Turkish steel producer Tosyalı Demir Celik Sanayi A.S. (Tosyalı Demir Celik) has ordered an EAF Quantum, a twin vacuum-degassing plant, and a two-strand slab caster for a greenfield project in Iskenderun, Turkey. The Tosyalı Group operates another steel plant in Osmaniye, Turkey, and a DRI direct hot-charge melting plant in Algerie. The company operates several rolling mills known for flat products and welded pipes. Tosyali Holding’s new greenfield facility in Iskenderun will increase its capacity for semi-finished products for the existing downstream facilities.
The 150-ton EAF Quantum and 150-ton twin vacuum-degassing plant with oxygen blowing will feature automated scrap yard management, charging, oxygen injection, sand refilling automation, and other Level 2 automation systems. The EAF Quantum can handle metallic scrap and virgin materials such as HBI and pig iron. The electrical energy requirement of the EAF Quantum is low, thanks to the scrap preheating system, FAST Tapping system, continuous foaming slag, and continuous submerged electric arc (flat-bath operation). These features reduce both the operating costs and the CO2 emissions.
The EAF Quantum is a highly productive furnace that will reach the lowest possible power-off times and short melting cycles. With significantly lower electricity consumption than a conventional EAF and the lower consumption of electrodes and oxygen, the EAF Quantum has an overall advantage in the specific conversion cost of around 20 percent. Compared to traditional EAFs, total CO2 emissions can also be reduced up to 30 percent per ton of crude steel. An integrated dedusting system with modern automatic off-gas control also fulfills all environmental requirements.
The twin vacuum-degassing plant provides further treatment and steel quality to the product portfolio of Tosyali Demir Celik. With oxygen blowing, Tosyalı Demir Celik will be able to produce steel grades starting from ULC grades up to high carbon grades, peritectic grades, API grades, dual-phase grades, and high strength low alloyed (HSLA) steel grades. The plant will include TPQC (Through-Process Quality Control) and is ready for Industry 4.0.
TWO-STRAND CONTINUOUS SLAB CASTER
The two-strand continuous slab caster can provide 2 to 3.4 million metric tons of slabs annually and process a wide range of steel grades. With a machine radius of ten meters and a maximum casting speed of 1.6 meters per minute, the caster produces slabs with a thickness of 225 millimeters ranging from 900 to 1,800 millimeters. The straight cassette-type Smart Mold includes the Mold Expert for breakout detection, DynaWidth for automatic width adjustment, and the DynaFlex mold oscillator. LevCon automated mold-level-control system is also included, featuring “autostart” casting functions and auto-adaptive bulging compensation. Smart Bender, Smart Segments, and I-Star rollers will make up the strand-guiding system.
The Dynacs 3D secondary cooling system dynamically calculates and controls the temperature profile along the entire strand. DynaGap Soft Reduction 3D improves the interior quality of the slabs. The roll gap dynamically adjusts during the final solidification per the operating points calculated by Dynacs. This minimizes segregation in the center of the strand.