Objective
Energy savings through hot charging slabs into the mill dispite the problems of a variable order book. The aim is to maximise the heat contained in the hot slabs, thereby reducing the energy consumption of the reheating furnaces.
This is achieved by :
- A modification of the metal management procedure between steelworks and the rolling mill by :
- gatherings or orders
- gatherings of slabs
- time schedules
- Transfer systems of hot slabs towards the processing site
- A processing site where all the operations on the hot products will be carried out by :
- new oxy-cutting yards
- mechanical deburring device
- Computer control of the reheating furnaces.
The project was represented for a 950000 tons annual total production, among which 450000 tons of hot feeding charge. The expended savings amounted to 6158 TOE/year or 0.137 TOE/hot rolled ton.
Savings achieved.
With cold slabs the energy consumption is around 350 therms/t.
The savings achieved by hot charging are :
At the furnaces
By using higher charging temperatures with mother slabs 172 therms/t, daugther slabs 76 therms/t making an average saving of 90.4 therms/t.
Using the computer
By reducing exhaust temperature and achieving correct slab exit temperature 17.3 therms/y.
At scarfing
There has been a decrease in scarfing requirement following the reduction of cooling cracks. This results in a gain of 5 kg of steel per tonne. The energy saved on the meltin of this steel is 1.4 therms/t. As there is less scarfing, a saving is made in the combustion of the scarfing torches of 1.9 therms/t.
At flame cutting
The higher is the slab temperature the higher is the torck speed. Saving is estimated at 1.8 therms/t.
The positioning of the torches by measuring the slab temperature has resulted in a gain of 6.4 kg of steel per tonne with a resultant saving on reheating of2.2 therms/t.
The total of these savings amounts to 115 therms/t.
Degree of success : 84 %
In the future it is intended to further improve the scheduling from the continuous caster to the rolling mill by approximately 15 %, ie for a production of 870000 t/year and 45 % hot charging a saving of 50 Mtherms/year or 5000 TOE/year could be achieved.
Problems : The hot flame cutting and the mechanical deburring devices are original techniques. These two installations required adjustement periods longer that what was foreseen.
The experience acquired during the gradual putting into action of this project required the modification of several initially foreseen stages such as.
So it was that several electromechanical rotating grippers for the handling of hot slabs had to be replaced by a set of non rotating mechanical grippers.
Furthermore, the heat insulated casings which did not bring the foreseen savings were replaced by a computerized running between the continous casting and the rolling mill, which allows a maximum reduction of the intermediate storage time.
To use at the maximum the heat (calories) contained in the hot slabs and consequently reduce the heat consumption of the reheating furnaces.
This will be achieved by :
1. A modification of the metal management procedure between steelworks and the rolling mill.
2. Transfer systems of hot slabs towards the processing site.
3. A processing site where all the operations on the hot products will be carried out.
4. Heat consumption in the reheating furnaces has been reduced by using a computer controlled regulation system.
The project is in the building phase, with a new feeding system under consideration. In view of the importance and the cost of this system, the initial study is being repeated and the system should be operational by mid-86.
Based on 1984 data, it is estimated that the total energy saving will reach 0.0137 TOE/T of steel (against a forecast of 0.0136 TOE/T).
The volume to be handled under this project depends on the customers orders and to which extent they can be grouped. To improve this, a special planning team has been set up.
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Coordinator
1360 TUBIZE
Belgium
The total costs incurred by this organisation to participate in the project, including direct and indirect costs. This amount is a subset of the overall project budget.