Cappel Stahl Consulting GmbH

Bad Essen, Germany

Cappel Stahl Consulting GmbH

Bad Essen, Germany
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Isdemir B.S.,Iskenderun Demir Ve Celik A.S. | Husken R.,Kudttner GmbH and Co. KG | Cappel J.,Cappel Stahl Consulting GmbH
AISTech - Iron and Steel Technology Conference Proceedings | Year: 2012

Iskenderun Demir Ve Celik A.S. in Turkey is operating an integrated steelplant located in Iskenderun in the south east of the country near the Syrian border. It is the largest plant in Turkey and has a total capacity of 5,4 mtpy and is supplying various steel grades in long and flat product shape to serve the local market and exports basically to countries around the Mediterranean Sea and overseas. The products of the company are billets, wire rod, rebar, slabs, hot rolled coils, plates and cold rolled coils. The markets vary from construction, agriculture, appliance, tank and boiler fabrication, ship building, line pipe, low alloy heat treatment steels and HSLA applications. The plant comprises two 6-strand billet casting machines (2,5 mtpy) and two 2-strand slab casting machines (5,2 mtpy). Over the last decade Isdemir has realized huge modernization and revamping projects in order to increase its annual steel output. The unique location of the company at the Mediterranean Sea, but without any own operated raw material sources creates a special metallurgical process route sensitive in terms of Sulfur and Phosphorous control. The demands of the process routes to control higher levels of Phosphorous in integrated steelmaking have been discussed in various presentations in the past. The emphasis of this paper is to explain the control of hot metal Sulfur coming with high levels of 1.500 ppm and more from the Blast Furnace during steelmaking by combined technology of Hot Metal and Steel Desulfurization. The benefit sharing between the BF and the BOF shops will be recognized and the requirements of high quality steel products on Sulfur control will be reviewed.

Sener B.,Iskenderun Demir Ve Celik A.S. | Husken R.,Kuttner GmbH and Co. KG | Cappel J.,Cappel Stahl Consulting GmbH
Iron and Steel Technology | Year: 2013

Experts explain the control of hot metal sulfur coming in high levels from the blast furnace during steelmaking by the combined technology of hot metal and steel desulfurization. The benefit sharing between the BE and the BOF shops is recognized and the requirements of high-quality steel products on sulfur control are reviewed. Extensive examinations reveal that all steel types are on a different sulfur level and require special treatments according to their specifications. The total De-S required is split between the different product stages during liquid steel production. The main goal is to guarantee that the desulfurization reaction must be completely stopped after release of the liquid steel to the caster.

Husken R.,Kuttner GmbH and Co. KG | Cappel J.,Cappel Stahl Consulting GmbH
MPT Metallurgical Plant and Technology International | Year: 2012

One of the most significant improvements in steel quality was the limitation of the sulphur content. That development was driven by the introduction of hot metal and steel desulphurization in integrated steelmaking plants. A side effect was the possibility of optimizing the slag composition in the blast furnace with respect to increased productivity and reduced costs. This article describes the state-of-the-art in desulphurization by explaining the sources of sulphur in iron and steelmaking, the quality requirements of steel products and the desulphurization technology.

Guoguang Z.,Shanghai Meishan Iron and Steel Co. | Husken R.,Kuttner GmbH and Co. KG | Cappel J.,Cappel Stahl Consulting GmbH
Stahl und Eisen | Year: 2012

TBM bottom stirring is a technology introduced worldwide to enhance the metallurgical efficiency of the BOF process. By applying this technology inert gas injection through the bottom of the BOF vessel enhances the mixing effect of the top lance blowing jet. Slag Splashing was introduced in BOF operations to increase vessel campaign life, but generally it negatively impacts the efficiency of the bottom stirring. At Meishan Steel in China an operation practice was developed that successfully combines the advantages of both technologies.

Guoguang Z.,Shanghei Meishan Iron and Steel Co. | Husken R.,Kuttner GmbH and Co. KG | Cappel J.,Cappel Stahl Consulting GmbH
AISTech - Iron and Steel Technology Conference Proceedings | Year: 2012

Meishan Steel in China is an integrated steelplant located close to Nanjing in Jiangsu province in China, 250 miles NW from Shanghai. The plant has a total annual capacity of 3.50m tons per year (tpy) supplying various steel grades including cold forming steel, structural steel, automotive structure steel, corrosion resistant structural steel, welding gas cylinder steel, checker plate, built welded line pipe steel and others. Because of the iron ore source used hot metal Phosphorous content is rather high with 0.12 - 0.15%. To achieve low Phosphorous contents in the molten steel below 0.011 - 0.017% in 2002 the TBM (Thyssen Bottom Metallurgy, with single hole stirring elements) bottom stirring technology was introduced in the plant to improve the performance results. Since the vessel tap weight of 150 t/heat only is rather low, the downtime for BOF reline was reduced by increase of refractory lining life by introduction of slag splashing. Over the last decade a combined technology of long BOF campaign live (10,000 heats and more) with performing TBM bottom stirring was successfully developed. This paper describes the operation technology applied at Meishan steel and demonstrates the benefits achieved by combined blowing technology.

Husken R.,Kuttner GmbH and Co. KG | Fechner R.,Kuttner LLC | Cappel J.,Cappel Stahl Consulting GmbH
AISTech - Iron and Steel Technology Conference Proceedings | Year: 2011

Increasing demands for low Phosphorous [%P] contents in the steel on the one hand and continuously growing pressure on reducing cost during the last years on the other hand, have led to the necessity of using cheaper and also poorer raw materials. In case of iron ore as the major raw material for steel making, many steelmakers are today faced with very high [%P] contents in the Hot Metal coming from the Blast Furnaces. Due to its reducing conditions, the iron melting process in the Blast furnace is not capable of removing [%P] significantly. Therefore it is up to the steelmaking shop to optimize and develop the BOF process in order to give answers to this demanding development. The Combined Blowing Technology based on top-blown oxygen and inert gas injection through the converter bottom using a Jet-Stream with supersonic velocity is already applied by Küttner since many years all over the world. This paper presents a summary of two decades experience in the Combined Blowing Technology with special respect to the excellent De-[%P] capabilities beside other metallurgical and economic benefits. Using the Küttner Jet-Stream Combined Blowing Technology [1], initial [%P] contents of > 2000 ppm can be reduced to finally 100 ppm or even less. Simultaneously carbon is removed by top-blown oxygen in the vessel without need for separate hot metal De-[%P] units or any other special treatments. These results are achieved along with reduced consumption of lime, lower iron content in the slag, lower oxygen content in the steel, and less slopping.

Lemperle M.,Kuttner GmbH | Jennes R.,Kuttner GmbH | Cappel J.,Cappel Stahl Consulting GmbH
6th Int. Congress on the Science and Technology of Ironmaking 2012, ICSTI 2012 - Including Proceedings from the 42nd Ironmaking and Raw Materials Seminar, and the 13th Brazilian Symp. on Iron Ore | Year: 2012

The OxyCup plant at Tisco, Taiyuan, China, started operation as scheduled in June 2011. The plant was designed to process 600,000 tpy of self-reducing brick produced from dust and sludge residues together with approximately 100,000 tpy of pit scrap and skull. The plant layout includes a brick fabrication with material handling, mixing tower and curing hall. Two types of brick are produced in two different lines with residues from carbon steel production as well as from stainless steel production. Two individual operating OxyCup shaft furnaces are used to reduce and melt the brick and skull to liquid hot metal for Carbon steel and a liquid iron/chromium/nickel alloy for stainless steel and slag according to the quality of the charge material respectively. The furnace top gases are de-dusted in a wet gas cleaning system and used for hot blast generation at the plant and electricity generation in a separate power plant on site. To increase the availability of the furnaces >8,000 hpy, a third furnace is installed to replace one of the other two in case of refractory repair and mechanical/electrical maintenance.

Urban W.,Huttenwerke Krupp Mannesmann GmbH | Weinberg M.,Huttenwerke Krupp Mannesmann GmbH | Cappel J.,Cappel Stahl Consulting GmbH
Stahl und Eisen | Year: 2014

The removal of phosphorus from the furnace charge is a well understood process today and is described by using the phosphorus partition ration between metal and slag Lp = (%P2O5)/[%P]. The L p depends on the melt temperature, the Fet content in the slag, slag basicity, slag volume, MgO content in the slag and the steel carbon content. Other parameters are the phoshorus input with the hot metal and the phosphorus content of the steel product specification. Furthermore the results also vary with the individual plant equipment available and the dephosphorization strategy applied.

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