Tenova papers at AISTech2023

Advancements in Scrap Optimization Leading to Lower Steelmaking Production Costs

by Vittorio Scipolo, Tenova Goodfellow Inc., Douglas Zuliani, Tenova Goodfellow Inc.

iSCO is the main tool in Tenova’s Intelligent Scrap Yard Management System for optimization of the scrap mix cost charged in basic oxygen furnaces (BOFs) and electric arc furnaces. Scrap, composition and transformation costs are fundamental constraints to consider during process optimization. The type of scrap loaded in the furnace can be properly optimized to guarantee tapped steel will meet the required specification at the minimum overall cost. iSCO takes into account all scrap mix constraints, including each material's chemical analysis, weight and volume, guaranteeing overall cost is optimized. The iSCO module and its integration at two North American BOF plants will be presented in this paper.

Date: Monday, May 8

Time:9:30 AM - 10:00 AM

Room:410A

Master Session: Oxygen Steelmaking: Scrap

Decarbonizing the Iron and Steel Industry Under the New Energy Order

by: Francesco Memoli, Tenova Inc., Claudio Galimberti, Rystad Energy

How is the new energy scenario influencing the geography of the steel industry? Efforts to decarbonize steel production are underpinned by new legislation, but such efforts could run afoul of world trade rules. Who benefits most from this evolving situation and at what pace will our industry transform?

Date: Monday, May 8

Time: 9:30 AM - 10:00 AM

Room:330A

Master Session: Decarbonization: New Decarbonization Technologies

Advanced Water Leak Detection Solutions for EAF Steelmaking Using Offgas and Acoustic Technologies

by: Vittorio Scipolo, Tenova Goodfellow Inc., Marco Luccini, Tenova Goodfellow Inc., Armando Vazquez, Tenova Goodfellow Inc., Douglas Zuliani, Tenova Goodfellow Inc.

Steelmakers face the potential of a water leak in the electric arc furnace representing a high operational risk for production interruption and damage of plant assets. This paper reviews critical factors needed for effective water detection using the latest proprietary technological developments achieved by Tenova. NextGen® offgas analysis for continuous chemistry measurement (H2, CO, CO2, O2, H2O) alerting in real time, abnormal high humidity or high hydrocarbons, and an acoustic solution confirming the integrity of water-cooling panels. The combination of both technologies provides unprecedented detection capability, incorporating state-of-the-art sensors, advanced digital prediction models on a single platform, achieving significant operational protection.

Date: Monday, May 8

Time: 10:30 AM - 11:00 AM

Room: 320

Location: Master Session:Electric Steelmaking: Robotics Applications

Valorization of the Offgas Energy for a More Sustainable Electrical Steel Industry

by: Enzo Josef Chiarullo, Tenova S.p.A.

Electrical steelmaking is playing significant role in sustainability improvement especially in terms of energy and resources efficiency. Nevertheless, still today, 25-30% of the energy input in electric arc furnace (EAF) steel production is lost in the offgas. This waste is an economic and environmental loss which proven technologies can recover and transform to benefit for steelmaker. In recent years, Tenova developed the iRecovery® system for recovering the thermal power available in the EAF waste gas and valorizing it. The iRecovery technology, through an evaporative cooling system, generates steam which can be further utilized directly in steel production or for electrical power generation.

Date: Monday, May 8

Time: 10:30 AM - 11:00 AM

Room: 355

Master Session: Environmental: EAF Gas Flow Emission & Energy Optimization

EAF Optimization: An Important Factor in Reducing Steelmaking Energy Intensity and GHG Emissions

by: Douglas Zuliani, Tenova Goodfellow Inc., B. Babaei, Tenova Goodfellow Inc.

To control and optimize real-time electric arc furnace process dynamics, offgas technology needs to reliably provide all measurements needed for dynamic control without error-causing assumptions: an analyzer providing analysis of %CO, CO2, H2, O2, H2O and N2; velocity/temperature sensors to convert % analysis to mass flow; a programmable logic controller interface for heat specific measurements; and fundamental mass and energy balance software to dynamically control/optimize the quantity/timing of chemical and electrical “net” energy after actual energy losses. This paper describes an industry-unique solution with plant results demonstrating next-generation dynamic, optimized control for reduced conversion costs and increased yield and productivity.

Date: Monday, May 8

Time: 11:30 AM - 12:00 PM

Room: 320

Master Session: Electric Steelmaking: Robotics Applications

Roller Hearth Heat Treatment at the Cutting Edge of Technology

by: Mike Allan, Tenova Inc., Erik Koenig, Tenova (LOI Thermprocess GmbH)

The demands on heat treatment plants for tubes/bars, with regard to green steel production with constant quality requirements, are continuously increasing. The demands on the heating systems are becoming increasingly important in heat treatment. However, the role in setting the exact atmosphere control, which determines the material surface, is becoming more and more significant. This presentation gives an overview of the state of the art, focusing on different heating systems; in addition, how AMS2750/CQI-9 auditing with a specially developed all-in-one software solution is met.

Date: Monday, May 8

Time: 11:30 AM - 12:00 PM

Room: 359

Master Session: Long Products: Digitalization & Project Technologies

Large Electric Arc Furnace Equipped With Electro-Magnetic-Stirrer as a Model for the Efficient and Reliable Transition of the Steel Industry

by: Andrea Grasselli, Tenova S.p.A., Silvio Reali, Tenova S.p.A., Zaeim Mehraban, ABB AB, Lidong Teng, ABB AB

Consteerrer® Electro-Magnetic-Stirrer enhances the bath homogenization, stirring power, temperature gradient during power-on and heat transfer from the arcs to the metallic charge in the large Consteel® EAFs of tapping size of 300 tons of liquid steel and more. Results show that the efficiency of the Consteel® EAFs operation is increased, reducing the electric energy consumption and power-on time, reducing the oxygen content in the steel, and increasing the scrap yield. A successful industrial case and solid reference model in view of the transition of the production plants in response to the recent challenges of steel industry.

Date: Monday, May 8

Time: 2:30 PM - 3:00 PM

Room: 321

Master Session: Electric Steelmaking: EAF Efficiencies & Improvements

Digital Packages: Modular Solutions for the Digital Twin of Furnaces

by: Michele Roveda, Tenova

Tenova furnace digital packages are an Industry 4.0 solution to shift the furnaces from traditional to more technological production units. They improve: Process quality, efficiency, plant availability through artificial intelligence/machine learning algorithms and alerts/alarms. The former allow field data analysis and new insights to production; the latter provide assistance to maintenance by monitoring the critical parts. They combine with Tenova Dynamic Furnace, the digital twin of the real furnace: specifically designed to help the engineers in developing new heating strategies and obtain evaluations of furnace behavior. Figures are available since 2020 while development is still ongoing.

Date: Monday, May 8

Time: 3:30 PM - 4:00 PM

Room: 313A

Master Session: Hot Sheet Rolling: Digitalization

Tenova Ultralow-NOx Regenerative Burners Working With Hydrogen and Oxygen Enrichment

by: Alessandro Della Rocca, Tenova, Davide Astesiano, Tenova, Claudio Leoncini, Tenova

The decarbonization process is divided into different phases which concern both the efficiency of the plants to reduce consumption and the use of electricity from renewable sources to minimize environmental impact and CO2 emissions. For this reason, the choice of a high-efficiency regenerative combustion system capable of operating with variable amounts of hydrogen fits perfectly with this need. In order to take advantage of the use of electrolyzers that produce hydrogen and oxygen, the burner is able to operate with high-temperature air which is enriched with oxygen for further increasing efficiency maintaining the NOx emissions at a very low level.

Date: Monday, May 8

Time: 3:30 PM - 4:00 PM

Room: 330B

Master Session: Energy & Utilities: Reheating Technologies for Decarbonization & Panel Discussion

The ENERGIRON Technology: The Perfect Fit Between Decarbonization and Direct Reduction

by: Joel Morales, Tenova HYL, Jorge Martinez, Tenova HYL

Direct reduction has proven to be the right solution for decarbonizing the steelmaking industry, due to the readiness of the technology and effectiveness in abatement of the greenhouse gas emissions. Two main routes should be considered: intensive use of hydrogen (H2) (carbon direct avoidance) and capture/use of CO2 (carbon capture and utilization). One consists on the progressive conversion of the blast furnace-basic oxygen furnace facilities to direct reduction-electric arc furnace (DRI-EAF). Second is the production of hot metal by installing a gas-based direct reduction plant feeding DRI to an open-slag bath furnace (DRI-OSBF). The ENERGIRON® DRI technology provides the needed flexibility during the current period of energy transition.

Date: Monday, May 8

Time: 4:00 PM - 4:30 PM

Room: 310B

Master Session: Direct Reduced Iron/Decarbonization

Automatization of Roll Shop Operation Beyond Roll Grinding

by: Alfredo Brambilla, Tenova, Davide Quaglia, Tenova

Project requirements for automation of roll shop operation beyond the sole control of the roll grinder’s process have been occurring with increased frequency for several years. Tenova is responding to this trend by combining the adoption of proven solutions, established starting with pioneer roll shop projects in the late 1980s and enhanced through three decades of experience in designing and delivering total automation solutions. High-level software-controlled CNC loader cranes, a variety of automatized engineering developments, as well as the latest applications based on digital technologies, allow for the seamless integration of workflow across different machines and functions. As a result, operational safety, repeatability and plant productivity are maximized.

Date: Tuesday, May 9

Time: 11:00 AM - 11:30 AM

Room: 331AB

Master Session: Rolls: Roll Shop Equipment/Processes

Machine-Learning Applications for a Smart Scrap Yard

by: Giovanni Bavestrelli, Tenova S.p.A.

In electric arc furnaces, more than 60% of the total production cost corresponds to metallic raw materials. Scrap availability as well as cost and quality factors require implementing actions focused on not only the scrap market but also on optimal charge preparation and improved process control. To achieve good performance, it is necessary to assess the influence of scrap quality on the final product. This paper describes the design, development and deployment of machine-learning applications to improve evaluation, tracking and management of scrap materials to optimize the quality of the liquid steel produced and reduce its cost.

Date: Tuesday, May 9

Time: 2:00 PM - 2:30 PM

Room: 321

Master Session: Electric Steelmaking: Scrap

State-of-the-Art Heavy Plate Heat Treatment

by: Holger Kehler, LOI Thermprocess GmbH, Mike Allan, Tenova Inc.

The development of high-performance steels is increasingly based on the combination of chemical composition and tailored heat treatment. The targeted cooling of the materials, which determines the structural composition, plays a particularly important role in setting the properties. In combination with subsequent tempering, the properties are finally set. This presentation gives an overview of the state-of-the-art equipment used for heating and cooling of heavy plates, with a focus on mathematical models. Thanks to this tool, the appropriate heating/cooling settings can be determined and consistent product quality is ensured.

Date: Wednesday, May 10

Time: 9:30 AM - 10:00 AM

Room: 359

Master Session: Plate Rolling: Plate Equipment Upgrades & Optimized API Skelp Production

The Decarbonization of Reheating Furnaces: A Stepwise Approach

by: Alessandro Della Rocca, Tenova, Davide Astesiano, Tenova, Claudio Leoncini, Tenova, Michele Roveda, Tenova

The decarbonization of steel scrap recycling must involve reheating furnaces due to their impact on carbon footprint (80–330 kg CO2e/ton with respect to 500 kg CO2e/ton from the melting process). Tenova proposes a stepwise approach following the availability of critical resources (green electricity and hydrogen) and minimizing the technology risk. The first decarbonization step involves increasing efficiency (-10% of CO2), the second involves use of electricity via induction preheating (-30% of CO2), and the third step must consider green hydrogen combustion (up to -70% of CO2) due to process constraints (scale formation, efficiency and flexibility).

Date: Wednesday, May 10

Time: 9:30 AM - 10:00 AM

Room: 330B

Master Session: Electric Steelmaking/Decarbonization