Badische Stahl Engineering GmbH

Kehl, Germany

Badische Stahl Engineering GmbH

Kehl, Germany

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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 | Libera K.,Badische Stahl Engineering GmbH | Eriksson R.,Ovako Hofors AB
AISTech - Iron and Steel Technology Conference Proceedings | Year: 2012

The installation of a combined burner system in a stainless EAF was successfully accomplished. The results with respect to reduction of electrical energy consumptions and P-ON times are promising. Furthermore this installation is one of the first, which is used for oxygen injection in the steel bath apart from the burner mode. Due to the correct slag chemistry and temperature the oxygen penetration in the steel bath works successfully. The usage of the combined burner system in a special steel EAF with the use of heavy oil as fuel showed a tremendous decrease of electrical energy consumption and P-ON times. Additionally an increase of the metallic yield was achieved. The previous skull formation inside the furnace was prevented. The optimization of a shaft furnace was conducted by an improved arrangement of burners underneath of the shaft and by modification of the operational profile. Furthermore the more efficient usage of post combustion has improved the overall performance of the shaft furnace, particularly with respect to oil and energy consumptions. Also an improvement of the metallic yield could be observed.


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.


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.


Grosse A.,Badische Stahl Engineering GmbH | Opfermann A.,Badische Technology and Services GmbH | Libera K.,Badische Stahl Engineering GmbH | Gokce F.,Badische Stahl Engineering GmbH | And 2 more authors.
AISTech - Iron and Steel Technology Conference Proceedings | Year: 2014

The increased use of oxygen in electric steelmaking has led to tremendous improvements with respect to electrical energy consumption and P-ON time in the last 40 years. The ongoing developments of BSE burner technology resulted in the highest efficiency and maintenance friendly equipment coupled with high reliability. The latest installation of the VLB system at North American Höganäs has improved the energy consumption by 6 % and the P-ON time by 7.6 % with a lower gas consumption as compared with previous results. At Outokumpu Nirosta Bochum BSE installed the second chemical energy package at a stainless steelmaking plant within two years. The energy consumption could be reduced by 4 % together with a 46 % reduction of refining oxygen due to higher efficiency. Additionally the electrode consumption was reduced by 9 %. Since the end of 2012 BSW has been testing a new burner technology at its own steel plant. The movable VLB continues in operation since October 2013 and the first experiences are promising. The technology enables a higher efficiency during burner mode due to an improved heat transfer to the scrap. The tilting mechanism results additionally in a further reduction in refractory wear. The first practical results are expected for publication the second half of 2014. © 2014 by AIST.


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.


Feger S.,Badische Stahl Engineering GmbH | Zehnle K.,Badische Stahl Engineering GmbH | Volkert A.,Badische Stahlwerke GmbH
MPT Metallurgical Plant and Technology International | Year: 2014

Analyzing the scrap yard logistics and operation methods is very likely to bring to light neglected potential for improvement and possibilities for cost savings at virtually every steel plant around the world. When looking for the optimal layout of a scrap storage facility or when comparing different layouts, various criteria have to be considered. The scrap storage capacity is limited by the size of the bays. Therefore, plants often build scrap bunkers. For smaller amounts of scrap, also delivery by truck is possible. But in that case, it has to be taken into consideration that the scrap bay is accessible by truck only at the front sides. A high degree of coordination between the crane drivers and the drivers of the towing vehicles or pallet carriers is needed, which may lead to delays. Also certain environmental issues have to be taken into account. Eventually, every steel plant has its particularities. These have to be taken into consideration when evaluating a layout and its ability to serve a highly productive steel plant.


Feger S.,Badische Stahl Engineering GmbH | Wiegele B.,BSW Anlagenbau und Ausbildung GmbH | Greinacher J.,Badische Stahl Engineering GmbH | Berger T.,Badische Stahlwerke GmbH
Steel Times International | Year: 2012

The German minimill group Badische recognise the workforce to be the driving success of a plant's performance, people contributing 80% of productivity gains with only 20% attributed to investment in equipment. This article reviews their internal and external training philosophy.


Pfundstein C.,Badische Stahl Engineering GmbH | Fleischer M.,Badische Stahl Engineering GmbH | Baumgartner S.,Badische Stahl Engineering GmbH
Steel Times International | Year: 2010

German group Badische Stahl-Engineering (BSE) has complied a database, Best Practice Database, which compares the technical situation and cost performance of a number of EAF steel plants across the globe. It shows best practice examples per region, steel grade or section and also gives information about the general performance of the steel industry. The database helps the steel industry to overcome the challenges faced by the steel industry. These challenges include lack of qualified personnel, achieving operational efficiency, exploiting profit opportunities, successful raw material management, and environmental protection. In order to cope with the situation, BSE is developing the BSE Academy, which is based on experience of the demand of education on different levels of responsibility. The database applies continuous qualification of the workforce by training and hiring skilled workers and applies the best available technology in order not to become subject to sudden and unexpected political pressure.

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