Understand Atmosphere In Carburizing Applications Using ...
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Understand Atmosphere In Carburizing Applications Using Simulation and
Real-Time Carbon Diffusion
Damian Bratcher
Super Systems, Inc
Salvador Alvarado
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Understand Atmosphere In CarburizingApplications Using Simulation and Real-TimeCarbon Diffusion
• In gas carburizing the source of carbon is acarbon-rich furnace atmosphere producedeither from gaseous hydrocarbons or fromvaporized hydrocarbon liquids. Usingtheoretical steps with anticipated processvariable inputs, the prediction of the carbonavailable to the steel surface and diffusioncan be simulated. Inputs captured during areal-time run can predict the carbon buildup in a part. The simulation and real-timedata can be matched up to comparemetallurgical results.
• We will cover principles of atmospherecarburizing including sensor and controltechnology. Analysis of input variablesassociated with carburizing applications andunderstanding the effects the atmosphere,temperature and time has on results. Wewill look at information using 3-gas analysisversus oxygen probes and review what anatmosphere would look like during acarburizing run. We will review real worldscenarios with actual data that comparessimulation versus calculated carbon transferand diffusion against met lab results.
• En un gas carburante la fuente de carbono es unaatmósfera de rica de carbono se produce ya sea apartir de hidrocarburos gaseosos o de los líquidos dehidrocarburos vaporizados. Utilizando pasosteóricos con entradas de la variable de procesoprevisto, la predicción del carbono disponible a lasuperficie de acero y de difusión puede sersimulado. Entradas capturados durante unaejecución en tiempo real puede predecir el carbonose construyen en una parte. Los datos de simulacióny en tiempo real pueden ser emparejados paracomparar los resultados metalúrgicos.
• Vamos a cubrir principios de la atmósfera decarburizado que incluye sensores y tecnología decontrol. Análisis de las variables de entradaasociados con las aplicaciones de carburizado y lacomprensión de los efectos de la atmósfera, latemperatura y el tiempo tiene en los resultados.Vamos a mirar la información usando el análisis de 3gases frente a sondas de oxígeno y revisar quéambiente se vería durante una carrera decarburizado. Vamos a revisar los escenarios delmundo real con datos reales que compara lasimulación frente a la transferencia de carbonocalculada y difusión contra los resultados delaboratorio conocido.
Comprender Atmosferas en Aplicaciones deCarburizado usando Simulación y Tiempo-Realde Difusión de Carbono.
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Agenda• The Basics
• Furnace Process Variables
• Generator Process Variables
• Nitrogen Methanol Process Variables
• Sensor Technology• In-Situ Probes
• Infrared (IR) Technology
• Probe Plus IR
• Gas Composition• Generator
• Furnace
• Why Precision Matters?
• Scenarios
• Tube leak
• Bad generator gas
• Temperature control
Agenda• Los básicos
• Variables de Proceso en Hornos
• Variables de Proceso en Generadores
• Variables de Proceso con Ni – Met
• Tecnología de Sensor
• Probetas In-Situ
• Tecnología Infrarrojo (IR)
• Probeta Plus IR
• Composición del Gas
• Generador
• Horno
• ¿Porqué es importante la Presición?
• Escenarios
• Fuga en Tubos
• Mal generación de Gas
• Control de Temperatura
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Agenda• Case Study
– Desired results
– Simulated run
– Adjusted process
– Actual metallurgical results
• Benefits of Simulation & Control
Agenda• Estudiar el caso
• Resultados deseados
• Proceso Ajustado
• Resultados Metalúrgicos Reales
• Beneficios de la Simulación y Control
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Acc
ura
cy
Timeline
Gas Flow
Process Monitoring
Process Control Simulation
+ Process
What’s Important
Qué es importante
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What’s Important?
• Atmosphere Content
• O2
• CH4
• CO
• CO2
• N2
• H2
• Dew Point
• Temperature
¿Qué es importante?
• Contenido de la Atmósfera
• O2
• CH4
• CO
• CO2
• N2
• H2
• Punto de Rocío
• Temperatura
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What’s Important?• Atmosphere Content
• O2
• CH4
• CO
• CO2
• N2
• H2
• Dew Point
• Temperature
¿Qué es importante?• Contenido de la Atmósfera
• O2
• CH4
• CO
• CO2
• N2
• H2
• Punto de Rocío
• Temperatura
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What’s Important?• Decarburization
• O2 (FeO and CO)• 2Fe + O2 = 2FeO
• CO2 (C + CO2 = 2CO)• H20 (Dissociates to H and O)
• C + 4H = CH4
• C + O = CO• FeO is formed
¿Qué es importante?• Decarburización
• O2 (FeO y CO)• 2Fe + O2 = 2FeO
• CO2 (C + CO2 = 2CO)• H20 (Se disocia en H y O)
• C + 4H = CH4
• C + O = CO• Se forma FeO
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Process Variables in a Carburizing ApplicationVariables de Proces en Carburizado
• Hot Zone
• Quench
• VestibuleTemperature
• Hydrocarbon
• CO, CO2
• Ammonia
• Air
Gases
• Transfer Time
• Probe Conditioning
• End of Cycle
Events
• Soak Time
• Guarantee Temperature
• Safeties / AlarmsOther
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Producing The Right Atmosphere• Prepared Atmosphere For
Carburizing• Endothermic Based
• Generator• Air / Gas Mixture
• Nitrogen Based• Nitrogen / Methanol
Produciendo una Atmósfera adecuada
• Preparando Atmósfera paraCarburizado• Endotérmico
• Generador• Mezcla Air-Gas
• Nítrogeno• Nitrógeno - Metanol
Prepared Atmosphere
Natural Gas
Carburizing Atmosphere
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Producing The Right Atmosphere
Cooled
• Endo Flow in SCFH
• Air / Gas Ratio = 2.7 (CH4)
CH4 Air
20% CO
40% H2
40% N2
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Endothermic Generators• Process Variables
• Dew Point or CO2• Ratio / Carburetor• Composition of gas source• Catalyst condition• Temperature
Generadores Endotérmicos• Variables de Proceso
• Punto de Rocío o CO2• Ratio / Carburador• Composión de la fuente de gas• Condición del catalizador• Temperatura
CH4 Air
20% CO
40% H2
40% N2
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Endothermic Generators
• Trim Control
• Dew Point Using Oxygen Probe
Generadores Endotermicos
• Control de ajuste
• Punto de rocío usandoprobetas de oxígeno
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NITROGEN METHANOL
• N2 (SCFH) = 66% of “feed” gas
• CH3OH (L/hr) = 33% of “feed” gas
CH3OH N2
20% CO
40% H2
40% N2
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Prepared Atmosphere Issues
• CO level in furnace is not 20%
• Generator• Air infiltration
• Water leak
• Endo gas variation
• Nitrogen/Methanol Systems• Sparger problems
• N2 bubbles in the methanol line
• Furnace temperature
Problemas preparando Atmósfera
• El nivel de CO en el horno no es 20%
• Generador• Infiltración de Aire
• Fuga de agua
• Variación de Endo gas
• Nitrógneo / Metanol• Problemas del Rociador
• Burbujas de N2 en la líneade metanol
• La temperatura del horno
CH4 Air
20% CO
40% H2
40% N2
CH3OH N2
20% CO
40% H2
40% N2
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Measurements in the Furnace
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Carbon Potential - %C
Probe mV
TempCOF
Carbon Potential Calculations
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CO Factor / Process Factor
% CO
Alloy
Parts
Furnace
Other
COF
EndoNitrogen Methanol
Accurate Carbon Readings
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Carbon Potential - %C
Probe mV
TempCOF
Carbon Potential Calculations
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CH4 Air
20% CO
40% H2
40% N2
Carbon Potential - %C
Probe mV
TempCOF
%CO Ability To Carburize%CH4 Ability To Carburize
What Happens With Bad Generator Gas
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20% CO
40% H2
40% N2
Carbon Potential - %C
Probe mV
Temp
COF
Precision Control
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Other Technology Available• Probe Assumes from Generator
/ Nitrogen Methanol• Probe requires a consistent CO
level
• Compensation can be done for deviation• Verify using shim stock, dew
point, bar stock, NDIR gas analysis, etc.
• COF Settings• Process based
• Set in programmable controller
• Real-time compensation • NDIR gas analysis
Otra Tecnología Disponible• Asume la sonda del generador de
metanol / Nitrógeno• La sonda requiere un nivel
de CO coherente
• La compensación puede ser hecho para la desviación• Para ello, utilice para
laminillas, punto de rocío, barra de acciones, análisis de gases NDIR, etc.
• Ajustes de COF• proceso basado• Situado en el controlador
programable
• La compensación en tiempo real• Análisis de gases NDIR
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Carbon Potential - %C
Probe mV
TempCOF
Gas Analysis
Atmosphere Gas Analysis
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Signal
Infrared DetectorOptical Path
Sample Gas
Light Source
Selective filter for gas type
Non Dispersive Infrared Absorption Sensor
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Probe Plus IR
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CO Compensation – % Carbon
• % Carbon Tracking
• Furnace 1 - Compensated
• Furnace 2 - Non-compensated
Compensación de CO - %C
• Siguiendo %C
• Horno 1 – Compensado
• Horno 2 – Sin compensar
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
FURNACE 1-COMPENSATED
Standard Deviation.056.094
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CO Compensation – % Carbon
• % Carbon Tracking
• Furnace 1 - Compensated
• Furnace 2 - Non-compensated
Compensación de CO - %C
• Siguiendo %C
• Horno 1 – Compensado
• Horno 2 – Sin compensar
0
0.2
0.4
0.6
0.8
1
1.2
1.4
FURNACE 1-COMPENSATED FURNACE 2-NON COMPENSATED
Standard Deviation.037.097
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Computerized Prediction Predicción Computarizada
Turn this / hacer estoInto this / dentro de eso
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Creating a Blueprint• Carbon Profile
• Customer Requirements
• Material Chemistry
Creando un Proyecto
• Perfil de Carbono
• Requerimientos del Cliente
• Composición Química
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Material Chemistry• Variations in chemistry
Composición Química
• Variaciones en la Química
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Why does base carbon matter? ¿Porqué importa la base del Carbón?
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What is important? ¿Qué es importante?• Atmosphere Content
• O2
• CH4
• CO• CO2
• N2
• Temperature
• Contenido de Atmósfera• O2
• CH4
• CO• CO2
• N2
• Temperatura
Carbon Potential
Cp
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Carbon Simulation Simulación de Carbono• Simulation software for carbon
diffusion in batch carburizing furnace applications• Prediction of carbon transfer
between atmosphere and steel• Diffusion of carbon into the work
pieces
• Software de simulación para la difusión del carbono en las aplicaciones de horno de carburizado tipo Batch.• Predicción de la transferencia de
carbono entre la atmósfera y el acero
• Difusión del carbono en las piezas de trabajo
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Controlling Simulation Controlando con Simulación• Boost / Diffuse
• High carbon and temperature during boost increases carburizing case penetration• Time savings – 25%• Case quality improved
• Empape / Difusión
• Alto contenido de carbono y la temperatura durante la elevación aumenta la penetración caso de carburación• Ahorro de tiempo - 25%• Caso mejoró la calidad
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Controlling With Simulation - Boost Control con Simulación - Empape
• Measure carbon available above the desired profile
• Segment ends when excess carbon equals deficient carbon• This is the control variable
• Medir el carbono disponible por encima del perfil deseado
• Segmento termina cuando el exceso de carbono es igual a carbono deficiente
• Esta es la variable de control
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Controlling With Simulation - Diffuse Control con Simulación - Difusión
• Segment ends when excess carbon depleted or deficient carbon is zero
• Segmento terminacuando el exceso de carbono agotado o carbono deficientees cero
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Controlling With Simulation Controlando con Simulación• Actual values for carbon
potential measured and used
• Time becomes the variable• Rich atmosphere…shorter
time• More precision
• Los valores reales de potencial de carbono medidos y usados
• El tiempo se convierte la variable• Atmósfera rica ... tiempo
más corto• Más precisión
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Building Assurance Asegurando el Proceso
• Run the simulation in advance
• Verify the results
• Ejecutar la simulación en avanzado
• Verificar los resultados
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Building Assurance Asegurando el proceso
• Run the results through the mathematical process
• Ejecutar los resultados a través del proceso matemático
Actual ProcessCarbon Profile
Actual ProcessCarbon Profile
Actual ProcessCarbon/Temp. Profile
Actual ProcessCarbon/Temp. Profile
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Building Assurance Aseguramiento de la construcción
• Compare the Met Lab Results
• Comparación de los resultados del laboratorio metalúrgico
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Accuracy Exactitud
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Thank You Gracias
Damian [email protected]
7205 Edington DriveCincinnati, OH 45249513 772 0060www.supersystems.com