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Steelmaking at ArcelorMittal Dofasco

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Title: Steelmaking at ArcelorMittal Dofasco


1
Steelmaking at ArcelorMittal Dofasco
Group 1 Andrew, Fran, Matt, Megan, Mikaela
2
ArcelorMittal Dofasco
  • Started out as Dominion Foundries and Steel in
    1912 making 80 tons of steel castings
  • Produce over 4 million tons of high quality flat
    rolled steel
  • Introduced innovative profit sharing program in
    1938
  • Became fully integrated mill in 1951
  • In 2006, was acquired by world giant Arcelor, who
    later merged with Mittal, forming ArcelorMittal
    Dofasco
  • Awarded sustainability and Top Employer Awards

3
Dofasco Products
  • Products include galvanized steel, tin plate and
    tubular products for the automotive, construction
    and packaging sectors

4
Primary Services
  • Dofasco divided into 2 main areas
  • Primary
  • Finishing
  • Primary area consists of
  • Raw Materials Handling
  • Cokemaking
  • Ironmaking
  • Steel making
  • KOBM
  • EAF
  • Continuous Casting

5
Dofasco Primary Flow Sheet
6
KOBM Basic Oxygen Steelmaking
  • KOBM Technical Information
  • 300 tonne Basic Oxygen Converter
  • 70 Hot Metal 30 Scrap Charge
  • O2 Input- 70 Top Lance 30 Bottom Tuyeres
  • Lime Dolime Bottom Injection
  • Alloy/Flux Handling System

7
Steelmaking in the KOBM
  • Typically consists of 6 steps
  • Charging of Scrap Metal
  • Charging of Hot Metal
  • Blowing of Oxygen
  • Sampling
  • Tapping of Steel
  • Slag off

8
Steelmaking in the KOBM
9
Blowing
  • KOBM unique because oxygen blown into molten iron
    through both
  • the top of the furnace (by a main lance)
  • the bottom of the furnace (by tuyeres)
  • Oxygen used to selectively oxidize C, Si, P, Mg

10
Tapping Slag Off
  • Once adequate concentration of carbon in bath,
    tilt furnace to get molten steel out
  • Molten steel melts plug, flows into ladle
  • Ladle moves onto Ladle Metallurgy and Vacuum
    Degassing

11
Specific Steelmaking Process Principles
  • Model Carbon content to improve times and
    increase efficiency
  • End Point Determination Reaction
  • 2CO O2 ? CO2

12
Specific Steelmaking Process Principles
  • Batch Process potential problem of unmelted
    Scrap

13
Economics Operating Costs
  • Annual Production Rate 2.4 million tons
  • Average cost per ton (crude steel) 353.50
    (highly variant with input costs)

5
3
Iron Ore Iron Ore Transport Coking Coal Coking
Coal Transport Steel Scrap Oxygen Refractories
Electricity Labour
2
6
31
13
7
13
20
14
Operating Variables
  • Many variables can contribute to operability and
    flexibility, including
  • Amount of scrap or hot metal charged
  • Temperature of hot metal being charged
  • Temperature of furnace (the bath itself)
  • Composition of the bath

15
Operability Operating Window
  • Critical parameters for our operating window are
    C and Blowing Time (essentially amount of
    oxygen)

16
Safety
  • 6 Levels of Safety
  • Process Control
  • Alarms
  • SIS
  • Safety Relief
  • Containment
  • Emergency Response

1. Pit under furnace capable of holding 100 of
contents
17
Safety
  • 6 Levels of Safety
  • Process Control
  • Alarms
  • SIS
  • Safety Relief
  • Containment
  • Emergency Response

2. Laser and Thermal Imaging of Refractory
Materials
18
Safety
  • 6 Levels of Safety
  • Process Control
  • Alarms
  • SIS
  • Safety Relief
  • Containment
  • Emergency Response

3. Red stripe on Hard Hat for New Workers
19
Safety
  • 6 Levels of Safety
  • Process Control
  • Alarms
  • SIS
  • Safety Relief
  • Containment
  • Emergency Response

4. If there is a loss of furnace cooling water,
O2 blow turns off.
20
Safety
  • 6 Levels of Safety
  • Process Control
  • Alarms
  • SIS
  • Safety Relief
  • Containment
  • Emergency Response

5. Dofascos Onsite Fire/Security/Medical
Personnel.
21
Safety
  • 6 Levels of Safety
  • Process Control
  • Alarms
  • SIS
  • Safety Relief
  • Containment
  • Emergency Response

6. If there is a loss of power, the furnace will
immediately tap or tilt to prevent tuyere damage
22
Safety
  • 6 Levels of Safety
  • Process Control
  • Alarms
  • SIS
  • Safety Relief
  • Containment
  • Emergency Response

7. Extended diagnostics must be successful to
begin blowing procedure.
23
Troubleshooting
24
Troubleshooting
25
Wrap-up
  • The Future of Steelmaking
  • Unique Process Specifications Issues
  • Environmental Concerns

26
FUTURE OF STEELMAKING AT DOFASCO
27
Refractory Lifetime
  • Costs 1,000,000 in materials alone to replace
    refractory lining
  • Try to reuse slag as lining
  • Downtime in furnace production more substantial-
    already use slag as for protection

28
Improved Models
  • Models for C in bath based on CO and CO2 models
    (multi-variant statistical control)

29
Steelmaking Energy Issues
  • To save money, reuse gases as fuel in steelmaking
  • Ratio of Coke Oven Gas (COG) and Blast Furnace
    Gas (BFG)
  • Hope for Co-Generation Facility

30
UNIQUE PROCESS SPECIFICATIONS AT DOFASCO
31
Steelmaking Input Issues
  • Raw materials are shipped to Dofasco
  • Harbor freezes in the winter
  • Stockpile during shipping season

32
Steelmaking Output Issues
  • Steelmaking business unit consists of only BOF
    furnace and EAF furnace
  • More downstream processing than upstream
    processing- must import

33
Steelmaking Scrap Issues
  • Scrap metal varies in quality- important to
    evaluate quality to ensure safety

34
Steelmaking Shipping Issues
  • Steel used for high-end applications
  • Sensitive to moisture and contaminants- need
    climate controlled environment

35
ENVIRONMENT AT DOFASCO
36
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37
Steelmaking Problems
  • Steelmaking a dirty business
  • New environmental regulations require stricter
    control for Point of Impingement- Dofasco has
    asked for an extension
  • Dofasco policy always leading the group for
    Canadian steelmakers
  • ISO 14001 Certified

38
Unique Issues at Dofasco
  • Right next to the harbor
  • Required for the process
  • On reclaimed land
  • Extremely careful about effluent and wildlife

39
Unique Issues at Dofasco
  • Try to discourage birds from nesting, so borrow
    wildlife and tether them near water to discourage
    birds

40
Unique Issues at Dofasco
  • Very conscious groups in Hamilton for air
    emissions
  • Have 1 guy to watch for emissions 24 hours a day
  • Steelmaking uses bag house to minimize emissions

41
Acknowledgements
  • Thanks to people at Dofasco ArcelorMittal who
    provided information on the process and the site
  • Rick Finlay
  • Joseph Lasowski

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