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IÇDA – TURKEYHigh quality steel bars and high alloy steels since 1970
PLANT INFORMATION
Annual production 1,800,000 t of good billets
Production mix Billets
Steel grades
150 mm sq., 180 mm sq., 200 mm sq.
Low and medium c-steel (rebar / SBQ grades)Raw material Charging ratio: 100% steel scrap
PROJECT INFORMATION
Customer IçDA
Location Turkey
Commissioning 2003
ThE bIggEsT sTEEL PRODUCER IN TURKEYHigh efficiency with ultra-high chemical power EAF
IçDA is the biggest steel producer in the private sector in Turkey based on production capacity. The company com-missioned its first steelwork in 2003. Overall, it achieves an average production of 1.65 million t per year. The steelwork incorporates the first UHCP (Ultra-High Chemical Power) electric arc furnace supplied by SMS Concast worldwide and has a ladle size of 180 t.
TOP qUALITY COMPONENTs MEET ThE
DEMANDs OF ThE PLANT OPERATOR
The technological equipment of this plant, e.g. scrap preheating, EAF, LF and CCM, was entirely supplied by SMS Concast. Various IçDA design suggestions were taken into consideration: the maximized rate of energy input and reduction of power-off times has been a key factor during the development of the plant. Furthermore, the single bay design and the controlled metallurgical operation by a superior automation system. A high efficiency of the plant is guaranteed by a continuous high yield. SMS Concast’s state-of-the-art technology is a success factor for plant operators in order to optimize cost control.
A wELL-CONNECTED PROCEss ChAIN
sAvEs REsOURCEs
Scrap for the steelwork is brought by ship and unloaded in the close by harbor. The ships are reloaded with good billets. Short transportation distances are positively influencing the overall performance of the plant. The well-connected pro-cess chain saves time, money and is more environmentally friendly.
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IÇDA 2 – 220 T EAF wITh UhCPExpansion of capacity and performance
sECOND sTEELwORK COMMIssIONED IN 2008
In September 2008 IçDA commissioned the second steelwork with an UHCP (Ultra-High Chemical Power) EAF at its Biga location. Supplied by SMS Concast, the UHCP furnace features a productivity of 320 t/h and stands for top performance. Special design measures ensure the high power input density of 230 MW. This makes it possible for IçDA to produce 2.2 million t of high-quality steel products per year.
The plant comprises a 220-t EAF, a ladle furnace and an eight-strand Convex® billet caster. With these facilities, IçDA turns liquid steel into square billets 150 mm x 150 mm or 180 mm x 180 mm in size.
The capacity and performance of electric steelworks shops have been drastically increased so that – with capacities over 220 t – these plants can hardly be called minimills anymore.
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wIThIN ThE FIRsT YEAR ThE MONThLY PRODUCTION CAPACITY INCREAsED
whEN AT ThE sAME TIME ELECTRICITY CONsUMPTION DECREAsED
During the start up phase the target of 1.5 mio t per year, e.g. 125,000 t per month, was achieved as shown in the diagram. Within four years of meltshop operation, a continuous optimi-
zation of the process technology allowed to achieve outstand-ing results. As a result of that, the production output in 2007 exceeded the original design capacity by 20 %.
140000
120000
100000
80000
60000
40000
20000
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Mar
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Apr
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May
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Jul 0
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Aug
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MONThLY PRODUCTION
IÇDAS ̧ – TurkeyMinimill designed by
SMS Concast
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PLANT LAYOUT AT IÇDAShort transportation distances are positively influencing the
overall performances
transport on rail
transport by over head crane
Material flow
480460440420400380360340320300
Dec
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Jan
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Feb
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Mar
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Apr
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May
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Jun
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Jul 0
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*GB: good billet, LS: liquid steel
(2003) Initial (2007) Actual
Electrode consumption EAF 1.3 kg/t GB* 0.92 kg/t GB*
Electrode consumption LF 0.22 kg/t GB* 0.15 kg/t GB*
Electrical energy EAF 380 kWh/t LS* 280 kWh/t GB*
Electrical energy LF 22 kWh/t LS* 20 kWh/t GB*
ELECTRICITY CONsUMPTION
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Electric arc furnace
Ladle furnaces
Vacuum degasser
Continuous casting machine
Fume dedusting plant
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ELECTRIC ARC FURNACE
TypeHeat sizeHot heel
Shell diameterShell volume
Electrode armsElectrode diameter
Electrode regulationTransformer
Scrap chargesTap to tap timeConso injector
Power on
ElectricOxygen
Natural gasElectrode
Shell life timeRefractory life
TypeHeat sizeHot heel
Shell diameterShell volume
Electrode armsElectrode diameter
Electrode regulationTransformer
Scrap chargesTap to tap timeConso injector
Power on
ElectricOxygen
Natural gasElectrode
Shell life timeRefractory life
IçDA produces with the first UHCP EAF supplied by SMS Concast. The EBT-type furnace, with large tapped steel capacity, is also equipped with a CONSO-tech oxygen injection system and off-gas analysis using laser detectors.
AC full platform, EBT tapping180 t nominal20 t7.8m / 8.0 m200 m3
Conductive type (Cu)650 mmDigital hydraulic type168 MVA2 – 3 buckets43 – 47 minn Wall installation 4 x 4,500 Nm3/h / 6 MWn EBT installation 2 x 4.000 Nm3/h / 6 MW32 min (3 buckets)
< 300 kWh / t good billets48 Nm3 / t good billets5.2 Nm3 / t good billets0.9 kg / t good billets20 days (> 450 heats)> 600 heats / campaign
AC full platform, EBT tapping250 t nominal30 t8.3 m260 m3
Conductive type (Cu)750 mmDigital hydraulic type230 MVA2 buckets32 – 34 minn Wall installation with 8 CONSO
injectorn Each CONSO injector can work
as oxy-gas burner or oxygen lance.n The installed burner power will
be 7 MW per unit, corresponding to the natural gas flow rate of 730 Nm3/h and oxygen flow rate of 1.500 Nm3/h
34 min
< 42 kWh / t good billets41 Nm3 / t good billets4.9 Nm3 / t good billets1.3 kg / t good billets20 days (> 450 heats)> 600 heats / campaign
CONSUMPTION fIgURES
CONSUMPTION fIgURES with 100% non-preheated scrap
ELECTRIC ARC FURNACE
In its second steelworks IçDA uses a 250 t UHCP EAF with a 8.3 m shell diameter by SMS Concast.
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TypeNominal ladle capacity
Electrode armsElectrode diameterElectrode regulator
TransformerHeating rate
StirringLadle cars
ElectricElectrode
TypeRadius
Number of strandsStrand distance
Section rangeCast section size
Billet lengthLadle support type
Tundish car type
Tundish shapeTundish flow regulation
Mould typeElectro magnetic
stirringCasting speed
Dummy bar typeCutting device
DischargeCooling bed type
Product identification
LADLE FURNACE
The 175 t ladle furnace is equipped with a water cooled roof, conductive electrode arms, and an automatic tempera-ture and sampling device.
JIB Type CS 175175 t nominalConductive type (Cu)460 mmDigital hydraulic type25 MVA plus 20 %4.0 K / minDouble argon porous plugTwo cars with crane access on both sides of the ladle furnace
0.45 kWh / t and K0.010 kg / kW
CONVEX® 20-9 CCS9 m61,200 mm120 mm sq. to 200 mm sq.150 mm sq., 180 mm sq.,200 mm sq.6–18 mTurret with lifting / lowering and weighing systemFull overhead with lifting / lowering systemT-typeMechanical stopper mechanismCONVEX Technology®
Mould-EMS (adjustable height)2.8 – 4.4 m / minRigidTorch cuttingOverhead cross transferHydraulic turnoverBillet marking machines, one on each side of the turnover cooling bed
CONTINUOUs CAsTINg MAChINE
The high production 6-strand SBQ-Caster uses SMS Concast’s CONVEX® mould technology. The caster is equipped with a full range of supplementary features such as an automatic stopper control system, mould stirrers and a billet marking machine. The CCM can produce up to 1.8 mio t of good billets per year.
CONSUMPTION fIgURES
sMs Concast
Toedistrasse 9
8027 Zurich
Switzerland
Phone: +41 44 204 65 11
Fax: +41 44 202 81 22
www.sms-concast.ch B40
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