siemens vai presentation heatopt 29-08-2012
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SIMETAL EAF Heatopt
Siemens VAI - all rights reserved
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Markus Dorndorf Siemens_VAI_Presentation_Heatopt.ppt
Contents
ContentsImprovements in EAF steelmakingTechnical SolutionControl Strategy References
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Heatopt improvements for EAF
Need of:Quick responding, flexible process controlOptimized material inputTransparent process monitoringEnvironmental complianceReliable and continuously high process efficiency
The improvements through SIMETAL EAF Heatopt system:Decrease of electrode and energy consumptionDecrease of conversion costsOptimization of gas, oxygen and carbon inputReal-time control and process improvementAutomation of melting process
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Technical principle
Combination of proven technologies:Lomas – Low Maintenance Off gas Analyzing SystemSAM – Single Air Measurement of Velocity and FlowFOX – Foaming Slag Xpert
Now working together under one holistic model
This leads to:controlled injection of gas, oxygen and carbonimproved carbon injectiondynamic control of post combustiontraceability of calibrationhigher process stability
Lomas SAM FOX
Collecting data
Heatopt
Calculating inputs
Oxygen Gas Carbon
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Lomas®
Features:Analyzing data used for Heatopt
Continuous measurement of CO, CO2, H2, O2, CH4
Extremely short response time
BenefitsHighest reliability and availabilityLow maintenance systemEAF process optimizationAutomatic detection of dangerous situationsRemote control for the highest level of on-the-job safety
Lomas SAM FOX
Heatopt
Lomas
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EAF
Analyzing Containerventvent
draindrain
Analyzing Container:
Contains the gas treatment and the gas analysis. Air conditioned, with CO/O2 monitoring and emergency ventilation system.
Lomas® EAF Application
Local Cabinet Cooling water
N2 for probe cleaning
measurement gas
Sampling probe
Local cabinet:
Distributes cooling water to the sampling probe and N2 for probe cleaning.
Sampling Probe:
Water cooled sampling probe, with PLC-controlled heating of the extraction pipe to prevent blocking.
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Lomas® Gas Sample Probe
Patent-protected gas sampling probe.
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Lomas® features
Lomas is a gas analyzing system with a high availability and a fast reaction time.Very short response time (T90) (less than 15 sec., depending on site conditions)Low maintenance costs.Backwashing of probe and Filter cleaning every charging and tapping.High accuracy in measurement and data evaluation.Availability of more than 99,5%, even under extremely hot (up to 1.800 °C) and dust-laden (up to 2.000 g/Nm3) gas conditionsMeasurement of CO, CO2, H2 , O2 , CH4
Off gas data collection for process model Heatopt.
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PROCESS MODEL
MAIN PLC
CO, CO2 ,O2, H2, CH4
HMI LEVEL1
EAF
Lomas® EAF APPLICATION
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Lomas® Gas Sample Probe and Cabinet
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SAM
Features:Analyzing data used for Heatopt
Tribo-electric cross correlation technology for air flow measurement
Extremely short response time
BenefitsSimple velocity / speed controlHighest reliability and availabilityEasy maintenanceRemote control for highest level of on-the-job safety
Lomas SAM FOX
Heatopt
SAM
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SAMTribo-Electric Cross Correlation Technology
Repeatable on line gas flow measurementAccuracy not affected by particulateNo calibration, No drift, No purgeDust concentration from1mg/m³ to 2000 g/m³Operates up to 1100 °C
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SAMConclusion
One pair of sensors per duct plus one thermocouple for temperature correction to normal cubicmeter.
Continuous measurement of the transport velocity of the particles (dust particles from the air preheater).
With particle velocity (= gas velocity) and duct dimension, gas volumetric flow will be determined directly.
No calibration, no drift, no pressure drop.
Absolutely linear measurement characteristics
for all duct dimensions in a wide gas velocity range
Applicable for high temperatures up to 1000°C (1800°F).
Easy retrofit into existing ducts
No scheduled maintenance
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SAMConclusion
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FOX300
Features:Analyzing data used for Heatopt
High current harmonics analyzing for calculation of slag foaming index
BenefitsBest arc coverage by controlled slag heightHighest energy efficiency for melting processLonger electrode lifetime
Lomas SAM FOX
Heatopt
FOX
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Heatopt system
Features:Applies a holistic process model to the EAF process
Combines all measurements and furnace data
As add-on, can be switched on and off
BenefitsOptimized use of:Oxy/ Fuel burners; Oxygen jets; Carbon injectors; Post combustion
Reduction of conversion costs
Better system transparency through monitoring
Lomas SAM FOX
HeatoptHeatopt
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Realtime process optimization
Measurement toolsLomas SAM FOX
EAF Model calculationHeatopt
Furnace inputsOxygen Gas Carbon
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Off Gas data from Lomas and SAM
Control of PC injector Control of Oxygen Injection Control of NG burner
PC ratio Carbon Reaction Ratio Lambda ratio
PC = CO2
CO2 + CO=
CH4O2
Carbon mass balance using SAM and Off Gas chemistry
Heatopt system
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Heatopt addon: existing plant stays independent
OxygenGas
Carbon
EAF Customer PLC
Customer Visualization
Lomas SAM FOX
Heatopt PLCAnalysis add-on
Existing
Heatopt HeatoptVisualization Heatopt add-on
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Implementation as cooperation process
You We
Need for higher efficiency
Heatopt presentation
Programming your Heatopt behavior
Implementation Performance guaranteePerformance check
Generating questionnaire
Answer the questionsCalculating performance
guarantees
Contracting the project
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Results
Lower conversion costs Efficient use of resources (raw materials and energies)Higher process transparencyIncrease of product qualityFulfill environmental requirementsIncreased safetyHighest EAF availability
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References
First partner: Steel Dynamics Inc., Roanoke (USA)
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Contact
Dr. Markus DorndorfHead of R&DSiemens VAI Metals Technologies GmbH
Reithallenstr. 1D-77731 Willstätt
Phone: +49-7852 41 00
E-mail: markus.dorndorf@siemens.com
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