INTECO EPH TECHNOLOGY · our core activities. INTECO is able to design and build single units as...
Transcript of INTECO EPH TECHNOLOGY · our core activities. INTECO is able to design and build single units as...
INTECO
EPH
TECHNOLOGY
The INTECO Group
INTECO is a 100% private Austrian engineering company founded in 1973 and is
specialized in the field of steel plant as well as special metal & casting technology and is
fully committed to the steel and related industries.
Supply of various equipment and process technology for the steel industry is one of
our core activities. INTECO is able to design and build single units as well as whole
production plants for the metallurgical industry from one hand ensuring single cast
design of the entire plant.
In the last 45 years INTECO has acquired the technology and know-how for the
entire production of quality steels, special steels, metal powders, ferro-alloys and
non-ferrous metals by working with metallurgists and process experts who have
worked and gained valuable long-term experience in the metal production
industry worldwide.
Introduction
Hard Facts
The INTECO Group
HEADQUATERBruck an der Mur, Austria
EMPLOYEESApprox. 400 worldwide
TURN OVERApprox. 100 Mio €
EXPERIENCEOver 45 years
LOCATIONS14 Offices on 4 Continents
The INTECO GroupLocations
The INTECO Group
PR
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MELTING & REFINING
PR
OC
ESS
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INTECO Metals Application Suite (IMAS)
SPECIAL MELTING REMELTING POWDER TECHNOLOGY
VACUUM TECHNOLOGY HEAT TREATMENT
ROLLING MILLS
CASTING TECHNOLOGY
TITANIUM TECHNOLOGY
Product Portfolio
The INTECO Group
Selected Customers
EPH TechnologyElectro Plasma Heating
EPH
Concept
Heating steel with argon stabilized plasma arc
Heating of small ladles or tundishes (temperature compensation)
Avoiding C-pick up because of plasma shrouded arc
Heating rates of 5°C [ 9°F]
EPH heating devices shall be used for maintaining a constant temperature or increasing the temperature of the liquid steel in the
LMF as well as in the tundish. Conventional graphite electrode with a bore whole diameter of approx. 15mm [16/32”] for plasma
gas supply are used. The so generated plasma stables the arc.
Based on the INTECO ESH process the EPH concept was developed
In the 1980`s Development and Patenting of INTECO‘s Electro-Slag Heating (ESH) Process.
ELECTRO-SLAG HEATING
INTECO Developed & Patented Technology
Principle:
Compensation of temperature losses during casting
Isothermal casting over a long period of time
Possibility of casting near liquidus
No time restriction during casting
Avoiding re-oxidation during casting
Possibility of metallurgical treatment
Reduction of non-metallic inclusions
Reduced radiation (no arc)
Newly developed power controller (IHEC)
Benefits:
Graphite or consumeable electrodes
Single or multiple electrode system
Free choice of current (AC or DC)
General:
Resistance heating of electrically conductive slag
ELECTRO-SLAG HEATING
INTECO Developed & Patented Technology
The INTECO Electro-Slag-Heating (ESH) process is used for controlling the
temperature in various metallurgical aggregates such as tundishes and ladles.
The INTECO ESH concept uses two graphite electrodes that are initially aligned
to a common bottom position and then simultaneously moved
electromechanically. The electrodes are immersed in a slag layer covering the
steel surface, offering the possibility for metallurgical treatment during heating
and/or casting. Joule heating resulting from the electrical current passing the slag
is used to efficiently heat the steel. A variable voltage or current source is installed
to adjust the electrical energy input.
The target of the heating process is to keep the steel temperature at the nozzle at a predefined and constant value over the whole pouring
process, independent from the tundish content and other disturbing influences (like failures in the measurements, troubles with stirring
system, irregular electrode consumption, etc.).
Based on its many years of experience with controllers for electro-slag re-melting furnaces and electric arc furnaces, INTECO has
developed a sophisticated control system also for the ESH-process. The basic design comprises the so-called IHEC, which fulfils all the
above mentioned requirements. As an option a temperature tracking and prediction model is offered.
In-house simulation of the ESH-Process.
Cu
rren
t De
nsity
The 1st generation is a further
development of the traditional
method to produce powder in an
atomizing chamber utilizing a
tundish (approx. 1 t), requiring
frequent refilling which leads to
entrainment of slag.
1972
ESH for TOOL STEEL POWDER
1991Installation of the first ESH plant
with a heat size of 7 ton at
ERASTEEL KLOSTER AB,
Söderfors, by INTECO.
Development of the
ERASTEEL ASP® Process
7 t Tundish & Argon Stirring & ESH
1999Installation of the second ESH
plant with a heat size of 8 ton at
BÖHLER Edelstahl, Kapfenberg,
by INTECO.
Development of the
BÖHLER microclean® Process
8 t Tundish & Elec.-magn. Stirring & ESH
2011Installation of the third ESH
plant with a heat size of 14 ton
at ERASTEEL KLOSTER AB,
Söderfors, by INTECO.
Development of the
ERASTEEL DvalinTM Process
14 t Tundish & Argon Stirring & ESH
Development of Today‘s State of the Art HSS Process
Pre-alloyed metal is poured into
a funnel, acting as a fairly small
tundish; no temperature control,
high risks of entrainment of slag.
Traditional MethodDevelopment and Patenting of
INTECO‘s Electro-Slag Heating
(ESH) Process.
ESH with IHEC®
1980‘s
HEATING
Comparison of Technologies
Induction Heating (IH)
• No slag layer
• No protection layer between metal
and atmosphere
• Strong stirring during heating
• High refractory wear
• No metallurgical work possible
• Weak separation of non-metallic
inclusions,
Electro-Plasma Heating (EPH)
• With or without slag layer
• High radiation heat load from the
plasma arc
• High refractory wear
• Combined ESH/EPH process
possible
• Minimized Carbon Pick-Up
Electro-Slag Heating (ESH)
• Resistance heating with
metallurgical active slag
• Reduced melt oxidation due to
separation of melt and atmosphere
by the slag layer
• Metallurgical treatment possible
• Argon or electromagnetic stirring
• Highest powder purity, separation of
non-metallic inclusions
ESH / EPH… has developed the combined ESH/EPH-System
Electro-Plasma Heating (EPH):
• For ultra-low carbon requirements
• No contact between graphite electrode and liquid slag
• Argon plasma gas introduced via hollow electrodes
• Operation with flexible slag layer thickness possible
• Multifunctional ESH/EPH operation possible
EPH
Electrical supply
EPH
Plasma gas supply
ESH / EPH
Melt Stirring
Argon Stirring
- Tearing of protective slag layer due to purging
- Good stirring efficiency
- Chances of entrapment of non-metallic inclusions
Electromagnetic Stirring
- Undisturbed protective slag layer
- Very good stirring efficiency and control
- Low amount of non-metallic inclusions
- Safe process, due to external installation
EPH6
1211
1 2 5
97
3 4
8 10
1. HC-clamp
2. Lifting drive
3. Electrode arms
4. 2nd lifting drive
5. Electrode with gas connection
6. Electrode clamp
7. HC supply line
8. Locking horizontal movement
9. Locking swivelling
10. Swivelling device with lifting
spindle
11. Electrode alignment
12. Electrode storage
EPH
EPH
EPH
Secondary Metallurgy
LF-roofLadle in
treatment station
Electrode alignment
Electrode storage
VD-cover
Cover manipulator
N2-Tank
Filter
EPH
EPH (LF)
Electrode
Operator gate
Electrode clamp
Vacuum drought
Liquid steel
Porous plug
Ladle
WFM feeding telescope
Off gas connection
VD (DETEM) Plant
Oxygen lance
Alloy addition
Suction line
Vacuum cover
Vacuum ladle
Vacuum trough
Splash cover
Bursting nozzle
Porous plugVacuum pump
VD - Plant
7
12
1 2 5
97
3 4
8 11
6
10
1. Vacuum cover
2. Furnace camera
3. Compensator
4. Vacuum filter
5. Vacuum valve
6. Nitrogen tank
7. Cover Manipulator (car)
8. Treatment ladle
9. Vacuum trough
10. Suction line
11. Cyclone
12. Vacuum pump
Segment Caster
Segment Caster
1
4
5
9
6
78
1. Tundish car
2. Stopper rod
3. Tundish with stirring coil
4. Mould oszillator with mould
stirrer
5. Bloom discharge system
6. Billet car
7. Stirrer car
8. Mould
9. Torch cutting
3
2
Segment Caster
2
31
1. Withdrawal system
2. Steel structure withdrawal
system
3. Steam exhaust system
PRODUCTION MANAGEMENT
INTECO Metals Application Suite (IMAS)
ERPLEVEL 4
Equipment Control
Material and Equipment
Know-How
Review
Production Planning
IMAS Process Automation
IMAS Plant Management
Data Recording and Tracking
Supervision and Modeling
Control and Monitoring
SHOP FLOOR
OFFICE FLOOR
PRODUCTION MANAGEMENT
IMAS – BUSINESS INTELLIGENCE:
Integration / combination of different data warehouses.
Generation of individual dashboards as desktop or web
application and mobile devices.
Application of advanced
analytics for the evaluation
of historical data in order to
support well-founded
business decisions.
PRODUCTION MANAGEMENT
Our Technology – Your Advantage
• Quality improvement due to standardized and centralized
know-how
• Modular design
• Online production monitoring and supervision
• Data processing and analysis for continuous know-how
improvement
• Seamless integration into any existing IT landscape
• Low to high operator guidance
• Highest availability and reliability due to modular state-of-
the-art software development
• Easy-to-use operation interface dedicated to office and
pulpit operations
• Production reporting from detailed melt report to monthly
recaps
• Business intelligence integration for advanced analytics
DISCLAIMER
© INTECO melting and casting technologies GmbH.
All rights reserved.
The content of this presentation is subject to
copyright. Unauthorized use, reproduction or transfer
of the content, or of parts of this content, is
prohibited. Please contact the publisher concerning
permission to use the content.
INTECO
melting and casting technologies GmbH
Wienerstrasse 25
A-8600 Bruck a.d. Mur
Tel.: +43 (0)3862 53110 0
Fax: +43 (0)3862 53844
Email: [email protected]
Contact: Dr. Stefan Griesser
Have an eye on our technology www.inteco.at