furnace technology for smelting furnaces_eng
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furnace technology to calculate energy and material consumptionTRANSCRIPT
Furnace Technologyfor Smelting Furnaces
TENOVA is a world-wide supplier of advanced technologies, product and servicesfor the metal and mining industries
Tenova is a world-wide supplier of advancedtechnologies, products and services for the metal andmining industries providing innovative integratedsolutions.Combined process automation andmetallurgical know-how enhance the value deliveredto the customers.
Tenova is committed to further develop its technologyin the areas that mostly impact the future of theindustries it serves: quality of the products delivered bythe customers, energy saving and environmentalsafeguard.
Tenova Pyromet is the industry leader in thedevelopment, design and supply of electric smeltingfurnaces and complete smelting plants for theproduction of ferroalloys, base metals and wastetreatment.
Global Presence Tenova Pyromet benefits from the world-wide network provided by Tenovaoffices located in 5 continents. This network of qualified and competentpeople provides knowledge about the local business practices and languageand can ensure real time service to customers.
Heritage Tenova Pyromet is the result of the successful merger between the submergedarc furnace division of Techint Technologies and Pyromet Technologies.
Tenova Pyromet is based in Johannesburg, South Africa, where the successfuldevelopment, design, supply, erection and commissioning of smelters byTenova Pyromet for the ferroalloy and platinum industry has made it a majorplayer in the industry.
The Tenova Pyromet in-depth knowledge and understanding of the ferroalloysand base metals smelting process and technology is applied to a wide rangeof projects for customers. Tenova Pyromet has an extensive reference listof successful projects and applies this technology to the benefit of ferroalloyand base metals customers world-wide.
The Tagliaferri furnace design which has roots dating back to 1968 is partof Tenova Pyromet’s proud heritage. The excellent design of these Tagliaferrifurnaces is proved by the praise and repeat orders received from their owners.
Business Tenova Pyromet has designed and built electric arc furnaces of various types,for various applications, on 5 continents, and is one of the world’s leadingdesigners and builders of smelting furnaces.
Clients have benefited from Tenova Pyromet’s sound, practical, reliabletechnology, and expert advice on furnaces and related equipment andproduction processes. Tenova Pyromet match appropriate and reliabletechnology with process requirements and furnaces are custom designedto suit client’s application, material type and quality, process and otherrequirements.
Tenova Pyromet furnaces are used for the production of ferroalloys and basemetals, for slag cleaning, for alloy conversion and refining, for waste disposaland for pilot plant and research purposes.
The company performs engineering, supplies equipment and implementsprojects which range from greenfield and brownfield furnace projects, furnaceupgrades, furnaces revamps and auxiliary equipment such as pollution controland automation.
Tenova Pyromet performs ongoing research and development of new andimproved technologies for the smelting industry.
FurnaceTechnology
Tenova Pyromet’s specialisation in Submerged Arc Furnace design andtechnology and a comprehensive list of current and past furnace projectsensure continuous operation and technical feedback.
This further increases Tenova Pyromet’s leading edge technology and depthof experience and fulfil our passion for continuous improvement and providingthe best available practice to customers.
The raw materials, operating philosophy and smelter layout of these projectsare unique for each customer. Therefore, each project provides the opportunityfor the Tenova Pyromet design, project and process engineers to interactwith the customer to design a smelter which combines the best availablepractice with the customer’s particular raw materials, operating philosophyand site layout.
The most important aspects of designing a furnace is understanding theeffect of the client’s specific raw material on the furnace design and determiningthe correct furnace critical dimensions such as diameter and depth of thefurnace crucible, electrode diameter, electrode spacing, length, width, feedchute arrangement, alternating or direct current, transformer characteristicsand bustube arrangement.
Tenova Pyromet has mastered these fundamental design aspects, which areunique for each project.
Control of the furnace process, safety and equipment protection is achievedby advanced automation developed by Tenova Pyromet with input from thecustomer.
Tenova PyrometElectrode Column
The patented Tenova Pyromet electrode holder is now widely considered tobe the industry standard.
It has set new standards in reliability and availability.
The Tagliaferri electrode regulating and slipping device has proved its reliabilityby receiving sterling reviews from furnace operators.
Tenova Pyromet and Outotec have developed a multiple pre-heating technology.
The process of pre-heating uses the energy contained in furnace waste gasto pre-heat mix being fed into the furnace to temperatures up to 550ºC. Thisreduces the moisture content and volatiles of the material being fed into thefurnace, stabilises the furnace and reduces the specific power consumptionper ton of product.
The combination of these benefits contributes to an increase in furnaceproduction capacity. Further benefits such as improved control, availabilityand maintenance are some of the benefits provided by the multiple pre-heaterconcept.
MultiplePre-Heating System
Control Systems
Furnace Control
The Tenova Pyromet control system is designed to be user friendly withimproved efficiency and is suitable for new and old submerged arc furnaces.Retrofitting to existing furnaces is fairly straightforward. A small increase inpower input can make a significant difference to furnace profitability.
The furnace controller achieves a higher average power input to the furnaceand maintains stability in the furnace. The automatic electrode slippingsystems, reduce electrode breakages and helps keep all the electrodes ata constant length. This also significantly increases furnace performance andstability.
Higher average power input increases product output. Stability of the furnaceoperation ensures more accurate control of the metallurgical process whichfurther increases production output and reduces operating costs.
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The Lining Management System (LMS) is a tool that allows furnace operatorsand managers to monitor the sidewall and hearth lining condition and thedelivery of energy to the process. The LMS software provides useful informationregarding lining temperatures, heat losses, remaining refractory thickness,and freeze lining formation. The operator is able to select and view specificisotherms.
The Windows based interface allows the operator to quickly and effortlesslyswitch between the 2D overview display, a tabulated results display, a trendingfacility, and a 3D display window. The 3D interface allows the operator toview a 3D image of the furnace crucible in real time.
In addition to refractory monitoring, the LMS is also capable of monitoringcopper cooler status, such as: hotface temperatures, freeze lining thicknessand heat losses.
LiningManagement System
To be effective in reducing emissions and waste, equipment and systemsmust be reliable, with high availability and high efficiencies.
Tenova Pyromet is committed to preserving our environment. This includesthe control of pollution arising from industrial activities, as well as theconservation of natural resources.
As technology suppliers to the smelting industry, this entails identifying &investigating available technologies, and where appropriate developing newtechnologies, as well as the design of suitable plant and equipment, for• the reduction of emissions,• the reduction of waste, and• the reduction of energy use
Environmentalproducts
Tenova Pyromet has built AC and DC furnaces to treat waste products ortailings streams from other processes. These furnaces convert a wasteproduct (such as steel plant dust) into a saleable alloy and a vitreous slagthat can be used as road fill or a cement additive.
Reduction of Waste
Energy Recovery Tenova Pyromet is actively pursuing methods to recover energy from smeltergas streams and using this to reduce power consumption and greenhousegas emissions. The development of multiple pre-heaters (with Outotec Oyj)seeks to optimise the feed temperature to a furnace using energy from thewaste gas stream. The gas stream containing carbon monoxide or wasteheat is also used as a fuel source for the generation of power, reducing theexternal power demand of the smelter.
To effectively reduce emissions and waste, equipment and systems must bereliable, with high availability and high efficiencies.
The range of Tenova Pyromet equipment for gas conditioning and cleaningincludes:• Evaporative cooling• High-efficiency cyclones• Radiating and forced draught coolers• Reverse-flow bag filter plants• Reverse-pulse bag filter plants• Venturi scrubbers
Gas Cleaning Systemsand Equipment
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Tenova Pyromet’s copper products, including water-cooled copper furnacerefractory coolers, water-cooled copper launders, water-cooled coppertapholes and other speciality products, are designed using advancedtechniques such as Finite Element Analysis (FEA) and Computational FluidDynamics (CFD), and are manufactured using high purity copper to exactquality standards.
Each copper product solution is tailored to the specific requirements of theplant and process needs.
Water-cooled copper panels at the sidewall freeze the slag to provide aprotective layer.
CopperProducts
Water-cooled copper launders reduce component wear through use of thefreeze lining principle. Lower wear gives longer launder life and reduceslong-term maintenance expenditure and downtime production losses.
The design of the Tenova Pyromet water-cooled copper components, suchas the maxicool system for the furnace sidewall, and the copper laundersremove inherent risk to the safety of personnel and equipment.
Tenova Pyromet’s copper tapholes are designed as part of an integratedsolution involving the complete design of the taphole area, including the blockand its surrounding refractory lining.
Services
Studies
The combination of Tenova Pyromet’s innovative culture and an in-depthunderstanding of the smelting business has ensured many innovations rangingfrom detailed design improvements that improve efficiency and reliabilitythrough to groundbreaking changes that effect the direction of the industry.
The studies are divided into the following general areas:• Conceptual: This class of study has an expected estimate accuracy of
between +35 to -30%.• Pre-Feasibility: This class of study has an expected estimate accuracy
of between +25 to -15.• Feasibility: This class of study has an expected estimate accuracy of
between +15 to -10%.
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Engineering Modellingand Investigations(FEA and CFD Modelling)
Finite Element Methods (FEM) and Computational Fluid Dynamics (CFD)are used extensively in the design process at Tenova Pyromet. In addition,these techniques are used to assist clients in the optimization of theiroperational processes, furnaces and auxillaries.
Extensive smelter design experience combined with the company's moderncomputational modelling capabilities has resulted in many innovative andpractical solutions for clients.
Tenova Pyromet has used these techniques to develop its unique electrodecolumn system, copper cooling systems for furnace sidewalls, tapholedesigns, furnace control systems and copper launders.
Performanceand Reliability
Tenova Pyromet is committed to offering tailored solutions to meet customerrequirements and targets.
Tenova Pyromet's track record is characterised by projects completed onor earlier than the planned schedule, fast ramp-up to design productioncapacity, meeting and exceeding emission control requirements and, aboveall, by the supply of reliable and efficient technology and equipment.
Tenova Pyromet’s success is attributed to a combination of innovativetechnology, leading design, extensive experience and sound project execution.
Commitmentto Innovation
Quality
Tenova Pyromet's involvement in a smelter project can be tailored to suit thecustomer's requirements, and may cover:• Turnkey supply of furnace equipment, which can be expanded to include
associated equipment and basic engineering for client scope• Supply of key equipment, for new and furnace upgrade projects• Erection and commissioning supervision• Studies, from feasibility through to bankable level• Engineering and modelling investigations
To meet our customer expectations, quality and continuous improvement ofservice in line with the best industry practice and standards are priorities atTenova Pyromet.
Tenova Pyromet’s quality management system is certified to ISO 9001:2000,for "The Design and Supply of Smelting Technology and Equipment". ISO9001:2000 directs attention to customer focus, meeting customer needsand continuous improvement.
EnvironmentalResponsibility
Having a long-term vision in the smelting industry means taking industry-related environmental issues seriously.
Consistent with its vision and values, Tenova Pyromet is committed to effectiveenvironmental management, having adopted an environmental policy thatincludes:• Reduction of waste• Energy recovery• Prevention of pollution• Conservation of resources
Focus on People People are vital to success and growth at Tenova Pyromet. Qualified staffis the lifeblood of the company.
Outstanding engineering and management expertise in every area of activity,a strong focus on the customer, a passion for innovation and continuousflexibility: these are the features that distinguish Tenova Pyromet professionals.
Tenova Pyromet enhances and optimises the talents of the individual for thegood of the team and to the benefit of the customer. By supervising everystage of professional growth and providing on-going knowledge and skillstraining, Tenova Pyromet guarantees the expertise of its people.
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Tenova TIMECTIMEC Co. Ltd.Huashan Road 666Tianjin Marine High Development Area300459 Tianjin - ChinaPhone +86 22 59830100Fax +86 22 [email protected]
Tenova TITBTechint Industrial Technologies (Beijing) Co. Ltd.1700 Air China Plaza36 Xiaoyun LuBeijing 100027 - ChinaPhone +86 10-8447 5656Fax +86 10-8447 [email protected]
TenovaTechint East EuropeVoznesenskij per., dom 20, Stroenie 3125009 Moscow - RussiaPhone + 7 495 726 59 43/44Fax +7 495 937 77 [email protected]
Tenova PYROMETTenova Pyromet (Pty) Ltd10 Sherborne RoadParktown, JohannesburgPO Box 61582, Marshalltown, 2107South AfricaPhone +27 11 480 2000Fax +27 11 482 [email protected]
Tenova METAL MAKINGTenova S.p.A.Via Monte Rosa, 9320149 Milan - ItalyPhone +39 02 4384 7945Fax +39 02 4384 [email protected]
Tenova CORECore Furnace Systems Corp.Cherrington Corporate Center100 Corporate Center DriveCoraopolis, PA 15108-3185USAPhone +1 412 262 2240Fax +1 412 262 [email protected]