#61 - Biggest Steel Melting Unit in China

TENOVA SUPPLIES MCC BERIS JIANGSU HEAVY INDUSTRY CORPORATION WITH THE BIGGEST MELTING UNIT EVER BUILT IN CHINA

Milan, April 26th 2012 – Tenova achieved the first heat of the biggest Melting Unit ever built in China for MCC Beris Jiangsu Heavy Industry Corporation - Feida Group: a highly innovative Medium and Heavy Plate Casting-rolling Production Line.

The benefits offered by the technology provided, which combines Tenova Electric Arc Furnace and Consteel® with other forefront technologies in China from Beris permitted unprecedented flexibility in operations and production capacity together with emission reduction.

The plant is located in Jiangsu province, an industrial area near Shanghai which is home to China’s most advanced production facilities. It is equipped with a Consteel® system and a 250 t/h EAF feeding a continuous casting unit for slab production. With a nominal tapping capacity of 220t and maximum liquid steel capacity of 360t, this project is the No. 1 in China. It is also equipped with the biggest electric arc furnace transformer manufactured in China, rated 140 MVA.

The production capacity is 1.8 Mt with the capability of producing the thickest slab ever made in China achieving a big rolling reduction immediately after the casting.

Started from 1997 Tenova has installed 11 Consteel® systems in China, out of 40 installations in the world, a tangible proof of the great operational flexibility, versatility and decrease of environmental impact of the technology that is well appreciated in the Country.

Example of CONSTEEL installation.

The Consteel system reduces workplace noise and dust and eliminates bucket charge operations. The absence of charge buckets minimizes dust formation in the canopy hood, while the pre-heating section of the conveyor acts like a deposit chamber, allowing dust to settle on the scrap for recycling inside the furnace. Overall dust emissions are 5 - 9 kg/tls lower than those of a conventional top-charged EAF. The reduction of total energy required for melting has a tremendous impact on the reduction of GHG (Greenhouse Gases) emissions. Consteel provides the most environmentally friendly technology available on the market, with the ability to meet strict government regulations.

Consteel is the choice of steelmakers worldwide. If you are a steel maker interested in higher productivity and lower costs, contact Tenova Goodfellow for more information about the award-winning CONSTEEL® system.

Tenova GOODFELLOW

170-7070 Mississauga Road

Dupont Building - Mississauga

Ontario L5N 7G2 - CANADA

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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#60 - What is LOI?

LOI is a company in the Tenova Group that makes reheat furnaces for the steel industry. Their full name is Tenova LOI Italimpianti, and they are the leading global supplier of reheating and heat treatment plants for the steel, aluminium and automobile industries.

When iron is produced in a melt shop, it may initially be in the form of rough castings called ingots. Iron in this form is not directly useful for most applications because of carbon-related brittleness. To produce usable steel, the iron is taken to a finishing mill. The finishing mill re-heats the iron and rolls or shapes it into steel coils, bars, or other shapes. A special atmosphere is frequently used in a reheat furnace to impart specific properties to the steel.

Tenova LOI Italimpianti makes these types of furnaces. With more than 4,000 furnace installations, LOI Italimpianti is the name behind some of the largest, most technologically advanced, and most efficient reheating furnace plants in the world.

If you are a steel maker interested in higher productivity and lower costs, contact Tenova for more information.

http://www.tenovagroup.com/companies_loi_italimpianti.php?id_company=5

http://www.loi-italimpianti.de/

LOI Thermprocess GmbH

Am Lichtbogen 29

45141 Essen

Germany

phone  +49 201 1891 1

fax +49 201 1891 321

info@loi-italimpianti.de

Tenova Core

Cherrington Corporate Center

100 Corporate Center Drive

Coraopolis, PA 15108-3185

USA

phone +1 412 262 2240

fax +1 412 262 2055

info@tenovacore.com

Tenova GOODFELLOW

170-7070 Mississauga Road

Dupont Building - Mississauga

Ontario L5N 7G2 - CANADA

Phone +1 905 567 3030

Fax +1 905 567 3899

goodfellow@ca.tenovagroup.com

For information on gas analyzer systems for reheat and heat treating furnace atmospheres, 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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#58 - Shiny object syndrome

At Nova, we’re always looking to show each other how erudite yet how cleverly humorous we are. (Obviously these are short conversations.) We recently articulated a behavior that we call ‘shiny object syndrome’. The term is not yet fully entrenched in the Nova lexicon, but there are some accepted usages in current circulation.

The term generally refers to behavior that is an outward manifestation of ‘disconfirmation bias’. We discussed that in a previous post. There we learned that disconfirmation bias is “the tendency to accept supportive evidence of a belief uncritically, but to actively refute or discount evidence that challenges that belief.” Shiny object syndrome can be thought of as a symptom of disconfirmation bias.

How so? Well, there are a few ways.

1. Sometimes in an effort to discount evidence that challenges our belief, we may allow ourselves, and also encourage our listeners to become unduly distracted and enamored by other unrelated details. We may make a great issue of an otherwise unimportant thing. Those other details are like a ‘shiny object’ that distracts attention from the real issues.
2. Sometimes it’s more serious. Sometimes we are trying to distract others from seeing our own failures. Politicians have perfected the art of deflecting attention from their own questionable activities. But this may happen to a lesser degree in manufacturing environments when the consequences of ill-fated designs need to be minimized to save face. Being ‘penny-wise, pound-foolish’ is often at the root of these situations.
3. We can actually use shiny object syndrome to our advantage when presenting an important proposal to someone with chronic disconfirmation bias disorder. We may distract the sufferer from attempting to refute legitimate evidence by giving them a shiny object to focus on.
4. In sales situations, the figurative shiny object may be used by a salesperson to distract the buyer from asking difficult questions about the item for sale. In some cases, the shiny object is actually the item for sale.

There are probably other manifestations of shiny object syndrome that we have not cataloged yet. But now that the phenomenon is documented, other examples are likely to surface.

When not on the lookout for behavioral disorders, we make gas analyzers for oxygen, carbon dioxide, methane, hydrogen, and many 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
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.

I recently stumbled across another interesting mention of shiny object syndrome here. Point #3 in the article mentions it in connection with social marketing.

Photo modified from © 2008 Tack-O-Rama Collection

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#57 - Calibration Procedure for NOVA Model 380

The Nova Model 380 Tri-Gas Analyzer for hydrogen-cooled power generators has been mentioned in this blog before. (http://nova-gas.blogspot.ca/2011/12/45-portable-hydrogen-purity-analysis.html)

This analyzer has three analysis ranges:

Range 1 - Measures Hydrogen in Air from 0-100%.  Normally used to monitor hydrogen purity from 90-100%. 

Range 2 - Measures Hydrogen in CO2.  For use when the generator is being purged with CO2 as a blanketing gas, or when the hydrogen is refilling the generator after a shutdown. 

Range 3 - Measures Air in CO2. For use when air is displacing the CO2 blanketing gas prior to opening up the generator or when CO2 is displacing air prior to refilling the generator with hydrogen.

Calibration

We occasionally get requests to post the calibration procedure for these instruments. Because it is a simple process, it can easily be described in a blog post. So here goes:

• Range 1 - H2 in Air

1. The 380WP should be calibrated at least once a month and also checked on pure hydrogen prior to checking hydrogen purity in Range 1.
2. Using the range switch, select Range 1.  With the pump switched on, allow approximately 1 LPM of air to flow through the analyzer.  Adjust the 'AIR REF ZERO' knob located on the right side of the analyzer until the reading is zero.
3. Next, turn the pump off and allow 1 LPM of 100% hydrogen to flow through the analyzer.  Remove the top cover and adjust the top panel ‘1 H2 IN AIR SPAN’ potentiometer (pot) until the reading is 100.

• Range 3 - Air in CO2

1. Select Range 3.  With the pump off, allow 1 LPM of 100% CO2 to flow through the analyzer.
2. Adjust the knob marked 'CO2 REF ZERO' located on the right side of the analyzer until the reading is zero.
3. With the pump on, flow 1 LPM of air through the analyzer.
4. Adjust the top panel pot marked ‘3. AIR IN CO2 SPAN’ until the reading is 100.

• Range 2 - H2 in CO2

1. Select Range 2.  The zero is shared with Range 3, so it will not have to be set up again in Range 2.
2. With the pump off, allow 1 LPM of 100% hydrogen to flow through the analyzer.
3. If the reading is not 100, adjust the top panel pot marked ‘2. H2 IN CO2 SPAN' until the reading is 100.

Calibration is now complete.

Notes

For calibration, main plant sources of H2 and CO2 may be used, or two high pressure cylinders with 0-30 PSI pressure regulators. These cylinders should contain the following gases:

• 100% H2 for Range 1 and 2 span calibration.
• 100% CO2 for Range 2 and 3 zero calibration.
• Note: Range 1 will zero on air and Range 3 will span on air.

Gas cylinders can usually be purchased from a specialty gas or welding gas supplier. The gas cylinder pressures should be regulated down to approx. 2-5 PSI (14-35 kPa) and have a flow control valve to meter the gas flow into the analyzer. Flow through the analyzer should be approximately 1 LPM.

The Nova Model 380 Tri-Gas Analyzer is being used for hydrogen-cooled power generators all around the world. Maintenance staff at power utilities love the 380 because it’s quick and easy to use.

We’re Nova. We make gas analyzers for carbon dioxide, hydrogen, air, and other gases.

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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#56 - Generic vs Brand-name terminology – Part 3

We have been talking lately about industry terminology. So without further ado, here are some terms that we use in our industry and what they mean to us: 

• Gas analysis system – this generally refers to the complete system of gas analysis and may include the probe, filter, sample line, gas conditioning system, analyzer, and other related components.
• Probe – this is the portion the gas analysis system that pokes into the process to take a gas sample. (Some systems have a filter and a gas sensor mounted in a probe. See ‘in-situ probes’.)
• Filter – there is frequently a filter somewhere near the probe that removes particulate from the sample while it is still close to the original temperature.
• Sample line – is the tube through which the sample flows to the analyzer.
• Gas conditioning system – are the components or systems that remove or mitigate undesirable constituents from the gas sample such as excess moisture, excess temperature, corrosive gases, analytical interferences, etc. These systems may be internal or external to the gas analyzer.
• Gas analyzer – basically the analyzer is the instrument that measures and displays a reading pertaining to the gas of interest.
• Gas analyser – same as gas analyzer, just regional difference in the spelling. Both are valid and I have enabled both spellings in the spell-check function on my computer (this is to show peaceful solidarity with all regions; hey, I’m an activist now! that was easy.).
• Detector / sensor – technically these two items are subtly different, but we basically regard both of them as the part of a gas analyzer that ‘sees’ the gas. The output of the sensor or detector is what is translated into a meaningful gas reading on the gas analyzer.
• Extractive systems – generally refer to the types of systems that extract a gas sample from the process and send (or pull) it to a gas analyser for analysis.
• In situ systems – generally refer to systems in which the analysis is done in a probe at the process. No gas is extracted.
• Process analysis – to us this refers to analyses of gas that is inside of and internal to the customer’s process.
• Ambient analysis / monitoring – analysis of gas in ambient (usually breathable) air. This condition implies different pressures, temperatures, and gas ranges than what is associated with enclosed processes.
• Portable analyzer – meaning self-explanatory, except that it also implies that the analysis will be temporary. This is because there is usually little or no sample conditioning components built-into the instrument.
• Permanent-mount analyzer – meaning self-explanatory, except that it also implies a larger and more complete system that can do continuous gas analysis indefinitely.
• Continuous analyzer – same as permanent-mount analyzer
• On-line / in-line analyzer – same as permanent-mount analyzer
• SOx – short-form that usually stands for ‘oxides of sulfur’. For many gas analysis applications, the most relevant oxide of sulfur is SO2 (sulfur dioxide).
• NOx - short-form that usually stands for ‘oxides of nitrogen’. For many gas analysis applications, the most relevant oxides of nitrogen are NO (nitrogen oxide) & NO2 (nitrogen dioxide). Of the two, NO is usually present in a much higher proportion. Therefore, NOx may sometimes be analyzed as NO only.
• NOx and SOx – no real definition here beyond what is said above; but we do receive many written and verbal inquiries for analysis of NOx & SOx where the customer does not state which oxides of sulfur and nitrogen are required. We are starting to think that the expression ‘NOx & SOx’ is over-used almost to the point of irrelevance.

There are many other words in the Nova lexicon of course. But these are frequently-used terms that sometimes require clarification with our customers. Notice that I didn’t say ‘misunderstood by our customers’. The terms defined above are how we at Nova use and understand them. Our customers may have their own usages. It matters not who is ‘right’. We simply need to take the time to come to a common understanding of terminology and proceed from there.

Use whatever terms you like – just explain them and be clear on what you are talking about. We will try to do the same.

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
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 modified from © 2008 Tack-O-Rama Collection
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#54 - TENOVA RE ENERGY Enters South Korean Market

Düsseldorf (Germany), March 2, 2012 - Hyundai Orders Heat-Recovery Systems for EAFs

Tenova Re Energy signed a contract with Hyundai Steel for the supply of two iRecovery® systems for Hyundai's plant in Incheon, South Korea. The heat-recovery systems have to be installed on a 90-ton and an 80-ton EAF. The design of iRecovery systems is based on an evaporative cooling system that uses water at boiling point under high pressure. Such water, used as a cooling fluid, is forced into the cooling circuit. The absorption of energy coming from the EAF off-gases converts part of the cooling water into steam available for further applications. Industrial steam is available for applications like vacuum degassing or power generation. Start-up of the first system is scheduled for March 2013, while the second will be put into operation as early as August 2012.

http://www.tenovagroup.com/pdf/press/138-TENOVA%20RE%20ENERGY%20-%20Hyundai.pdf
http://www.tenova-reenergy.com/en/home.html

If you are a steel maker interested in higher productivity and lower costs, contact Tenova for more information about their award-winning products and systems. 

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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#53 - What is CONSTEEL?

The CONSTEEL® system is a unique steel-making process developed by TENOVA. It is the only commercial process that continuously pre-heats and feeds the metallic charge (scrap metal, pig iron, hot briquetted iron, etc.) into an electric arc furnace (EAF) while simultaneously controlling gaseous emissions. The charge is loaded directly from the scrap yard or the railcar to the charge conveyor, and pre-heated by furnace off-gas as it is automatically transported to the EAF.

The pre-heated charge is fed into the EAF where it is melted by the liquid steel in a continuous cycle. This permits constant flat bath operation, a key advantage over conventional batch processes where scrap is melted directly by the electric arc. The EAF gases are sent to a fume-cleaning plant where carbon monoxide and pollutants are burned in a combustion chamber without consuming fuel. The system uses heat from the flue gas for cogeneration of hot water and/or steam.

The Consteel system technology simplifies steelmaking logistics by minimizing scrap movements. Furnace bay crane activities using charge buckets are virtually eliminated, for lower operating and maintenance costs. Leakages in the water-cooled furnace sidewalls, roof and lances caused by arcing or scrap impact are avoided, thus minimizing the risk of water entering the furnace. The Consteel equipment is designed for high reliability and low maintenance, including reduced refractory maintenance. The result is a safer, more congenial working environment compared to typical conditions in the steel industry.

The ConsteeI system satisfies key melt shop requirements in the minimill business:

• Fast payback
• High Flexibility
• Low production costs
• Reduced environmental impact
• High productivity
• Personnel safety

Improved Environmental Sustainability

The Consteel system reduces workplace noise and dust and eliminates bucket charge operations. The absence of charge buckets minimizes dust formation in the canopy hood, while the pre-heating section of the conveyor acts like a deposit chamber, allowing dust to settle on the scrap for recycling inside the furnace. Overall dust emissions are 5 - 9 kg/tls lower than those of a conventional top-charged EAF. The reduction of total energy required for melting has a tremendous impact on the reduction of GHG (Greenhouse Gases) emissions. Consteel provides the most environmentally friendly technology available on the market, with the ability to meet strict government regulations.

Addendum Jan 28, 2013 - here are a couple more pictures of Tenova CONSTEEL installations:

 

 

 

Consteel is the choice of steelmakers worldwide. If you are a steel maker interested in higher productivity and lower costs, contact Tenova Goodfellow for more information about the award-winning CONSTEEL® system.

Tenova GOODFELLOW
170-7070 Mississauga Road
Dupont Building - Mississauga
Ontario L5N 7G2 - CANADA
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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