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How much is the cost of electric arc furnace steelmaking?
Updated: 2022-04-28 Attention:
Since 2016, with the elimination of domestic medium frequency furnaces, electric arc furnaces have sprung up and ushered in new development opportunities. Only overnight, electric arc furnaces have become more expensive than "Luoyang paper".
Undoubtedly, as an electric arc furnace, it will become a new main force and a new research topic in the development of domestic iron and steel industry in the future. But how much does it cost to make steel? How are these costs constituted? At present, there is no authoritative department or production enterprise that can give a clear statement, which has become a "mystery" that everyone wants to know.
With this problem that everyone is concerned about, as a small editor in the steel plant for many years, he went to several production areas with relatively concentrated electric arc furnaces in China, conducted field investigation and Research on many electric arc furnace production plants, obtained hand-made data on the steelmaking process and cost of electric arc furnace, wrote this article and officially published it.
In the words of the author Xiaobian: I hope that by reading this article, we can lift the "mysterious veil" of the cost of electric arc furnace steelmaking, so that we can better understand all aspects of it, so as to be more conducive to our own production and operation.
Many "mysterious" secrets about EAF steelmaking can not be seen in textbooks and other expert articles. This article is indeed worthy of your expectation.
The following is the full text of the Compendium:
Visit the mysterious area of short process EAF steelmaking production cost (all scrap smelting)
In 2017, after all the intermediate frequency furnaces were hanged (in theory), Xi'an electric furnace manufacturers such as PENGYUAN, Huachang, Huachuang, hongxinyuan, Taoyuan metallurgy and other electric furnace manufacturers ushered in a golden period of historical opportunity for development in history. It is reported that a factory received 6 waves of electric arc furnace ordering manufacturers one day and received 45 electric arc furnace production orders one month. It can be seen that in 2017, electric furnace manufacturers have made a lot of money, and there is a shortage of electric furnace designers. The subsequent benefits are related supporting production enterprises of electric furnace and related products, such as electric arc furnace transformer, refining furnace transformer, electrode, alloy, steel-making auxiliary materials, refractory and a series of products, which soar all the way with the spring breeze of electric furnace in various factories, and are proud of horseshoe disease!
In 2018, the rapid electric arc furnace steelmaking was put into operation one after another. It is always a mystery that people are looking forward to and eager to find out the production cost of electric arc furnace steelmaking. Due to the opacity of its cost, electric arc furnace steelmaking has been covered with a mysterious veil! Let's talk about the composition of the total production cost of electric furnace.
1、 About the construction cost: for a new 80 ton continuous production kangsidi horizontal charging ultra-high power electric furnace, the total cost is basically about 50 million yuan, that is: 1. The cost of new plant (some enterprises use the old plant); 2. Kangsidi continuous feeding system (represented by Henan Taihang Quanli Heavy Industry Co., Ltd.) 3. Main equipment of electric arc furnace (the new electric furnace is basically between 75-120 tons, and few exceed 100 tons); 4. Main equipment of refining furnace (basically matched with electric arc furnace) 5. Continuous casting equipment (mostly used) 6. Dust removal system (this is a large project, which must pass due to the tension of environmental protection policy) 7. Waterway system; 8. Power auxiliary system. The above eight items basically cover the whole production system of electric arc furnace. For the steel rolling system, there is no need for capital investment, and the old original equipment is basically used. For the construction speed, the assumed speed of private enterprises can be said to be amazing. It took only half a year to build an electric furnace steelmaking enterprise with an annual output of 1 million tons.
2、 During the construction process, the electric furnace iron and steel enterprises began to prepare for production. During this period, the bosses of the steel enterprises saw the profit of more than 1000 yuan per ton of steel in the long process steel enterprises, which was really chicken red in their eyes. In order to make the electric furnace steelmaking put into operation one day earlier, the bosses want to take turns to build their own. At the end of the construction, the process of preparing for production is also a magnificent and arduous one. It is interesting to purchase electrodes. Before 2017, the market price of electrodes was 10000-20000 yuan per ton, which rose to 200000 yuan per ton at the end of 2017, and its shameless degree is unmatched. As the saying goes: a clever woman cannot cook without rice. The bosses still spend a lot of money on purchasing electrodes, and the price of a car of electrodes reaches an amazing more than 7 million yuan. For the recruitment of electric arc furnace production technicians, all enterprises also show their ability to dig corners. The salary of the head of electric arc furnace is fired to 50000 yuan per month, but there is still no recruitment. The wages of an assistant in front of the furnace, a foreman, a repairman and a refining furnace chief have also increased with the tide, and there are no people with a salary of more than 10000.
3、 When it comes to the early trial production, because the domestic electric furnace steelmaking technology is relatively long, the process technology is quite weak, and there is a shortage of technicians, especially for konsti's horizontal feeding and continuous production. In the process of trial production, there are many difficulties, safety accidents, production accidents and casualties. From February 2018 to now, it can be said that the electric furnace production enterprises have experienced the test of life and death, Basically achieved a smooth and stable production. New electric arc furnaces in Henan, Hubei, Guangdong, Guangxi, Zhejiang, Fujian, Xinjiang, Hebei and other places have successively achieved stable production. Taking the 80 ton electric arc furnace of a factory in East China as an example, its production situation is amazing. In just three months, the enterprise has reached production capacity. And the production cost has been controlled to the industry level. Let's analyze the composition of the current production cost of the enterprise one by one!
4、 Composition of production cost of electric arc furnace in a factory in Fujian (production index in July 2018; total production for 24 days; average daily output of 35 furnaces (average furnace output of 83 tons of molten steel); Total production 69896 tons;): Kangsidi horizontal feeding system; 80 ton electric furnace; 80 ton refining furnace; Six machine six strand continuous caster (producing hrb400e anti-seismic spiral conch; the local market sales price is 4000 yuan / ton):
1. Cost of iron and steel materials: the enterprise takes the purchase of a large number of local industrial leftovers, iron sales, heavy scrap, and primary and secondary broken materials as the production raw materials; The average price is controlled at 2300 yuan; Due to its good material type, the steel yield is relatively high, which can be basically controlled at 90%. The production cost of steel material is about 2300 yuan / 90% = 2555 yuan;
2. Electrode consumption cost: the price of electrode has dropped from high altitude, and the unit price of electrode for ultra-high power electric arc furnace steelmaking with a diameter of 600 has dropped from nearly 200000 yuan to about 70000 yuan; Ordinary power electrodes, such as those for refining furnaces with a diameter of 400, have fallen to about 50000 yuan. The electrode cost is: electric furnace steelmaking electrode cost: 70000 yuan * 0.0015 tons / ton of steel = 105 yuan + refining furnace steelmaking electrode cost: 50000 yuan * 0.00045 tons / ton of steel = 22.5 yuan = 127.5 yuan;
3. Electricity price cost: the composition of electricity price cost is mainly: (1) electric furnace power consumption: 384.7 kwh / ton; (2) Power consumption of refining furnace: 36.65 degrees / ton; (3) Dust removal power consumption: 20.63 degrees / ton; (4) Power consumption of oxygen generating station: 21.18 degrees / ton; (5) Power consumption of water treatment: 19.36 kwh / ton; (6) Other auxiliary power consumption: 8.1 kwh / ton; Total power consumption of six items: 384.7 + 36.65 + 20.63 + 21.18 + 19.36 + 8.1 = 490.62 kwh / ton * 0.68 yuan / kWh = 333.62 yuan.
4. Steelmaking fuel cost: the cost items of electric furnace steelmaking fuel mainly include: (1) natural gas: 2.5kg/ton steel * 3.25 yuan = 8.125 yuan; (2) Oxygen: 28KG / ton steel * 1.8 yuan = 50.4 yuan (3) nitrogen: 2.6kg/ton steel * 0.8 yuan = 2.08 yuan; (4) Argon = 632.2 yuan / ton of steel; The total cost is about 62.237 yuan without considering the factors that the gas price changes with the market.
5. Auxiliary material alloy cost: (1) lime: (2) dolomite; (3) Compound Deoxidizer; (4) Alloy (high manganese alloy, medium manganese alloy, ferrosilicon, other alloys, etc.) (5) carbon powder; (6) Carburizing agent; (7) Fluorite; (8) Silicon carbide; (9) Carbonized rice husk; (10) Drainage sand: the unit price of the above auxiliary materials involves data confidentiality, and the total cost is 121.86 yuan
6. Cost of other consumables: maintenance, cost of low value products, cost of various samplers, cost of thermocouples: cost of sitting bricks, sliding plates, institutions, etc., which are not provided temporarily due to data confidentiality. Total cost: 4.85 yuan
7. Contracting cost: medium contracting cost: 52 yuan + large contracting cost 4.8 yuan = 56.8 yuan.
8. Rolling cost: 129.75 yuan (continuous casting and rolling)
9. Workers' wages: 47.6 yuan in total;
The total production cost is: 1. Steel material cost: 2555 yuan+ 2. Electrode consumption cost: 127.5 yuan+ 3. Electricity price cost: 333.62 yuan; 4. Steelmaking fuel cost: 62.237 yuan + 5. Auxiliary material alloy cost: 121.86 yuan+ 6. Cost of other consumables: 4.85 yuan + 7, contracting cost: 56.8 yuan + 8, rolling cost: 129.75 yuan + 9, worker's salary: 47.6 yuan in total= 3439.2 yuan.
The selling price of spiral snail in the market excluding tax is 4000 yuan per ton, deducting the total production cost of 3439.2 yuan; The gross profit is 560.8 yuan; The deduction of environmental protection, taxes and financial expenses is calculated as 200 yuan; The net profit can basically reach 260 yuan; 70000 tons per month; Net profit of 18.2 million yuan; The construction cost will be basically recovered in three months. Therefore, although electric furnace steelmaking can not compare with the huge profit of 1000 yuan / ton of long process, it will emerge and remain invincible in the market trend of national environmental protection and industrial policies!
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