IÇDA TURKEY. High quality steel bars and high alloy steels since PLANT INFORMATION Annual production Production mix. 1,800,000 t of good billets

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1 IÇDA TURKEY High quality steel bars and high alloy steels since 1970 PLANT INFORMATION Annual production Production mix Billets Steel grades Raw material 1,800,000 t of good billets 150 mm sq., 180 mm sq., 200 mm sq. Low and medium c-steel (rebar / SBQ grades) Charging ratio: 100% steel scrap PROJECT INFORMATION Customer Location IçDA Turkey Commissioning 2003

2 The biggest steel producer in Turkey High efficiency with ultra-high chemical power EAF IçDA is the biggest steel producer in the private sector in Turkey based on production capacity. The company commissioned its first steelwork in Overall, it achieves an average production of 1.65 million t per year. The steelwork incorporates the first UHCP (Ultra-High Chemical Power) electric arc furnace supplied by SMS Concast worldwide and has a ladle size of 180 t. Top quality components meet the demands of the plant operator The technological equipment of this plant, e.g. scrap preheating, EAF, LF and CCM, was entirely supplied by SMS Concast. Various IçDA design suggestions were taken into consideration: the maximized rate of energy input and reduction of power-off times has been a key factor during the development of the plant. Furthermore, the single bay design and the controlled metallurgical operation by a superior automation system. A high efficiency of the plant is guaranteed by a continuous high yield. SMS Concast s state-of-the-art technology is a success factor for plant operators in order to optimize cost control. A well-connected process chain saves resources Scrap for the steelwork is brought by ship and unloaded in the close by harbor. The ships are reloaded with good billets. Short transportation distances are positively influencing the overall performance of the plant. The well-connected process chain saves time, money and is more environmentally friendly. 2

3 IÇDA t EAF with UHCP Expansion of capacity and performance Second steelwork commissioned in 2008 In September 2008 IçDA commissioned the second steelwork with an UHCP (Ultra-High Chemical Power) EAF at its Biga location. Supplied by SMS Concast, the UHCP furnace features a productivity of 320 t/h and stands for top performance. Special design measures ensure the high power input density of 230 MW. This makes it possible for IçDA to produce 2.2 million t of high-quality steel products per year. The plant comprises a 220-t EAF, a ladle furnace and an eight-strand Convex billet caster. With these facilities, IçDA turns liquid steel into square billets 150 mm x 150 mm or 180 mm x 180 mm in size. The capacity and performance of electric steelworks shops have been drastically increased so that with capacities over 220 t these plants can hardly be called minimills anymore. 3

4 IÇDAŞ Turkey Minimill designed by SMS Concast Within the first year the monthly production capacity increased when at the same time electricity consumption decreased During the start up phase the target of 1.5 mio t per year, e.g. 125,000 t per month, was achieved as shown in the diagram. Within four years of meltshop operation, a continuous optimization of the process technology allowed to achieve outstanding results. As a result of that, the production output in 2007 exceeded the original design capacity by 20 %. Monthly Production Dec 03 Jan 04 Feb 04 Mar 04 Apr 04 May 04 Jun 04 Jul 04 Aug 04 Sep 04 Oct 04 Nov 04 4

5 Plant layout at IÇDA Short transportation distances are positively influencing the overall performances Material flow transport on rail transport by over head crane Electric arc furnace Ladle furnaces Vacuum degasser Continuous casting machine Fume dedusting plant 4 (2003) Initial (2007) Actual Electrode consumption EAF 1.3 kg/t GB* 0.92 kg/t GB* Electrode consumption LF 0.22 kg/t GB* 0.15 kg/t GB* Electrical energy EAF 380 kwh/t LS* 280 kwh/t GB* Electrical energy LF 22 kwh/t LS* 20 kwh/t GB* Electricity consumption *GB: good billet, LS: liquid steel Dec 03 Jan 04 Feb 04 Mar 04 Apr 04 May 04 Jun 04 Jul 04 Aug 04 Sep 04 Oct 04 Nov 04 5

6 Electric Arc Furnace ELECTRIC ARC FURNACE IçDA produces with the first UHCP EAF supplied by SMS Concast. The EBT-type furnace, with large tapped steel capacity, is also equipped with a CONSO-tech oxygen injection system and off-gas analysis using laser detectors. In its second steelworks IçDA uses a 250 t UHCP EAF with a 8.3 m shell diameter by SMS Concast. Type Heat size Hot heel Shell diameter Shell volume Electrode arms Electrode diameter Electrode regulation Transformer Scrap charges Tap to tap time Conso injector Power on Electric Oxygen Natural gas Electrode Shell life time Refractory life AC full platform, EBT tapping 180 t nominal 20 t 7.8m / 8.0 m 200 m 3 Conductive type (Cu) 650 mm Digital hydraulic type 168 MVA 2 3 buckets min Wall installation 4 x 4,500 Nm 3 /h / 6 MW EBT installation 2 x Nm 3 /h / 6 MW 32 min (3 buckets) CONSUMPTION figures < 300 kwh / t good billets 48 Nm 3 / t good billets 5.2 Nm 3 / t good billets 0.9 kg / t good billets 20 days (> 450 heats) > 600 heats / campaign Type Heat size Hot heel Shell diameter Shell volume Electrode arms Electrode diameter Electrode regulation Transformer Scrap charges Tap to tap time Conso injector Power on Electric Oxygen Natural gas Electrode Shell life time Refractory life AC full platform, EBT tapping 250 t nominal 30 t 8.3 m 260 m 3 Conductive type (Cu) 750 mm Digital hydraulic type 230 MVA 2 buckets min Wall installation with 8 CONSO injector Each CONSO injector can work as oxy-gas burner or oxygen lance. The installed burner power will be 7 MW per unit, corresponding to the natural gas flow rate of 730 Nm 3 /h and oxygen flow rate of Nm 3 /h 34 min CONSUMPTION figures with 100% non-preheated scrap < 42 kwh / t good billets 41 Nm 3 / t good billets 4.9 Nm 3 / t good billets 1.3 kg / t good billets 20 days (> 450 heats) > 600 heats / campaign 6

7 Ladle Furnace Continuous Casting Machine The 175 t ladle furnace is equipped with a water cooled roof, conductive electrode arms, and an automatic temperature and sampling device. The high production 6-strand SBQ-Caster uses SMS Concast s CONVEX mould technology. The caster is equipped with a full range of supplementary features such as an automatic stopper control system, mould stirrers and a billet marking machine. The CCM can produce up to 1.8 mio t of good billets per year. Type Nominal ladle capacity Electrode arms Electrode diameter Electrode regulator Transformer Heating rate Stirring Ladle cars CONSUMPTION figures Electric Electrode JIB Type CS t nominal Conductive type (Cu) 460 mm Digital hydraulic type 25 MVA plus 20 % 4.0 K / min Double argon porous plug Two cars with crane access on both sides of the ladle furnace 0.45 kwh / t and K kg / kw Type Radius Number of strands Strand distance Section range Cast section size Billet length Ladle support type Tundish car type Tundish shape Tundish flow regulation Mould type Electro magnetic stirring Casting speed Dummy bar type Cutting device Discharge Cooling bed type Product identification CONVEX 20-9 CCS 9 m 6 1,200 mm 120 mm sq. to 200 mm sq. 150 mm sq., 180 mm sq., 200 mm sq m Turret with lifting / lowering and weighing system Full overhead with lifting / lowering system T-type Mechanical stopper mechanism CONVEX Technology Mould-EMS (adjustable height) m / min Rigid Torch cutting Overhead cross transfer Hydraulic turnover Billet marking machines, one on each side of the turnover cooling bed 7

8 SMS Concast Toedistrasse Zurich Switzerland Phone: Fax: sales@sms-concast.ch MEETING your EXPECTATIONS B403.04/13 en Printed in Switzerland