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Opfermann A.,Badische Technology and Services GmbH | Grosse A.,Badische Stahl Engineering GmbH | Wohlfahrt S.,Badische Stahlwerke GmbH
SEAISI Quarterly (South East Asia Iron and Steel Institute) | Year: 2013

Synopsis: In 1968, production at the Badische steel plant started with a plant capacity of 300.000 t. Now, approx. 50.000.000 t and 630.000 heats later, the plant has reached an output of more than 2 Mio.t finished product per year. The improvement of the processes at Badische has therefore a 45 year old tradition. The combination of engineering at BSE and steel production at BSW leads to one of the most efficient mini mills worldwide. The plant is operated with reliable equipment by well-educated, trained, and motivated people - this is our "Badische Philosophy". And this is the foundation for a successful steel production with high productivity and low costs. BSW operates two AC arc furnaces with 102 t tapping weight and 75 MW average power input leading to an average tap-to-tap-time of 41 min. Two ladle furnaces prepare the heats in 20 min only; casting is done via eleven strands on two casting machines. With more than 70% of hot charging the billets are rolled in a wire rod and rebar mill. Chemical energy input and optimization of the EAF process with chemical energy tools for faster melting and refining have continuously gained in importance in the steel production process. The aim worldwide is to produce with low energy consumption at low costs and with a low impact on the environment. Chemical energy tools have been in use for 30 years now - from door lances to combined systems with side wall tools and injection of solid agents - to create a more homogeneous melting and heating. Results of different operational tests at the BSW arc furnaces are displayed and discussed. Our aim is to look into the details and thus optimize the operation.

Opfermann A.,Badische Technology and Services GmbH | Grosse A.,Badische Stahl Engineering GmbH | Wohlfahrt S.,Badische Stahlwerke GmbH
Stahl und Eisen | Year: 2014

Since 1968 wire rod and rebar qualities have been produced at Badische Stahlwerke (BSW). Two production lines with EAF, LF and casters are used to produce the billets from scrap. In two rolling mills the billets are rolled to wire rod and rebar. The main aim of BSW was and is the most efficient Operation of the plant for the effective production of these basic steel grades. In this article results of operational trials and the interaction of process parameters at the EAF are shown.

Knoth V.,Badische Stahl Engineering GmbH | Doninger T.,Environmental protection Badische stahlwerke GmbH
Steel Times International | Year: 2010

Badische Stahl-Engineering (BSE), Germany, optimizes electric arc furnace (EAF) dedusting systems to meet the new process requirements and increase the overall productivity and cost efficiency, along with ensuring strict compliance with all environmental standards and local legislation. The company together with its subsidiary, Bender Corporation, is a leading global consulting and engineering specialist advising on the efficient layout of EAF melt shops and optimization of EAF melting practices and associated emission control systems. The company's objective is to define the design of an objective is to define the design of an emission control system for the off-gas on the latest basis to develop future technologies for to meeting the requirement of increasingly stringent legislated limits. The design and layout of a dedusting system depends on several technical factors, including considerations such as operating parameters and productivity.

Bandusch L.,AcelorMittal Hamburg GmbH | Dettmer B.,Georgsmarienhutte GmbH | Fandrich R.,Steel Institute VDEh | Kleimt B.,VDEh Betriebsforschungsinstitut GmbH | And 3 more authors.
Stahl und Eisen | Year: 2012

After the major decline in 2009, the European steel industry is still struggling to reach the pre-crisis level. The steel production with EAF is under constant improvement which can be seen by an increase in efficiency. Examples thereof are process automation as well as the use of off-gas energy for scrap preheating or steam generation. Simultanously, the performance of new plants is also increasing. One crucial challenge for the future of the European steel industry, if not today already, is the availability of electrical energy. Weak distribution grids as well as rising electricity prices are at hand.

Grosse A.,Badische Stahl Engineering GmbH | Opfermann A.,Badische Stahlwerke GmbH | Baumgartner S.,Badische Stahl Engineering GmbH
AISTech - Iron and Steel Technology Conference Proceedings | Year: 2011

With increasing costs for energy and CO2 emission certificates the optimisation of the furnace with respect to productivity is not always the objective. Rather, a more complex view is required which involves market conditions, like steel demand, availability of raw material, local conditions, etc. Moreover an efficient production and use of materials and tools is essential. The tests, which have been described in this paper, should show the interrelation of parameters and their impact on productivity, yield and consumption figures.

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