#51 - What is EFSOP?

Our long-time partnership with and our recent acquisition by Tenova Goodfellow Inc. has helped us learn a little about specialized steel-making processes such as operation of electric arc furnaces (EAFs).

 

Electric arc furnaces recycle steel scrap by melting and converting it into high quality steel by using high-power electric arcs. The steel may be processed in batches called 'heats', or continuously using specialized production systems. EFSOP® stands for Expert Furnace System Optimization Process and is a real-time off-gas based process control system for EAFs.

By measuring and analyzing carbon monoxide, carbon dioxide, oxygen, and hydrogen (CO, CO2, O2, & H2) continuously, EFSOP® uses real-time off-gas chemistry to optimize the chemical energy and post-combustion processes within the furnace. In addition, off-gas chemistry information is combined with other process variables to optimize electrical energy usage, carbon & lime usage, slag formation, and system heat load.

 

 

Goodfellow EFSOP® has provided steelmakers with the most reliable real-time off-gas based process control system for EAF. Through continuous upgrading and state of the art technology, EFSOP® is now the process control tool of choice for over 60 cost conscious, high productivity melt shops around the world. Low maintenance, fast payback and over 2 million heats analyzed has resulted in significant reductions in overall EAF conversion costs, including lower consumption of electrical power and other additives.

 

When combined with other process sensors and information, EFSOP® technology has proven to be an effective tool for identifying statistically abnormal off-gas composition including water, thereby increasing melt shop safety.

Process

 

1. A patented water-cooled probe continuously samples the off-gas exhaust, sending chemistry to the Analyzer.




2. A high-performance gas analyzer system measures levels of O2, CO, CO2 and H2 and sends the data to the operator screens and to the EFSOP® computer in the furnaces control pulpit.

3. The off-gas analysis is displayed in real-time in the control pulpit. The EFSOP® computer (closed loop control) and/or operator sends process adjustments to the plant PLC network, with control adjustments for burners and lances.

4. The plant PLC network communicates with the EFSOP® Analyzer and computer to receive new set-points for dynamic furnace control.

 

 

 

Results

• Steel yield increased
• Productivity increased
• Overall cost savings increased
• Electrical energy reduced
• Oxygen consumption reduced
• Natural gas consumption reduced
• Charge carbon consumption reduced
• Power on time reduced
• Electrode consumption reduced
• Refractory wear reduced

  

If you are a steel maker interested in higher productivity and lower costs, contact Tenova Goodfellow for more information about the award-winning EFSOP® system.

Tenova GOODFELLOW
Phone +1 905 567 3030
Fax +1 905 567 3899
goodfellow@ca.tenovagroup.com

 

For information on gas analyzer systems, give Mike or Dave at Nova a call, or send us an e-mail.
1-800-295-3771
sales at nova-gas dot com
websales at nova-gas dot com
http://www.nova-gas.com/
http://www.tenovagroup.com/
 
If you have a LinkedIn account, search for Nova Analytical Systems under Companies and follow us if you want.
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#50 - Generic vs Brand-name terminology – Part 1

Every industry and company has its own beloved terminology. This inside lexicon may in time develop into a company language. There are many intentions and reasons for brand-name terminology. A few of them are: 

1. The intent is sometimes to economize communication. A single industry term may be understood by its users to encompass a general set of conditions or product characteristics.
2. Another intent of specific terminology may be related to marketing tactics. A brand name may be selected because of the images that it conjures up in the mind of the buyer. These terms may be catchy but have little reference to the type or design of the product.
3. Company brands or terminology may also simply be a legacy left over from an earlier time. Perhaps the current product bears no resemblance to the original, but the name is well-known and is best left as is. 

I used to work in the coatings industry. That industry is somewhat over-populated by brands and types. The age of the industry combined with the sheer number of applications has produced a long rich vocabulary. Our company felt that this impeded the clear communication of ideas especially in the industrial maintenance market where the applications were more demanding. Too many brand names were completely cryptic regarding the actual chemistry of the product. We found some that even suggested characteristics and chemistries that were not completely accurate.

So we elected to call our products by their generic coating types and basic chemistries instead of by marketing-derived or legacy names. For example, we had Polyamide-Cured Epoxy instead of something like ‘Durapox’. We had Aliphatic Urethane instead of a brand name like ‘Superthane’ or something.

The intent was to convey clear information about the product chemistry. To an experienced user, this would in turn communicate information about the intended uses and applications. This approach was partially adopted for the retail side of our business also. (We had to be careful not to get too technical in retail situations.)

As a suggestion to any technical salesperson – we at Nova believe in cutting through the industry jargon when talking to customers. If there is a helpful piece of information hiding behind a brand name or industry term, then say so. Company reputations aside, most customers just want a product that works. In our industry, that means reliable gas analysis data. The marketing has only temporary value and is often slanted in favor of the seller rather than the buyer.

Speaking of marketing, we’re Nova. We make gas analyzers for oxygen, carbon dioxide, methane, hydrogen, and other gases. We are part of the Iron & Steel Division of the Tenova Group.

Give Mike or Dave at Nova a call, or send us an e-mail.
1-800-295-3771
sales at nova-gas dot com
websales at nova-gas dot com
http://www.nova-gas.com/
http://www.tenovagroup.com/

If you have a LinkedIn account, search for Nova Analytical Systems under Companies and follow us if you want.
 
Photo © 2008 Tack-O-Rama Collection
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#49 - We want to come to work with you (and learn how we can help)!

Don’t worry, a crack team of Nova operatives won’t be showing up unannounced at your facility anytime soon.

We respect that our customers know the chemistry or internal dynamics of their process probably better than we do. They aren’t coming to us for an education about their own process. In fact, it’s usually the other way round. The more we talk to our customers, the more we learn.

So while it would be a pretty rare thing for us to tell them something they didn’t already know, once in while we do have a flash of brilliance. We are an analytical company after all. We know about gas atmosphere analysis.

We make gas analyzers for atmospheric gases such as hydrogen, carbon dioxide, methane, etc. We can assume that our customer needs a gas analyzer because there are aspects of their process that they want to monitor with more precision. They are well aware that there is hydrogen and carbon dioxide or some other gas in their process. They just want a gas analyzer to know exactly how much, and to use that data as a process control.

So how do we propose to come to work with you and learn how to better help you? There are a couple of ways worth mentioning.

1. At the front end of the customer relationship, Mike & Dave at Nova are very interested in learning about your process. We may ply you with annoying questions about chemistry, pressure, temperature, and other fun stuff. We even have a special application form that some of our customers use to organize the relevant information. The data gleaned at this point will enable us to get you pointed in the right direction in terms of specifying gas analysis equipment. This whole process is the first step in Nova ‘coming to work with you’. 
2. During the quoting or design processes, we may have additional configuration issues to discuss with you. Perhaps there is an environmental condition that will affect the cabinetry or temperature management. Perhaps there are other gases in the sample which will interfere with accurate gas analysis. Excessive moisture or particulate in the sample may require sample conditioning components. Nova is still working with you to help you.
3. Sometimes after the analyzer is installed into the application, an issue of some kind arises. Give us a call. We are as interested in getting to the bottom of the problem as you are. Nova is still on the job. 
4. In challenging applications, such as with landfill gas or biogas analyzers, some customers have even decided to hire one of our engineers for a day or two to visit the site after the analyzer is installed. We can do an inspection, calibration, commissioning, and train your staff. Getting your analyzer off to a good start always produces the best results. Our intention is to have the gas analyzer doing its job reliably for as long as possible. 

We’re Nova. We make gas analyzers for oxygen, carbon dioxide, methane, hydrogen, and other gases.
Give Mike or Dave at Nova a call, or send us an e-mail.
1-800-295-3771
sales at nova-gas dot com
websales at nova-gas dot com
http://www.nova-gas.com/

If you have a LinkedIn account, search for Nova Analytical Systems under Companies and follow us if you want.
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