efficient processes

�K Optional slag detection using an infrared identification system (IRIS) – the precise and efficient way to improve steel quality

�K Automatic sand filling – for minimizing personnel requirements

Really robust: the mechanical design The mechanical engineering is designed for steady and exceptionally low-wear operation, with maintenance and repair limited as much as possible to planned periods. And when maintenance is needed, then it’s fast, efficient, and cost-effective. How does SIMETAL Ultimate make this possible?

Here are a few of the ways:�K The prismatic roller guide system for

electrode columns – for minimized vibration and electrode breakage

�K The sturdy, heavy construction of the tilt platform – for a long service life

�K The special way the panel is affixed to the shell cage – to avoid panel movements

�K The sealing between panels – for optimal tightness of the furnace

�K The construction of the slag zone panel – for increased service life of the refractory in the slag zone, which minimizes refractory repair times

�K The gantry design with a single-point roof lifting system – for easy access during maintenance

Produce, produce, produce: SIMETAL Ultimate – maximum toughness, maximum availability

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Your ultimate advantage

All key mechanical components and the automation are made by Siemens VAI. And you can be certain that as the EAF market leader, we deliver proven, supe-rior technology. Our own workshops ensure that spare parts are always avail-able right away – anywhere in the world.

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From 90 to 320 tons: data, facts, background

RCB 6 & C 3

Burner 7

Burner 1

RCB 2 & C 1

Burner 3 RCB 4 & C 2

Burner 5

Off-gas

PC 4

RCB 6 & C 4

RCB 1 & C 1

PC 1

RCB 2 & C 2

PC 2

RCB 3

PC 3

RCB 5 RCB 4 & C 3

Off-gas

Conventional 120-t EAF

Ultimate 300-t EAF

The SIMETAL Ultimate concept features a larger diameter, which permits single-bucket charging – thereby reducing the power-off time by about two minutes. It also ensures an improved radius-to-power-input ratio for an optimized re fractory index.

The transformer delivers 1.3 to 1.5 MVA/t liquid, of which up to 1.2 MW of active energy per ton of liquid can be used. RCB technology allows the complete exploita-tion of the chemical energy, regardless of whether an oxygen or carbon lance is used.

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Months120 1 2 3 54 6 7 8 9 10 11

1st heatJan 13, 2007 Jan 31, 2007

134 heats40,395 tons liquid

10th month664 heats

211,000 tons liquid

Contract: Nominal/month185,000 tons

2,200,000 tons/year

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Tap weight = 90 t Tap weight = 120 t

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s/m

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uid

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Months120 1 2 3 54 6 7 8 9 10 11

1st heatJan 13, 2007 Jan 31, 2007

134 heats40,395 tons liquid

10th month664 heats

211,000 tons liquid

Contract: Nominal/month185,000 tons

2,200,000 tons/year

900

800

700

600

500

400

300

200

100

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Tap weight = 90 t Tap weight = 120 t

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Start-up curve of 90-/120-t EAF

Start-up curve of 320-t EAF

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In electric steel production, oxygen plays a crucial role on the exothermic reactions that support the melting and refining process. These reactions are also responsible for heat distribution in the liquid metal. The goal is to find the process routes and mechanical components with the highest availability. In 1995, we developed Refining Combined Burner (RCB) technology that combined a conventional oxy/gas burner with a supersonic oxygen injection lance.

Injection process management Based on RCB technology, this high-power performance package operates completely automatically in accordance with the EAF process. The system includes oxy/gas burners and postcombustion oxygen injectors, and permits the injection of not only carbon but also any kind of fine material such as FeSi, FeCr, and dust. The injection pro-cess enables flexible and profitable solutions for any pro-duction route, ranging from 100% scrap to DRI/HBI or hot metal for carbon and stainless steel production.

RCB technology The innovative RCB system is especially designed to opti-mize the injection of oxygen and carbon into the EAF. It ideally complements the electric arc energy input with additional exothermic energy created by chemical reac-tions of fuel or gas, oxygen, and carbon injected into the furnace. The complete RCB unit includes a nose panel that houses the RCB and the carbon injection lance.

Get the ultimate performance from your EAF – with RCB technology

Ultimate and RCB

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The unique design of the nose panel provides a number of advantages compared with other systems:

K The distance between the oxygen/carbon streams and refractories minimizes refractory wear

K Ideal distance of the lance tip from the steel bath to enable a supersonic, laminar oxygen stream for a distance up to 1.8 meters; the nose panel positions allow a multipoint injection for a strong stirring of the bath

K Nose panel geometry that enables an oxygen and carbon impact angle for deep penetration into the slag and steel bath for intensive reactions

K Powerful and efficient burners K Recovery of postcombustion energy within the EAF

Main benefits: With more than 80 successfully operating RCB installa-tions worldwide, the benefits can be summarized as follows:

K Ideal for all furnace types with varying raw-material inputs and produced steel qualities

K Highly effective O2 input into steel bath at high penetration speeds in support of scrap melting

K High degree of bath agitation and heat generation for elimination of cold spots

K Efficient carbon/oxygen injection for faster and more consistent buildup of foamy slag

K Shorter power-on time and considerably lower conversion costs

K Closed-door operation for reduced energy losses and false-air intake

K Possibility for steel decarburization and recarbonization, if required

K High degree of personnel safety K Fast return on investment

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04.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0Diameter steel bath in m

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A: DSF 100 t – 100 MVA; 100% scrap; 3 x 2,400 Nm3/h O2

B: MMK, Russia; EAF 180 t – 150 MVA; 60% scrap – 40% HM; 5 x 2,400 Nm3/h O2

C: Çolakoglu, Turkey; enhanced oxygen injection 7 x 2,600 Nm3/h O2 – total 18,000 Nm3/hD: Çolakoglu, Turkey; EAF 300 t – 240 MVA; 100% scrap; 5 x 2,750 Nm3/h O2

Nose design for optimized impact angle

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Excellence from experience –selected success storieswith SIMETAL Ultimate

Success stories – showing how our technology delivers excellent results

NMLK – Kaluga Minimill, Russia

Revda – Maksi Group, Russia

Çolakoglu Metalurji A.S., Gebze, Turkey

Transformer: 740 – 1,350 V150 MVA

740 – 1,025 V100 MVA + 20%

800 – 1,600 V 240 MVA + 20%

Tapping weight: 120 t 90 t 120 t 320 t

Oxygen total: 40 Nm3/t 33 Nm3/t 39 Nm3/t 40 Nm3/t

Gas: 5 Nm3/t 5 Nm3/t 6.5 Nm3/t

Electrical energy: 350 kWh/t 325 kWh/t 334 kWh/t 360 kWh/t

TTT: 36 min 36 min 45 min 55 min

Productivity: 200 t/h 150 t/h 159 t/h 350 t/h

Production: 2,400,000 t/yr

RCB: 5 RCB/3.5 MW O2

2,500 Nm3/h3 RCB/3.5 MW O2

2,000 Nm3/h10 RCB/3.5 MW O2

2,750 Nm3/h

Burner: 2 burners; 3.5 MW 4 burners; 3.5 MW

Carbon injectors: 4 x 60 kg/min 3 x 60 kg/min 3 x 60 kg/min

PC O2 injectors: 4 x 400 Nm3/h 4 x 400 Nm3/h

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SIMETAL EAF Ultimate epitomizes the 40 years of experience in plant construction.

The integration of Voestalpine Industrieanlagenbau GmbH – and therefore VAIFuchs GmbH as well – into Siemens AG raised our expertise in complete systems to new heights. The success stories presented below provide just a brief im- pression of our comprehensive experience.

The heart of a new minimill

Customer: NMLK – Kaluga Minimill, Russia

Plant type: 120-t EAF Ultimate

Our solution: Single-bucket-charged EAF with high power input

The result: Ultimate productivity at low cost to feed highly productive minimill

Ultimate charging

Customer: Revda – Maksi Group, Russia

Plant type: 320-t EAF Ultimate

Our solution: Replace the traditional Siemens-Martin furnace with a totally optimized production line for steel billets. We supported the cus-tomer during the complete integration of the system; in addition, we developed a structured financing package together with the customer.

The result: The project was executed very quickly, considering the materials available. The designed capacity was achieved after only six months, which resulted in an extremely short start-up curve. This system has proven how Ultimate technology increases productivity in practice. This was just one of the many reasons that VAI Fuchs was awarded two more orders for the same equipment, this time for the entire production line.

The world’s most productive furnace utilizing scrap metal

Customer: Çolakoglu Metalurji A.S., Gebze, Turkey

Plant type: 250-t EAF Ultimate

Our solution: Among the world’s largest and most productive electric arc furnaces utilizing scrap metal; the development of this furnace has enabled us to implement an economical minimill concept for the production of flat steel products as well.

The result: Minimized investment and optimized consumption charges

Competence Center: Siemens VAI Metals Technologies GmbHReithallenstr. 1 77731 Willstätt-Legelshurst, GermanyPhone: +49 (0)78524100Fax: +49 (0)785241141E-mail: electricsteelmaking.metals@siemens.com

Headquarters:Siemens VAI Metals Technologies GmbHP.O. Box 4, Turmstr. 44 4031 Linz, AustriaPhone: +43 732 6592-0Fax: +43 732 6980-0E-mail: contact.metals@siemens.com

www.siemens-vai.com

Order No. E10001-M3-A30-V2-7600 Dispo No.: 21661 K-No.: 28103 | Printed in Germany GB 100831 WS 06110.5 | © 06.2011, Siemens AG

All rights reserved. Subject to change without prior notice. SIMETAL is a trademark of Siemens AG.

The information provided in this brochure contains merely general descriptions or characteristics of performance which in actual case of use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract.