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SIMETAL EAF FAST DRI

The future of DRI melting

Answers for Industry.

Local solutions for global demands

80
70.37 Mt

70

60

50

40

30

20

10

0
1970 1980
HDR

HBI

1990

2000

2010

CDRI

Asia
Middle East
North America
South America
Africa
C.I.S.

31.11 Mt
20.95 Mt
9.45 Mt
6.92 Mt
5.57 Mt
5.54 Mt

79.54 Mt

Increasing world DRI production

Middle East and Asia and especially India are the leading DRI producers

Your challenge
The world needs steel. Particularly in newly industrialized
countries, the demand for structural steel is growing at
a tremendous rate and these countries want to replace
costly steel imports with local steel production.

Todays market requirements:

Growing demand for steel

Regions that have easy access to gas are predestined for

steel production using DRI, in either cold or hot conditions. The Middle East region is perfectly suited for DRI
production, because abundant gas resources along with
comparably low gas prices are the cornerstone of successful DRI-based EAF steelmaking. Other regions around the
world also have a growing DRI-based EAF steel production:
DRI can also be produced in a coal-based process.

High gas resources in regions like the Middle East

resulting in easy DRI-based steelmaking
Weak power grids requiring the highest flicker
compensation to ensure best power quality
The need for sustainable steel production
Use of local iron-ore resources
To decrease conversion costs and receive an
attractive ROI, the challenges are:
Easy DRI access
Reduced operational expenditures
High productivity and efficiency
Totally integrated automation
Better steel quality

26
31
11

37

In trillion m:
117

64

Cumulative
production

3
15

5
35

3
8

Reserves

7
16

75

16

Resources

25

Reserves:
191.9 trillion m (=247.9 Gt SKE)
Production:
3.0 trillion m (=3.9 Gt SKE)

World gas resources

Boost your profits with FAST as

a new solution or modernization

FAST in working position

FAST in tilting position

FAST in new installation

The SIMETAL EAF FAST DRI enables DRI melting in a large
hot heel, which results in a pure flatbath operation. The
process is characterized by continuous DRI feeding, efficient and process-related oxygen and coal injection, foaming slag control by means of roof lances, and eliminates
the need for the installation of additional burner power.

FAST for your existing EAF

Increase the efficiency and productivity of your existing EAF.

In combination with the furnace advanced slag-free tapping system (FAST) with a siphon design for slag-free tapping, the new furnace concept permits feeding, tapping,
and taphole refilling during power-on continuous DRI.
In addition, the continuous input of electrical energy not
only improves productivity, it is also important for the
energy infrastructure with respect to flicker problems in
the regions power grids. The nearly constant heat load
extends refractory durability and minimizes equipment
wear through reduced thermal stress.

Due to an EAF modernization which is replacing the existing lower shell, you can get the opportunity of the furnace
advanced slag-free tapping system (FAST).
It is not necessary to replace components like the roof,
electrode-supporting arms, and dedusting system. With a
new lower shell and FAST, the furnace can achieve higher
productivity levels with a similar input of energy. Another
option is to reduce energy input and still obtain similar
productivity and improved efficiency.
If you modernize your existing EAF with Siemens VAIs new
technology, not only will your productivity and efficiency
grow, your overall capital and operating expenditures will
be reduced accordingly.

All of the advanced technologies just described for

Siemens VAIs new SIMETAL EAF FAST DRI will result in
lower capital and operational expenditures for your plant.

Competence in DRI melting

ELECTRICAL POWER INPUT

DRI Feeding (kg/min.MW)

OXYGEN INPUT
Nm/h

MW
100

5,000

1 heat

80

4,000

60

3,000

40

2,000

20

1,000

0
-10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60
TIME (min)
Elec. Energy

DRI

O Lance

Feeding, tapping, and taphole refilling under power-on conditions

Leading position in DRI-EAF technology

1
5 6

2
3
4

10
8 9

= EAF DRI
= EAF

12

11

Rocky Mountain Steel, Pueblo, U.S.

Altos Hornos de Mexico S.A. (AHMSA), Monclova, Mexico

Saudi Iron & Steel Company EAF 2, Al Jubail, Saudi Arabia

HYLSA, Monterrey, Mexico

Saudi Iron & Steel Company EAF 3, Al Jubail, Saudi Arabia

HYLSA, Puebla, Mexico

Saudi Iron & Steel Company EAF 4, Al Jubail, Saudi Arabia

Egyptian Sponge Iron & Steel Company ESISCO, Sadat City, Egypt

Suez Steel, Suez, Egypt

Scaw Metals, Johannesburg, South Africa

National Steel Company Ltd./NASCO, Dammam, Saudi Arabia

Qatar Steel, Mesaieed, Qatar

10

Saudi Iron & Steel Company EAF 1, Al Jubail, Saudi Arabia

Saudi Iron & Steel Company EAF 5, Al Jubail, Saudi Arabia

11

Krakatau EAF 5, Cilegon, Indonesia

Krakatau EAF 6, Cilegon, Indonesia
Krakatau EAF 7, Cilegon, Indonesia

12

BMM ISPAT, Karnataka, India

4

Highly productive and

low-cost DRI-based EAF steelmaking

Increases productivity by 10%

Our solution
SIMETAL EAF FAST DRI provides a continuous DRI melting
process. There is no need to stop electric power input or
the DRI feeding during tapping: Tapping and tap-hole refilling are performed under power-on conditions. This
achievement is possible thanks to a revolutionary mode
of shell movement combined with FAST, a slag-free tapping system. Siemens VAI developed its new SIMETAL EAF
FAST DRI as an improved DRI-based EAF process that can
meet the growing demands of DRI-based steelmaking.

Advantages of SIMETAL EAF FAST DRI,

based on cold DRI:
10% shorter tap-to-tap times

Due to its improved shell design and extensive liquid heel

operation, the DRI melting process is much more efficient.
In addition, slag carryover is reduced to an absolute minimum as a result of its siphon-type tapping channel design.
Thanks to its sophisticated modernization concept, even
existing furnaces can benefit from the major improvements of the FAST DRI system.

Slag-free tapping for better steel quality

Virtually no power-off times thanks to FAST tapping

Non-stop DRI feeding
Tapping and taphole refilling during power-on
20 kWh/t less energy consumption
10% less electrode consumption
10% higher productivity with a 150-ton EAF
Lower consumption of ladle additions and refractory
Higher alloy yield and better desulfurization
Reduced temperature loss
Lower tapping temperature

To boost productivity even more, it is possible to use hot

DRI with the FAST DRI system. Therefore, the hot link
our own development feeds the DRI at a temperature
of 600 C to the EAF.
The development of the SIMETAL EAF FAST DRI is the
outcome of our extensive experience and expertise with
the DRI process, and confirms Siemens VAI as the worlds
leaders in DRI EAF technology.

Competence Center:
Siemens VAI
Metals Technologies GmbH
Reithallenstr. 1
77731 Willsttt-Legelshurst, Germany
Phone: +49 7852 4100
Fax:
+44 7852 41141
E-mail: electricsteelmaking.metals@siemens.com
Headquarters:
Siemens VAI
Metals Technologies GmbH
P.O. Box 4, Turmstr. 44
4031 Linz, Austria
Phone: +43 732 6592-0
Fax:
+43 732 6980-0
E-mail: contact.metals@siemens.com
www.siemens-vai.com
Order No. E10001-M3-A143-V2-7600
Dispo No.: 21661 K-No.: 28103 | Printed in Germany
GB 120677 PP 08121.5 | 08.2012, 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.
All rights reserved. Subject to change without prior notice.
SIROLL and SIMETAL are trademarks of Siemens AG.