Acroni d.o.o., a prominent Slovenian steel producer and part of the Slovenian Steel Group (SIJ), has partnered with Primetals Technologies to revolutionize its steel production capabilities. Located in Jesenice, Slovenia, Acroni has installed a new Argon Oxygen Decarburization (AOD) converter enhancing its production capacity. This strategic upgrade aims to bolster Acroni's position as Europe's leading producer of stainless quarto plates and specialized steels, while significantly reducing production costs and improving product quality. A dedicated primary and secondary dedusting system provides all requested environmental compliance. Successful commissioning was in 2018.
Challenge
Prior to the installation of the AOD converter, Acroni faced significant bottlenecks in its stainless steel production process. The existing configuration, which involved crude steel production in an electric arc furnace followed by decarburization in a Vacuum Oxygen Decarburization (VOD) plant, was inefficient for stainless steel due to longer treatment durations, compared to carbon steels. This inefficiency limited production capacity and flexibility, hindering Acroni's ability to meet market demands for specialized steel grades. Additionally, the high degree of slagging of alloying elements like chromium in the existing setup increased production costs.
Regarding the dedusting system for the new AOD converter, Acroni faced the challenge of meeting increasingly stringent environmental regulations while maintaining operational efficiency and ensuring workplace safety. Acroni also sought a solution that not only ensured compliance with emission limits but also offered the potential for future energy optimization, aligning with their long-term sustainability goals in steel production.
Solution
The installation of the AOD converter at Acroni's facility has revolutionized its stainless steel production capabilities. With a nominal heat size of 95 metric tons, the converter reduces slagging, enabling the use of cheaper ferrochromium grades with higher carbon content. This significantly cuts alloying costs and enhances operational flexibility. The converter is equipped with a drive damper system, which minimizes vibrations and mechanical stresses, reducing wear and maintenance costs while extending the service life of the plant. The integration of a process automation system specifically designed for AOD converters optimizes raw material usage and minimizes treatment times, further boosting production efficiency.
The dedusting system at Acroni's facility is a dry technology solution that sets new standards in environmental compliance. Featuring a pulse jet filter with a forced draft cooler, the system handles a flow rate of approximately one million cubic meters per hour, efficiently capturing and cooling off-gases from the AOD converter and related units. This ensures emissions remain below current limits while enhancing energy efficiency and occupational safety. The dedusting plant also offers potential for the future installation of a waste heat recovery system, optimizing energy use and contributing to Acroni's commitment to sustainable steel production.
Overview of steel works at Acroni in Jesenice, Slovenia
Charging of AOD converter
Bag filter with clean gas stack and dust silo at Acroni
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Benefits
- Reduced production costs through the use of less expensive charging materials
- Increased productivity with up to 50% more heats per day due to reduced tap-to-tap time for stainless steel grades
- Extended service life and reduced maintenance costs due to the drive damper system
- Achieved lowest dust emission levels to ensure environmental compliance
- Enhanced energy efficiency and potential for waste heat recovery
Conclusion
- Installation of a 95-metric-ton AOD converter and dedusting system
- Increased production capacity by over 20%, resolving previous bottlenecks
- Incorporation of a process automation system designed for AOD converters
- Achieved environmental compliance with emissions below current limits
- Potential for future installation of waste heat recovery
