Iron making in induction furnace for casting steel billets

Abstract

Emmar Steel (ES) is an integrated steel plant having a production capacity of about 0.5 million tons of steel per annum. ES consists of two Mini Blast Furnaces (MBF), an Energy Optimizing Furnace (EOF), two Induction Furnaces (IF), a Ladle Refining Furnace (LRF) and a four-strand Continuous Casting Machine (CCM). ES is producing 130 mm2 mild steel billets to cater to the needs of rolling mills in Syria.War and sanctions on Syria pose problems in importing raw materials, equipment, spares and consumables, which leads to intermittent stoppage of MBF operation hampering production. In this scenario, when MBF was not in operation, the production of steel depends solely on induction furnaces.Due to increased generation of scrap during war time, steel scrap is available in plenty and at cheaper prices in Syria when compared to international market prices. Use of mixed scrap in induction furnaces poses problems in controlling chemistry of steel leading to the production of unwanted and unmarketable “off grades”. The present paper discusses a novel method of producing hot metal (liquid iron containing carbon around 3.0%) in IF which is subsequently converted into steel in EOF and cast into 130 mm2 billets.