2005 EAF Melt Shops in North America MARKET STUDY Final Report

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1 2005 EAF Melt Shops in North America MARKET STUDY Final Report Prepared for: by: AIM Project # 344 September 2005

2 FOREWORD This Report was prepared by AIM Market Research. Neither AIM Market Research, nor any person acting on its behalf: a) makes any warranty, express or implied, with respect to the use of any information, apparatus, method, or process disclosed in this Report or that such use may not infringe privately owned rights; or b) assumes any liabilities with respect to the use of or for damages resulting from the use of, any information, apparatus, method, or process disclosed in this Report. AIM Market Research is a privately owned market research and development firm. Copyright 2003 as a published work by AIM Market Research. All rights reserved. This report or its contents either in whole or in part may not be reproduced, stored in a data retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the express written consent of AIM Market Research. Page I-i

3 Unauthorized and/or unlicensed copying of any part of this report or its appendices is in violation of copyright law. CONTENTS LIST OF APPENDICES...? LIST OF FIGURES...ix LIST OF TABLES...xvi EXECUTIVE SUMMARY...ES-1 PROSPECT ANALYSIS... S-1 CONCLUSIONS...C-1 INTRODUCTION...IN-1 Section 1 - GENERAL MELT SHOP INFORMATION EAF Melting Furnaces Suppliers Age of EAFs Nominal Heat Sizes of EAFs Steel Production Heats Per Day Annual Steel Production Ladle Metallurgy Furnaces (LMFs) Suppliers Age of LMFs Ladle Degassing Satisfaction with Performance Vacuum Degassed Share of Heats Expectations to Increase Vacuum Degassing Plans to Enhance Product Line Quality by Adding Vacuum Degassing The Performance of Steam Ejector Fundamental Priorities of EAF Melt Shops Surveyed Section 2 OPERATING PARAMETERS & ENERGY COMPOSITION EAF Operating Parameters Tap-to-Tap Time Power-on Time Is the EAF Presently a Bottleneck to Steelmaking? Energy Composition of EAF Melting EAF Melt Shop Operating Costs Page I-ii

4 SECTION 3 AUXILARY TECHNOLOGIES Oxy-Fuel Burners Mounting Location Suppliers Rated Power Maintenance Practice Ownership of Carbon Injection Equipment Functions & Attributes of the Burner/Lance/Injector System Attributes of the Burner/Lance/Injector System Electrode Arms Type of Electrode Arms Manufacturers of Current Carrying Conducting Arms Plans to Replace Your Electrode Arms SECTION 4 CHARGE & ALLOY MATERIALS Bauxite Fines Used Tires Concerns About the Use of Tires The Use of Low Residual Scrap (LRS) or Alternative Iron (Al) Continuous Scrap Charging Cast Aluminum De-ox Notchbar Cones Shot Other Sources of Aluminum De-ox Steel Turning SECTION 5 REFRACTORY MONITORING & WEAR MEASUREMENT The Most Significant Refractory Erosion or Failure Problem Area EAF Ladles Could Continuous Monitoring Help? SECTION 6 - ELECTRICAL POWER & DISTRIBUTION EQUIPMENT PPC (Point of Common Coupling) Short Circuit MVA Rating Short Circuit Voltage Substation/Power Distribution Hardware Manufacturer The Substation / Power Distribution Engineer Installation Contractor Year of Start-Up Substation Transformer Rating (MVA) Page I-iii

5 EAF Transformers Manufacturers Age of Transformers Power Rating (MVA) Active Power RATINGS (MW) Current (Amps) Types of Delta Types of Buss SECTION 7 - POWER COMPENSATION EQUIPMENT Power Quality Requirements Power Factor Flicker Harmonics Dry Type Air Core Reactors Using a Series Reactor The Benefits of a Series Connected Dry-Type Air-Core Reactor Shops Interested In Learning About Applying A Dry-Type Air-Core Reactor Aware of Modeling Techniques to Select Cost Effective Solutions Required Payback Timeframe Added Benefit to Automatic On-Line Tapped Switchable Series Reactors Static Var Compensation Manufacturer Installation of SVCs The Benefits of an SVA Satisfaction With SVA Performance Interest In STATCOM Reasons For Not Using SVA Using (Only) Harmonics Filters SECTION 8 PROTECTIVE RELAYS Number of Protective Relays Installed Technology of Protective Relays Plans to Replace Electro-Mechanical Protective Relays Applying Differential Protection to Transformers Why Differential Protection Is Not Applied To The EAF and LMF Units Other Protection Systems Are Applied To The EAF and/or LMF Vaults Impedance Based Relay Systems Fire Supression Systems Flash Sensor Systems Manually Activated Systems Protection Systems Applied To DC-EAF Transformer Vaults EAF Melt Shops That Have Experienced Primary or Secondary Fault Events Page I-iv

6 SECTION 9 AUTOMATION Electrode Regulation Control System Leading Suppliers Year Installed Assessing Performance of Electrode Regulation Control System Level II Control System Year Installed Assessing Performace of Level II Control Systems SECTION 10 LAST MAJOR UPGRADE & PLANS TO CHANGE EAF MELT SHOP EQUIPMENT Last Major Melt Shop Upgrade Timing Plans to Add, Upgrade, or Replace Major Melt Shop Process Equipment Plans to Increase Power Systems or Transformers Equipment/Design Changes That Would Have The Greatest Impact on Quality Page I-v

7 LIST OF APPENDICES Appendix 1: List Of Plants Surveyed Appendix 2: Individuals Contacted and Interviewed Appendix 3: Prospect Analysis SECTION 1 GENERAL MELT SHOP INFORMATION Appendix 4: General Melt Shop Information - Melt Shop and Furnace Data Appendix 5: General Melt Shop Information - Steel Production and Fundamental Priority Appendix 17: Refining Practices - Ladle Degassing Appendix 18: Refining Practices - Plans to Add Ladle Degassing Appendix 19: Refining Practices - Ladle Degassing Performance Appendix 20: Refining Practices - Ladle Degassing Comments SECTION 2 OPERATING PARAMETERS & ENERGY COMPOSITION Appendix 6: General Melt Shop Information - EAF Operating Parameters and Experience Appendix 7: General Melt Shop Information - EAF Energy Consumption Appendix 21: Measuring Melt Shop Costs SECTION 3 AUXILARY TECHNOLOGIES Appendix 8: General Melt Shop Information - Characterize Oxy-Fuel Burners Appendix 9: General Melt Shop Information - Oxy-Fuel Burner Maintenance Practice Appendix 10: General Melt Shop Information - Relative Importance of Functions and Attributes of Burner / Lance / Injector Systems Appendix 11: General Melt Shop Information - Comments to Appendix 10 Appendix 12: General Melt Shop Information - Electrode Arms Characterize Existing Electrode Arms Appendix 13: General Melt Shop Information - Electrode Arms Plans or Wish List to Replace Appendix 14: General Melt Shop Information - Comments to Appendix 13 SECTION 4 IRON BEARING & OTHER ALLOY CHARGE MATERIALS Appendix 15: Refining Practices - The Use of Bauxite Fines Appendix 16: Refining Practices - Comments to Appendix 15 Appendix 22: Scrap Charging, Scrap & Other Alloy Charge Materials - Tires Appendix 23: Scrap Charging, Scrap & Other Alloy Charge Materials The Use of Low Residual Scrap or Alternative Irons Appendix 24: Scrap Charging, Scrap & Other Alloy Charge Materials - Comments Page I-vi

8 Appendix 25: Scrap Charging, Scrap & Other Alloy Charge Materials Adding Continuous Scrap Charging Appendix 26: Refining Practices Characterize The Cast Aluminum Deox Used Appendix 27: Refining Practices Cast Aluminum Deox Comments Appendix 28: Scrap Charging, Scrap & Other Alloy Charge Materials Steel Turnings Appendix 29: Scrap Charging, Scrap & Other Alloy Charge Materials Increasing Steel Turnings Use SECTION 5 REFRACTORY MONITORING & WEAR MEASUREMENT Appendix 30: Refractory Wear Measurement Appendix 31: Refractory Wear Most Significant Wear Area Appendix 32: Refractory Wear Measurement Need to Continuously Monitor Refractory Wear Appendix 33: Refractory Wear Measurement Benefits of Continuously Monitoring the Refractory Thickness SECTION 6 ELECTRICAL POWER & DISTRIBUTION EQUIPMENT Appendix 35: Major Electrical Equipment & Power Systems EAF Transformers Appendix 43: Major Electrical Equipment & Power Systems Substation/Power Distribution Appendix 46: Major Electrical Equipment & Power Systems Point of Common Coupling SECTION 7 POWER COMPENSATION EQUIPMENT Appendix 37: Major Electrical Equipment & Power Systems Reactor Are You Aware That Fixed Tap Dry-Type Air-Core Series Reactors Have Been Used Successfully With EAFs For Over 13 Years? Appendix 38: Major Electrical Equipment & Power Systems Using a Series Reactor? Appendix 39: Major Electrical Equipment & Power Systems Reactor If Not Using Why Not? Appendix 40: Major Electrical Equipment & Power Systems Reactor - Aware of Modeling Technologies Appendix 41: Major Electrical Equipment & Power Systems Reactor Payback Time Frame Appendix 42: Major Electrical Equipment & Power Systems Reactor - Comment Appendix 44: Major Electrical Equipment & Power Systems Static Var Compensation Appendix 45: Major Electrical Equipment & Power Systems Static Var Compensation If Not Using, Why Not? Page I-vii

9 Appendix 47: Major Electrical Equipment & Power Systems Static Var Compensation Comment SECTION 8 PROTECTIVE RELAYS Appendix 48: Major Electrical Equipment & Power Systems Protective Relays Characteristics Appendix 49: Major Electrical Equipment & Power Systems Protective Relays Differential Protection Appendix 50: Major Electrical Equipment & Power Systems Protective Relays Other Overcurrent Protection Appendix 51: Major Electrical Equipment & Power Systems Protective Relays If Dc EAF, Other Overcurrent Protection Appendix 52: Major Electrical Equipment & Power Systems Protective Relays Fault Events SECTION 9 AUTOMATION Appendix 53: Automation Electrode Regulation Control System Appendix 54: Automation Level II Control Appendix 55: Automation Comment SECTION 10 LAST MAJOR UPGRADE & PLANS TO CHANGE EAF MELT SHOP EQUIPMENT Appendix 36: Major Electrical Equipment & Power Systems Plans to Increase or Upgrade Transformer Appendix 56: Last Major Melt Shop Upgrade Appendix 57: Plans to Upgrade, Replace, or Add Any Major Process Equipment General Scope Appendix 58: Plans to Upgrade, Replace, or Add Any Major Process Equipment Detailed Scope Appendix 59: The Equipment/Design Changes That Would Have the Greatest Impact on Quality Appendix 60: The Key Decision Makers Appendix 61: Plans to Upgrade, Replace, or Add Any Major Process Equipment - Comment OTHER APPENDICES Appendix 34: Criteria to Evaluate Capital Projects Appendix 62: List of EAF Melt Shops Not Included in Survey Appendix 63: Survey Questionnaire Page I-viii

10 LIST OF FIGURES SECTION 1 - GENERAL MELT SHOP INFORMATION Figure 2 Manufacturers of EAFs in Melt Shops Surveyed Figure 3 Age of EAFs Surveyed Figure 4 EAF Heat Sizes of EAFs in Quality Long Products Plants Figure 5 EAF Heat Sizes of EAFs in Construction Long Products Plants Figure 6 EAF Heat Sizes of EAFs in Flat Rolled Products Plants Figure 7 Heats per Day of EAFs in Quality Long Products Plants Figure 8 Heats per Day of EAFs in Construction Long Products Plants Figure 9 Heats per Day of EAFs in Flat Rolled Products Plants Figure 10 Projected 2005 Steel Production in Quality Long Products EAF Shops Surveyed Figure 11 Projected Change in Steel Production 2004 to 2005 in Quality Long Products EAF Melt Shops Surveyed Figure 12 Projected 2005 Steel Production in Construction Long Products Shops Surveyed Figure 13 Projected Change in Steel Production 2004 to 2005 Construction Long Products EAF Melt Shops Surveyed Figure 14 Projected 2005 Steel Production in Flat Rolled Product EAF Shops Surveyed Figure 15 Projected Change in Steel Production 2004 to 2005 in Flat Rolled Products EAF Melt Shops Surveyed Figure 16 Manufacturers of LMFs in EAF Melt Shops Surveyed Figure 17 Age of LMFs in EAF Melt Shops Surveyed Figure 18 Share of EAF Shops Surveyed That Have Vacuum Degassing Figure 19 Share of Heats Degassed Figure 20 Fundamental Priority of EAF Shops Surveyed Figure 21 Fundamental Priority of EAF Shops Surveyed by Type of Plant SECTION 2 OPERATING PARAMTERS & ENERGY COMPOSITION Figure 22 Tap-toTap Time of EAFs in Melt Shops Surveyed in Quality Long Products Plants Surveyed Figure 23 Tap-toTap Time of EAFs in Melt Shops Surveyed in Construction Long Products Plants Surveyed Figure 24 Tap-toTap Time of EAFs in Melt Shops Surveyed in Quality Long Products Plants Surveyed LIST OF FIGURES (CONT) Page I-ix

11 Figure 25 Power-on Time of EAFs in Melt Shops Surveyed in Quality Long Products Plants Surveyed Figure 26 Power-on Time of EAFs in Melt Shops Surveyed in Construction Long Products Plants Surveyed Figure 27 Power-on Time of EAFs in Melt Shops Surveyed in Quality Long Products Plants Surveyed Figure 28 Is the EAF a Bottleneck to Steelmaking? Figure 29 EAF Tap-toTap Time Improvement Sought (Minutes &%) Figure 30 Energy Composition of EAFs in Melt Shops in Quality Long Products Plants Surveyed Figure 31 Energy Composition of EAFs in Melt Shops in Construction Long Products Plants Surveyed Figure 32 Energy Composition of EAFs in Melt Shops in Flat Rolled Products Plants Surveyed Figure 33 How Operating Costs are Measured in EAF Melt Shops Figure 34 How Costs are Measured in EAF Shops Surveyed by Type of Plant SECTION 3 AUXILIARY TECHNOLOGIES Figure 35 EAF Shops Surveyed That Have Oxy-Fuel Burners Figure 36 Suppliers Share of Oxy-Fuel Burners Used by EAF Shops Surveyed Overall Figure 37 Suppliers Share of Oxy-Fuel Burners Used by EAF Shops Surveyed Overall Figure 38 Power Ratings of Oxy-Fuel Burners in EAF Melt Shops Surveyed Figure 39 Suppliers Share of Oxy-Fuel Burners Used by Power Ratings Figure 40 Share of EAF Shops Surveyed That Outsource Oxy-Fuel Lance Repair Figure 41 Share of EAF Shops Surveyed That Own Carbon Injection Equipment Figure 42 Most Important Functions of the Burner/Lance/Injection System by EAF Shops Surveyed Overall Figure 43 Most Important Functions of the Burner/Lance/Injection System by EAF Shops Surveyed by Type of Plant Figure 44 Most Important Attributes of the Burner/Lance/Injection System by EAF Shops Surveyed Overall Figure 45 Most Important Attributes of the Burner/Lance/Injection System by EAF Shops Surveyed by Type of Plant LIST OF FIGURES (CONT) Figure 46 Share of EAF Shops Surveyed That Have EAFs With Current Carrying Conducting Arms Page I-x

12 Figure 47 Suppliers Share of Oxy-Fuel Burner Used by EAF Shops Surveyed Overall Figure 48 Suppliers Share of Oxy-Fuel Burner Used by EAF Shops Surveyed Overall SECTION 4 CHARGE & ALLOYING MATERIALS Figure 49 Share of EAF Shops Surveyed That Use Low Residual Scrap or Alternative Iron Units Figure 50 Share of EAF Shops Surveyed That Use a Form of Aluminum Deoxidation Figure 51 Share of EAF Shops Surveyed That Use Steel Turnings Figure 52 Reason for Limiting the Use of Turnings SECTION 5 REFRACTORY MONITORING & WEAR MEASUREMENT Figure 53 Share of EAF Shops Surveyed That Currently Use or Have Investigated Products That Measure Refractory Wear Figure 54 EAF Shops Surveyed That Acknowledged Knowing of a Technology That Continuously Monitors or Measures Refractory Wear Figure 55 Application Where Refractory Wear is the Most Significant Problem in the Melt Shop Figure 56 Application Where Refractory Wear is the Most Significant Problem in the EAF Figure 57 Application Where Refractory Wear is the Most Significant Problem in the Ladle Figure 58 Share of EAF Shops Surveyed That Acknowledged That a System That Continuously Monitors Refractory Wear Could Help Improve the Problem Figure 59 Share of Plants Surveyed That Said How a Continuous Monitoring Refractory Wear System Could Help Improve the Problem Figure 60 Share of Plants Surveyed That Said Where a Continuous Monitoring Refractory Wear System Could Help Improve the Problem in the Ladle Figure 61 Share of Plants Surveyed That Said How a Continuous Monitoring Refractory Wear System Would Help Improve the EAF Bottom Refractory by Type of Plant Page I-xi

13 LIST OF FIGURES (CONT) SECTION 6 ELECTRICAL POWER & DISTRIBUTION EQUIPMENT Figure 62 MVAsc Rating at Point of Common Coupling (PCC) in 35 Melt Shops Surveyed Overall Figure 63 KVsc Rating at Point of Common Coupling (PCC) in 48 Melt Shops Surveyed Overall Figure 64 Suppliers Share of Substation Equipment Used in EAF Melt Shops Surveyed Overall Figure 65 Suppliers Share of Substation Equipment Used in EAF Melt Shops Surveyed by Type of Plant Figure 66 Suppliers Share of Substation Engineering Provided to EAF Melt Shops Surveyed by Type of Plants & Overall Figure 67 Suppliers Share of Substation Installation Provided to EAF Melt Shops Surveyed by Type of Plants & Overall Figure 68 Age of Substations Serving Melt Shops Surveyed by Type of Plants & Overall Figure 69 Substation Power Ratings (MVA) Share of EAF Melt Shops Surveyed Overall Figure 70 Substation Power Ratings (MVA) Share of EAF Melt Shops Surveyed by Type of Plant Figure 71 EAF Transformer Suppliers Share of EAF Transformers Used in EAF Melt Shops Overall Figure 72 EAF Transformer Suppliers Share of EAF Transformers Used in EAF Melt Shops by Type of Plants Figure 73 Age of EAF Transformers in Melt Shops Surveyed by Type of Plant Figure 74 EAF Transformers Power Ratings (MVA) Share of EAF Transformers Used in EAF Melt Shops Overall Figure 75 EAF Transformer Power Ratings (MVA) Share of EAF Transformers Used in EAF Melt Shops by Type of Plants Figure 76 EAF Transformer Active Power Ratings (MW) Share of EAF Transformers Used in Melt Shops Surveyed Overall Figure 77 EAF Transformer Active Power Ratings (MW) Share of EAF Transformers Used in Melt Shops Surveyed by Type of Plant Figure 78 EAF Transformer Primary Voltage Ratings (KV) Share of EAF Transformers Used in Melt Shops Surveyed Overall Figure 79 EAF Transformer Primary Voltage Ratings (KV) Share of EAF Transformers Used in Melt Shops Surveyed by Type of Plant LIST OF FIGURES (CONT) Figure 80 EAF Transformer Primary Current Ratings (Amps) Share of EAF Transformers Used in Melt shops Surveyed Overall Page I-xii

14 Figure 81 EAF Transformers Primary Ratings (Amps) Share of EAF Transformers Used in Melt Shops Surveyed by Type of Plant Figure 82 Type of Delta Share of EAF Transformers in Melt Shops Surveyed Figure 83 Type of Delta Share of EAF Transformers in Melt Shops Surveyed SECTION 7 POWER COMPENSATION EQUIPMENT Figure 84 Share of EAF Shops Surveyed That Said Their Electric Utility Imposes Power Quality Requirements on Them Figure 85 Power Factor Imposed on 24 EAF Melt Shops Surveyed by Their Electric Utility Overall Figure 86 Share of EAF Shops Surveyed That Acknowledge Awareness That Fixed Tap Dry Type Air Core Reactors Have Been Used Successfully With EAFs for Over 13 Years Figure 87 Share of EAF Shops Surveyed That Presently Use a Fixed Tap Dry Type Air Core Reactor Figure 88 Series Reactor Ratings in EAF Melt Shops Surveyed Figure 89 Benefits Attributed to Dry Type Series Air-Core Reactor by EAF Shops Surveyed Overall Figure 90 Benefits Attributed to Dry Type Series Air-Core Reactor by EAF Shops Surveyed by Type of Plants Figure 91 Share of EAF Shops Surveyed That See Benefit Applying a Fixed Tap Dry Type Air-Core Reactor That Are Interested in Learning More About It Figure 92 Share of EAF Shops Surveyed That Are Aware of Modeling Techniques That Can Select the Most Cost Effective Solution Regarding the Application of Series Impedance Figure 93 Share of EAF Shops Surveyed That Have a StaticVar Control (SVC) System Figure 94 Share of 19 SVC Ratings (MVAr) in EAF Melt Shops Surveyed Overall Figure 95 Suppliers Share of 25 SVCs Installed in EAF Melt Shops Surveyed Overall Figure 96 Installation Provider s Share of 15 SVCs Installed in EAF Melt Shops Surveyed Overall Figure 97 Age of 25 SVCs Installed in EAF Melt Shops Surveyed Overall Figure 98 Benefits Attributed to SVCs by EAF Shops Surveyed Overall LIST OF FIGURES (CONT) Figure 99 Benefits Attributed to SVcs buy EAF Shops Surveyed by Type of Plant Figure 100 Why 25 EAF Shops Surveyed Are Not Using SVCs Overall Figure 101 Why EAF Shops Surveyed Are Not Using SVCs by Type of Plant Page I-xiii

15 Figure 102 Share of EAF Shops Surveyed Not Using SVC That Are Using Only Harmonic Filters or Capacitor Banks Figure 103 Number of Harmonic Filters or Capacitor Banks Used by 18 EAF Melt Shops Surveyed Overall Figure 104 MVAr Rating of Harmonic Filters or Capacitor Banks Used by 14 EAF Melt Shops Surveyed Overall Figure 105 KV Rating of Harmonic Filters of Capacitor Banks Used by 15 EAF Melt Shops Surveyed Overall SECTION 8 PROTECTIVE RELAYS Figure 106 Share of EAF Shops Surveyed Where At Least 50% of Their Protective Relays are Microprocessor or Electronic Based Figure 107 Technology of Protective Relays in Quality Long Products EAF Melt Shops Figure 108 Technology of Protective Relays in Construction Long Products EAF Melt Shops Figure 109 Technology of Protective Relays in Flat Roll Products EAF Melt Shops Figure 110 Share of EAF Shops Surveyed That Said They Plan to Replace Electro-Mechanical Protective Relays Figure 111 Share of EAF Shops Surveyed That Said Their EAF Transformers Have Differential Protection Figure 112 Share of EAF Melt Shops Surveyed That Said Their LMF Transformers Have Differential Protection Figure 113 Share of EAF Melt Shops Surveyed That Said That Impedance Protection is Applied to EAF and/or LMF Transformer Vaults Figure 114 Share of EAF Melt Shops Surveyed That Said Fire Protection is Applied to EAF and/or LMF Transformer Vaults Figure 115 Share of EAF Melt Shops Surveyed That Said That Flash Protection is Applied to EAF and/or LMF Transformer Vaults Figure 116 Share of EAF Melt Shops Surveyed That Said They Have Manually Activated Triping Applied to EAF and/or LMF Transformer Vaults Figure 117 Share of EAF Melt Shops Surveyed That Said They Have Experienced Primary or Secondary Fault Events in Their EAF Transformer of Other Vault Equipment Page I-xiv

16 LIST OF FIGURES (CONT) SECTION 9 AUTOMATION Figure 118 Electrode Regulation Suppliers Share of 55 EAF Melt Shops Surveyed Overall Figure 119 Electrode Regulation Suppliers Share of EAF Melt Shops Surveyed by Type of Plant Figure 120 Electrode Regulation Year of Installation in 52 EAF Melt Shops Surveyed Overall Figure 121 Electrode Regulation Year of Installation in EAF Melt Shops Surveyed by Type of Plant Figure 122 EAF Level II Control System Year of Installation in 47 EAF Melt Shops Surveyed Overall Figure 123 EAF Level II Control System EAF Melt Shops Surveyed by Type of Plants Figure 124 EAF Level II Control System Year of Installation in 45 EAF Melt Shops Surveyed Overall Figure 125 Electrode Regulation Year of Installation in EAF Melt Shop Surveyed by Type of Plant SECTION 10 LAST MAJOR UPGRADE & PLANS TO CHANGE EAF MELT SHOP EQUPMENT Figure 126 Year of Last Major Upgrade Indicated by 45 EAF Melt Shops Surveyed Overall Figure 127 Year of Last Major Upgrade Indicated by EAF Melt Shops Surveyed by Type of Plant Figure 128 Scope of Last Major Upgrade Indicated by 45 EAF Melt Shops Surveyed Overall Figure 129 Year of Last Major Upgrade Indicated by EAF Melt Shops Surveyed by Type of Plant Figure 130 Supplier of Last Major Upgrade Indicated by 45 EAF Melt Shops Surveyed Overall Figure 131 Share of EAF Melt Shops Surveyed That Said They Plan to Upgrade the EAF Melt Shop Figure 132 Share of EAF Melt Shops Surveyed That Said They Plan to Increase Power to the EAF Furnace Figure 133 Scope of Plans to Upgrade the 29 EAF Melt Shops Surveyed Overall Page I-xv

17 LIST OF TABLES SECTION 1 - GENERAL MELT SHOP INFORMATION Table 1 Number & Types of Power of EAFs Surveyed Table 2 Number of Ladle Furnaces in EAF Melt Shops Surveyed Table 3 EAF Melt Shops Where Performance of Vacuum Degasser Steam Ejector May Be Compromised SECTION 2 OPERATING PARAMTERS & ENERGY COMPOSITION Table 4 Location of Oxy-Fuel Burners in EAFs Surveyed Table 5 Plants with Current Carrying Conducting Arms on Their Wish List SECTION 4 CHARGE & ALLOYING MATERIALS Table 6 EAF Melt Shops That Charge Used Tires as a Feedstock Table 7 Location of Oxy-Fuel Burners in EAFs Surveyed Table 8A The Use of Low Residual Scrap (LRS) of Alternative Iron (Al) Units by the Quality Long Products Plants Surveyed Table 8B The Use of Low Residual Scrap (LRS) of Alternative Iron (Al) Units by the Quality Long Products Plants Surveyed Table 9A The Use of Low Residual Scrap (LRS) of Alternative Iron (Al) Units by the Quality Flat Rolled Plants Surveyed Table 9B Comments Regarding the Use of Low Residual Scrap (LRS) of Alternative Iron (Al) Units by the Quality Flat Rolled Plants Surveyed Table 10 Users of 5 lb. Notchbar Table 11 Users of 50 lb. Notchbar Table 12 Users of Other Size Bundles of Notchbar Table 13 Users of 2 Oz. Cones Table 14 Users of 4 Oz. Cones Table 15 Users of 6 Oz. Cones Table 16 Users of 3/8 In. Shot Table 17 Users of 3/8 In. Shot Table 18 Users of Other Types of Aluminum De-Oxidation SECTION 5 REFRACTORY MONITORING & WEAR MEASUREMENT Table 19 EAF Melt Shops That Have Considered or Are Using Refractory Monitoring or Measuring Technology Page I-xvi

18 LIST OF TABLES (CONT) SECTION 8 PROTECTIVE RELAYS Table 21 Fault Events Indicated by Quality Long Products Plants Table 22 Fault Events Indicated by Construction Long Products Plants Table 23 Fault Events Indicated by Flat Rolled Products Plants SECTION 10 LAST MAJOR UPGRADE & PLANS TO CHANGE EAF MELT SHOP EQUPMENT Table 24 Plans to Increase Power to EAF Furnace Operations Table 25 Cranes Table 26 Ladle Metallurgy Table 27 EAF Auxiliaries Table 28 EAF Electrical Table 29 EAF Environmental Table 30 EAF & EAF Mechanical Table 31 Melt Shop Table 32 Other Melt Shop Equipment Table 33 Changes That Would Have the Greatest Impact on Quality Page I-xvii

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