The Consteel process boosts productivity and improves energy efficiency of the continuous casting furnace with minimum environmental impact. The main highlights in implementing this continuous casting furnace technology are the conservation measures such as recovery of heat from furnace exhaust gas to pre-heat scrap prior to charging in the furnace, reduction in specific electrical energy, reductions in O2 (oxygen), and C (carbon) usage with no burner fuel consumption, increased production rate due to decreased tap-to-tap time, significant decrease in electrical disturbances on the network, lower electrode consumption and electrode breakage, increase in scrap yield, less dust is evacuated to the bag house, and cost reduction.
More environmentally friendly, fume generated by steel making from the continuous casting furnace mouth in the opposite direction with scrap charging ensures up to 300-350 ℃ preheating temperature to lower consumption.
This amount of preheating typically reduces energy consumption by 40 kWh/ton to 60 kWh/ton, electrode consumption by around 0.35 kg/ton, refractory consumption by around 1.2 kg/ton and tap-to-tap time by around 5 minutes to 6 minutes.
Key advantage over conventional batch processes where scrap is melted by the direct action of the electric arc. The EAF continuous casting furnace gases are sent to the exhaust gas cleaning plant in conditions suitable for the complete combustion of carbon monoxide (CO) and other pollutants without any fuel consumption.
CONSTEEL EAF proven benefits includes fast payback, high flexibility, environmental friendliness, safety of the operational personnel, minimum disturbance to the electric network, reduction in logistics, maintenance and manpower costs, improved use of chemical energy, lower electrode consumption, increase in scrap yield compared to batch-charged furnaces, continuous casting furnace control and optimization of operational parameters, and improved charge control through automated scrap quantity and quality tracking.