Siemens VAI Presentation Heatopt 29-08-2012

SIMETAL EAF Heatopt

Siemens VAI - all rights reserved

06-15-2012 I MTSiemens VAI - all rights reserved

Markus Dorndorf Siemens_VAI_Presentation_Heatopt.ppt

Contents

ContentsImprovements in EAF steelmakingTechnical SolutionControl Strategy References



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



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



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



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.


Markus Dorndorf Siemens_VAI_Presentation_Heatopt.ppt 7

Lomas® Gas Sample Probe

Patent-protected gas sampling probe.


Markus Dorndorf Siemens_VAI_Presentation_Heatopt.ppt 8

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.



PROCESS MODEL

MAIN PLC

CO, CO2 ,O2, H2, CH4

HMI LEVEL1

EAF

Lomas® EAF APPLICATION



Lomas® Gas Sample Probe and Cabinet



SAM


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



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



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



SAMConclusion



FOX300


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



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



Realtime process optimization

Measurement toolsLomas SAM FOX

EAF Model calculationHeatopt

Furnace inputsOxygen Gas Carbon



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



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



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



Results

Lower conversion costs Efficient use of resources (raw materials and energies)Higher process transparencyIncrease of product qualityFulfill environmental requirementsIncreased safetyHighest EAF availability



References

First partner: Steel Dynamics Inc., Roanoke (USA)



Contact

Dr. Markus DorndorfHead of R&DSiemens VAI Metals Technologies GmbH

Reithallenstr. 1D-77731 Willstätt

Phone: +49-7852 41 00

E-mail: [email protected]



Thank you for your attention!

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Siemens VAI Presentation Heatopt 29-08-2012

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