In the JSPL steel plant, the steelmaker converted the existing Electric Arc Furnace (EAF) into a Tenova FMF. Adopting the new Tenova technology, JSPL gained a saving on the production costs of around US-$ 15-18 per t of steel, resulting in a year saving of approx. US-$ 15-20 million – achieving a ROI in less than four months. The same new furnace can easily produce 32 heats with 89 % guaranteed yield, and has the potential of producing 36 heats with operation excellence. Moreover, it succeeded in producing 42 heats-through on 14 November 2015 - a world record.
The project was commissioned on 31 August and completed in a short span of six months from the effective start of the project. With efficient planning and collaborative teamwork, the project was accomplished in just ten days of Furnace Shutdown against 28 days as expected. Thanks to the good performance, Tenova has been rated as “Grade A vendor” by the customer.
The FMF solution is also suitable for those steelmakers that are looking for a transition from Basic Oxygen Furnace (BOF) to an EAF based steelmaking and for those EAF steel shops that aim to increase the hot metal percentage in their charge mix.
Tenova FMF is a modular concept of smelting furnace that can be developed from core equipment called base module with specific add-ons and has the flexibility of converting various charge mix of raw material (scrap, DRI, liquid hot metal, Pig Iron, etc.). Each module is designed with specific features in order to fit the requirements of the charge mix.
There are clear opportunities and application for FMF. Full range of metallic charges can be smelted with capital costs reduced to the minimum level. Flexibility is clearly the greater advantage of this solution for all the markets that are developing toward lower footprint steelmaking operations, and FMF fits certain specific charge mixes becoming even more convenient than classical solutions.
This project marks a milestone in the launch of FMF in Asian markets. In India, high energy cost and inconsistent/poor availability of raw material has necessitated the industry to explore cost effective steel making methods. Alternative methods to build flexibility in furnace for charging different types of raw materials – such as the one offered by FMF – are the need of the hour, and essential to control the cost of steel. In China, FMF can be the first step for the modernization of Oxygen steel plants offering a smoother transition to the scrap era.
(Source: Tenova S.p.A.)