Hubei Shunle partnered with Primetals Technologies to implement two Electric Arc Furnace EAF Quantum systems, setting new benchmarks in steelmaking efficiency and sustainability. Using 100% scrap steel as raw material, the plant achieves up to 50 heats per day, tap-to-tap times of less than 28 minutes, and remarkable reductions in energy consumption and emissions.
Challenge
In 2018, Hubei Shunle faced operational inefficiencies with its existing closed-roof, top-charging electric arc furnaces, including high energy consumption, elevated emissions, and limited production capacity. These challenges were compounded by the need to align with China’s carbon neutrality goals and reduce operating costs. Additionally, the COVID-19 pandemic posed logistical hurdles during the implementation phase, requiring innovative solutions for project execution and personnel training.
Solution
Primetals Technologies introduced Electric Arc Furnace EAF Quantum technology, addressing Hubei Shunle’s challenges with innovative features:
- Scrap preheating system: preheats scrap steel to 500–600°C using off-gas energy, while shortening energy consumption and accelerating melting cycles, reducing tap-to-tap times to less than 28 minutes and minimizing power-off durations to just 3 minutes
- Furnace Advanced Slag-Free Tapping (FAST) system: enables tapping under power-on conditions
- Automated scrap yard management: streamlines material handling and enhances operational efficiency
- Low consumption rates: achieves energy consumption of less than 312 kWh per ton, oxygen consumption below 24 cubic meters per ton, and electrode consumption under 0.7 kilograms per ton
These technologies improved productivity, reduced emissions, and aligned with Hubei Shunle’s sustainability goals.
The implemented solution adheres to the highest standards for green steel, as stated in the technical specifications for waste gas ultra-low-emission engineering of the iron and steel industry and the identification and authentication of product carbon footprints for the electric arc furnace (EAF) compact process.
Results
- Productivity up to 50 heats per day
- Tap-to-tap times of less than 28 minutes
- Energy consumption reduced to less than 312 kWh per ton of molten steel
- Dust emissions lowered to less than 5 kilograms per ton of molten steel
- Yield rate exceeding 95.6%, maximizing output and minimizing waste
- Zero direct CO2 emissions from steel production using 100% scrap steel
Benefits
- Lower energy consumption: the EAF Quantum reduces energy consumption to less than 312 kWh per ton, significantly lowering operational costs.
- Reduced operating costs: optimized energy and material usage, including low electrode and oxygen consumption, result in substantial cost savings.
- Higher throughput: achieving up to 50 heats per day with tap-to-tap times of less than 28 minutes ensures maximum productivity.
- Enhanced sustainability: the use of 100% scrap steel eliminates direct CO2 emissions from steel production, aligning with carbon neutrality goals.
- Improved process efficiency: innovations like scrap preheating and slag-free tapping reduce downtime and streamline operations, ensuring consistent output and reliability.
Conclusion
- Record-breaking productivity with up to 50 heats per day
- Significant reductions in energy consumption and emissions
- Advanced scrap preheating and slag-free tapping technologies
- Strengthened global competitiveness as a highly efficient minimill
- Ongoing support from Primetals Technologies for optimization and innovation
