#118 - Tenova Also Makes Marine Leisure Products

We were surprised to recently learn about this interesting nuance of our company. The Tenova Group is a technology supplier to the mining & minerals and iron & steel industries. These are heavy industries. However, we also have a group that makes walkway & platform systems for marine leisure applications.

Tenova Takraf manufactures the largest vehicles on earth. See this link.

Tenova TAKRAF is also now the sole distributor of the Jetfloat Modular System in southern Africa. The Jetfloat system was designed and patented through extensive research and development by Jetfloat International in Austria. Comprised of modular elements linked together to form the required shapes, Jetfloat platforms are quick to assemble on land and on water and are easily extendable. The Jetfloat system is a modular pontoon and marine docking system.

BENEFITS

■ No repair and maintenance costs.

■ Light-weight and easy to assemble without the need for cranes.

■ Easily extended or altered in steps of 500 mm.

■ No sharp edges, corners or connecting parts, making the product safe for all environments.

■ Various anchoring methods make it possible to use this system in many applications.

■ Secure handrail mounting, which can be supplied to specification.

■ Other accessories available for a versatile hassle-free installation.

■ High elastic resistance to impact by boats, wind and storms.

■ Long life, as they are fatigue and weather proof and resistant to saltwater, chemicals and acid.

The flexible and long-lasting Jetfloat modular pontoons and systems make ideal marinas, bathing jetties, bathing islands, floating pools, diving platforms, event platforms, self propelling rafts and aquaparks, which blend in harmoniously with their natural surroundings.

FEATURES

■ Single layered systems have buoyancy of 350 kg/m2.

■ Double and triple layered systems available for supporting heavier tonnage.

■ Wave and storm-proof – employable off-shore, with the correct anchoring system.

■ Resistant to UV rays, salt water and various other chemicals.

■ Resistant to weathering

SPECIFICATIONS

Jetfloat single element

■ Length: 500 mm

■ Width: 500 mm

■ Height: 400 mm

■ Weight: 6 kg

Jetfloat double element

■ Length: 1,000 mm

■ Width: 500 mm

■ Height: 400 mm

■ Weight: 11 kg

Standard colours are black, light blue and light grey. Handrails are available. Elements are blow-moulded using high quality Lupolen 5261 Z high density polyethylene. Superior quality control ensures a uniform thickness of 8 mm to provide best stability of the product all-round. Use of anchoring blocks, chain and eye props ensures that walkways and platforms remain in position for a long period.

INSTALLATION

Tenova TAKRAF is a qualified installer of the product, offering a highly competitive engineering works background. Its installation expertise is backed by numerous successful installations in Africa of the Jetfloat system for leisure applications since 2005.

To inquire about this product, contact:

Tenova Mining & Minerals (Pty) Ltd

1 Kramer Road

Bedfordview

Johannesburg

PO Box 75996

Gardenview, 2047

South Africa

phone +27 11 201 2300

fax +27 11 455 4547

enquiries.TMM@za.tenovagroup.com

#117 - Earth Day - April 22, 2013

The Face of Climate Change is the theme of this year’s Earth Day.

Because we are a company that is interested in gas and atmosphere analysis, our blog has frequently discussed aspects of climate change, or equipment that helps reduce environmental impact of industrial processes. Sometimes we just ramble about things that interest us or bug us.

For example:

Post #116 - Interesting comparison of Louisiana shore-line between the years 1932 & 2011
http://nova-gas.blogspot.ca/2013/04/116-interesting-comparison-of-louisiana.html

Post #105 - Canada’s Clean-Tech Sector - Jobs, Revenues and New Ways of Doing Business
http://nova-gas.blogspot.ca/2013/02/105-tenova-goodfellow-mentioned-in.html

Post #99 - Beijing Air Index Goes Off Scale
http://nova-gas.blogspot.ca/2013/01/99-beijing-air-index-goes-off-scale.html

Post #85 - Caribbean Applications
http://nova-gas.blogspot.ca/2012/11/85-caribbean-applications.html

Post #54 - TENOVA RE ENERGY Enters South Korean Market
http://nova-gas.blogspot.ca/2012/03/54-tenova-re-energy-enters-south-korean.html

Post #53 - What is CONSTEEL?
http://nova-gas.blogspot.ca/2012/03/53-what-is-consteel.html

Post #51 - What is EFSOP?
http://nova-gas.blogspot.ca/2012/02/51-what-is-efsop.html

Post #42 - Floating Cities and Ambient Air Analysis
http://nova-gas.blogspot.ca/2011/12/42-floating-cities-and-ambient-air.html

Post #40 - Driving Clean and Engine Exhaust Analysis – Part 2
http://nova-gas.blogspot.ca/2011/11/40-driving-clean-and-engine-exhaust.html

Post #38 - Driving Clean and Engine Exhaust Analysis – Part 1
http://nova-gas.blogspot.ca/2011/11/38-driving-clean-and-engine-exhaust.html

Post #26 - 7 Billion
http://nova-gas.blogspot.ca/2011/09/26-7-billion.html

Here is a link to the Earth Day video.

Here is a link to the Earth Day Network website.

Here is a link to reversing the negative affects of environmental damage. Just kidding. Clicking and ‘liking’ on its own is not the same as environmentally responsible living.

Image taken from Earth Day website.

#116 - Interesting comparison of Louisiana shore-line between the years 1932 & 2011

We saw this picture recently prepared by NOAA. Here's a link to the story.

The water isn’t lapping up at everyone’s doorstep. But that does not appear to mean that the levels aren’t rising.

Reduction of wetlands though development or through submersion no doubt further exacerbates these kinds of situations by removing the natural defenses. What will this shoreline look like in another 80years? Or perhaps a better question is: how far north will the shoreline be by then?

Louisiana is on our minds lately because Tenova HYL and Nova are involved in a couple of gas analysis projects there. Here are some pictures of one of those projects.

http://www.nova-gas.com/

https://twitter.com/NOVAGAS

http://www.linkedin.com/company/nova-analytical-systems-inc-

http://www.tenovagroup.com/companies_hyl.php?id_company=2

http://www.tenovagroup.com/

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#115 - EAF Process Flow and the Tenova Group

The Steel Manufacturers Association (SMA) has released its Public Policy Statement for 2013-2014. The SMA is the primary trade association for scrap-based electric arc furnace (EAF) steelmakers.

Tenova Core and Tenova Goodfellow are both associate member companies in the SMA. Tenova Core also has a representative on the 2013 Associate Member Executive Committee.

EAF steel producers are the largest recyclers in North America. Over 90 percent of the material input to EAFs is recycled ferrous scrap. EAFs also play a large role in conserving energy – steel produced from melted scrap consumes approximately one third the energy that steel produced from iron ore consumes.

The production share of EAF furnaces of total steel production has grown from approximately 35% in 1990 to 60% in 2012.

In the back of the print copy of the Public Policy Statement, there is a nice diagram of the EAF process flow. This simple graphic prompted me to compare the standard EAF process with the expertise and products that can be found within the Tenova Group. Many of the areas do have a match. My summary of the Tenova capability is no doubt incomplete, but this is a good start.

__________

Steel Scrap Handling

Scrap steel has a high weight per volume and requires energy to receive and move around. Scrap steel is usually not received in geometrically and compositionally homogenous states. Material handling is therefore an important part of the EAF input process. I wasn’t able to find a direct match in the Tenova Group to steel scrap materials handling. However, Tenova Takraf is a world leader in materials handling for ore and mining applications. They may have equipment in their product line that is suited for steel yard and scrap handling.

__________

Electric Arc Furnace

This is the heart of the EAF process where the input material is melted down by electric arc. There are several areas of the Tenova Group that have a high relevance to the EAF.

• Tenova Melt Shops manufactures electric arc furnaces. Tagliaferri is the historical brand of Tenova Melt Shops which has been designing and manufacturing EAFs since the very beginning of electrometallurgy.
• Consteel is a continuous metallic charge feeding and preheating system made by Tenova Melt Shops.
• EFSOP is an off-gas based process control technology produced by Tenova Goodfellow for energy optimization of electric arc furnaces.
• The KT Injection System is a wall-mounted, multi-point system for injecting oxygen and a wide range of fines of carbon, lime, DRI and other materials into the slag layer of an EAF.

__________

Ladle Metallurgy Station

After tapping the molten steel, the ladle metallurgy station fulfills several functions in preparing the melt to be processed in the continuous casting machine. Ladle furnaces also act as a buffer between the EAF and continuous casting line. Tenova Melt Shops offers complete ladle furnace packages.

Tenova Melt Shops offers complete ladle furnace packages including:

• Electric power supply
• Ladles
• Ladle transfer cars
• Additives charging and injections systems
• Dedusting
• Electrode make-up stations and other auxiliary equipment

__________

Caster

Continuous casting is the process by which the molten metal is cooled and solidified into heavy steel strips called billets, blooms, or slabs. The produced steel may be stored or immediately rolled into finished products. There does not appear to be a Tenova company that makes continuous casters.

__________

Rolling Mill

Rolling mills further process the slabs and strips into other semi-finished products such as bars, billets, beams, or wire. The Tenova Rolling & Finishing division manufactures all kinds of strip processing lines and cold rolling mills.

• Tenova Key Technologies - acid regeneration, iron oxide production, waste water treatment
• Tenova I2S - cold roll mills
• Tenova Presind Automation - integrated control systems and drives for processing lines and cold mills
• Tenova Multiform - strip processing line and cold rolling mills in the Indian and Asian markets including India, Bangladesh, Vietnam and Indonesia.
• Tenova Pomini - worldwide leader in production of roll grinders, for rolls belonging to flat products mills (steel and non-ferrous metals such as copper, aluminum) as well as paper mills.

__________

Finishing and Shipping

Further processing into finished products may follow the rolling mill or be integrated in with it. Inventory systems are used to store and stage the finished products prior to delivery.

• Tenova Strip Processing – pickling, tinning, galvanizing, color-coating, silicon steel, stainless steel lines, and many others

__________

The Tenova Group is an intelligently diversified company that covers many areas of the steel-making process. The expertise accumulated among the Tenova companies is available to steel-makers around the globe.

NOVA Analytical Systems plays a small role in this value chain by manufacturing gas analysis equipment for a wide range of industries.

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/

https://twitter.com/NOVAGAS

http://www.linkedin.com/company/nova-analytical-systems-inc-

http://www.tenovagroup.com/
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#112 - Fischer-Tropsch Process Applications

In the last year or so, we have had a few inquiries about providing analyzer systems for measuring the gases produced by Fischer-Tropsch (FT) processes. The FT process is a series of chemical reactions that produces liquid hydrocarbons from carbon monoxide (CO) and hydrogen (H2) in the presence of a metallic catalyst.

In the inquiries we have received, the FT process temperature is usually below 300°C with some variants running just a little more than common room temperature. Pressure is usually high – approximately 20-40 bar (300-600psi).

The FT process can produce synthetic lubrication oil and fuel from coal, natural gas, biomass, and other sources of carbon. If the feedstock is a solid, it must first be converted to a gas by the gasification process. Synthesis gas obtained from gasification may require some adjustments to the CO / H2 ratio in order to be utilized in an FT process.

FT plants tend to be associated with high capital costs and high operation & maintenance costs. Reliable availability of feedstocks plays a role in the economic viability of FT plants. Our most recent inquiry was from a company who has developed a more modular and portable FT reactor for smaller scale fuel production. This approach may lead to additional growth in FT applications.

All known FT inquiries to Nova so far have required analysis of CO / CO2 / CH4 / H2 in a single instrument in either portable or permanent-mount configurations.

Ranges required:

CO: 0-40.0 %

CO2: 0-10.0%

CH4: 0-10.0%

H2: 0-70.0%

The sample gas is always free of acids, NH3, and other corrosive byproducts that might harm the detectors in the analyzer.* Because it is a high pressure process, the sample extraction point generally has a regulator. However, the analyzer needs to have regulator also.

The formation of methane is usually undesirable in the FT process, so the requested CH4 ranges tend to be 0-10.0% or less. There may be trace amounts of other gaseous hydrocarbons. These will probably condense out if the customer has a chiller installed before the gas analyzer. The pressure drop and the chiller will also remove any moisture in the gas.

We have sold the Model 970 in portable and permanent-mount formats into FT applications.

Nova Model 974 permanent-mount analyzer recently built for a
Fischer Tropsch application

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/

https://twitter.com/NOVAGAS

http://www.linkedin.com/company/nova-analytical-systems-inc-

http://www.tenovagroup.com/

* These substances are absent because they will destroy the metallic catalysts which are critical to the FT process itself.

Inset process pictures Copyright © 2012 Repotec Umwelttechnik GmbH

http://www.repotec.at/index.php/homepage.html

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#111 - TENOVA Projects – ASA Metals

Project Description

In October 2007 ASA Metals awarded a lump sum turn key contract to Tenova Pyromet for the ASA Metals expansion project. The project was for the design, supply, installation and commissioning of 2x66MVA closed submerged arc furnaces, complete with Outotec single shaft pre-heating systems.

The Pyromet scope included the submerged arc closed furnaces complete with pre-heaters, raw material handling, screening, dust extraction, storage and batching, furnace off-gas scrubbing, electrical, automation and tapping equipment.

Scope

The Tenova Pyromet scope of work included civil works, structural steelwork, raw materials handling, storage and blending, HV, MV and LV electrical reticulation, plant automation, furnace off-gas cleaning and the furnace and auxiliary equipment and technology.

The complete plant was designed by Tenova Pyromet, and the majority of the technological equipment fabricated at Tenova's Timec facility located in China.

Tenova Pyromet provided guarantees for completion, furnace power, production capacity and product grade, all which was met shortly after the plant was commissioned.

One of the major challenges that had to be overcome was the physical site layout for the expansion project. The ASA Metals site is located on the slope of the Lebalelo Mountain near Burgersfort, South Africa. The Tenova Pyromet engineers delivered an innovative site layout which not only managed to fit the complete plant in a small foot print, but also provide unrestricted maintenance access.

Google Image of ASA Metals Plant

The new plant had to be constructed next to the existing operating plant, which meant that the construction philosophy had to be flexible and not interfere with the existing operation.

A further challenge was to manage the extensive logistics involved in supplying a substantial amount of equipment from Tenova's Timec workshop in China. All equipment fabricated met with Tenova Pyromet's world class quality requirements and was delivered to the ASA Metal site well within schedule.

 The smelter incorporates the following technology: 

• Pyromet submerged arc closed furnace technology
• Outotec single shaft pre-heating system
• Pyromet patented electrode columns, which are installed on all six of the ferrochrome furnaces constructed in South Africa during the last two years
• Complete plant automation system designed by Pyromet
• Pyromet designed furnace off-gas scrubbers, two per furnace with each scrubber rated at 130% of furnace capacity
• Fully integrated and automated raw material handling system from the mine through to the Pyromet ore beneficiation plant

Project Information

Project name:  ASA Metals Expansion Project

Client:  ASA Metals (Pty) Ltd

Site:  Burgersfort, Limpopo province, South Africa

Project description: Brownfield turnkey design, supply, erection, commissioning and equipment and process guarantees of furnaces, furnace building, off-gas scrubbing, slurry handling, raw material storage and batching systems, electrical HVA,MV, LV, control and instrumentation.

Disciplines included:  Process Technology, civil, structural, mechanical, electrical, instrumentation and automation

Produces:  Charge chrome (ferrochrome)

Furnace capacity:  2 x 66 MVA (54 MW)

Production capacity:  254,000 tpa charge chrome

Project duration: 20 months

Commissioned: July 2009

Plant startup: August 2009

Project Statistics

Concrete:  20 000 m3

Steel structures:  7 000 tons

Construction Man hours:  >1 million

Project team:  70 persons

Tenova PYROMET

Tenova Pyromet (Pty) Ltd

10 Sherborne Road

Parktown, Johannesburg

PO Box 61582, Marshalltown

2107 South Africa

Phone +27 11 480 2000

Fax +27 11 482 1942

Pyromet website

NOVA Analytical Systems

1-800-295-3771

sales at nova-gas dot com

websales at nova-gas dot com

http://www.nova-gas.com/

https://twitter.com/NOVAGAS

http://www.linkedin.com/company/nova-analytical-systems-inc-

http://www.tenovagroup.com/

#110 - Tenova Takraf – builds the largest vehicles on earth

Bucket Wheel Excavators (BWE) are among the largest terrestrial vehicles ever constructed. BWEs function basically as continuous cutting machines for soft to semi hard materials like clay, sand, gravel, marl and their blendings, as well as lignite and hard coal. They are used primarily in open pit mining operations.*

The characteristic parts of a Bucket Wheel Excavator are the cutting wheel with buckets, the wheel boom, the superstructure with counterweight boom, the substructure, the undercarriage with crawler tracks and a transfer boom to the bench conveyor (or a connecting bridge to the loading unit).

The bucket wheel concept has been in use in mining operations since the 1920’s. However, it was in the 1950’s that it came to be applied on truly massive scales in Germany. The biggest machine ever built, the Tenova TAKRAF Model SRs 8000, has a weight of 14,200 tons and moves 240,000m³ of overburden per day. This machine is also famously known as the Bagger293.

Project

Customer:  RWE Power AG (former Rheinbraun AG), Cologne

Plant Location:  Open Cast Mine Hambach (Germany)

Scope of work:  Turn-key project

Project Figures

Capacity per day: 240,000 m³ / 314,000 yd³

Cutting height: 51 m / 167 ft

Cutting depth: 17 m / 55 ft

Max. outreach of bucket wheel: 72.2 m / 236.9 ft

Center of discharge pulley: 138.75 m / 455.2 ft

Bucket wheel diameter: 21.6 m / 70.9 ft

Bucket wheel drive power: 3 x 1,120 to 1,680 kW

Nominal bucket volume: 6,600 L / 8.6 yd³

Length: 502 m / 1647 ft

Service weight: 14,200 t

Commissioned: 1995

Here is an excellent picture of this machine in action: http://en.wikipedia.org/wiki/File:Braunkohlenbagger_im_Tagebau_Hambach.jpg

Tenova TAKRAF manufactures BWE’s in a wide range of capacities between 200 and 16000m³/hr. Models are available with working heights from less than 5m to a maximum of 51m. The type and size of excavator used on a mining site is determined by the local mine conditions and the required cutting height and width.

Here is an excellent wide angle picture of a Takraf rail-based Bucket Conveyer Excavator (BCE): http://upload.wikimedia.org/wikipedia/commons/4/49/F60_in_Betrieb.jpg

It is worth pasting the above link into your browser and viewing it at its source. The picture is quite large and shows a high level of detail.

This style of excavator has its buckets attached to a conveyor instead of a wheel. This allows excavation from within and below their scope of movement. This is useful if the pit floor is unstable or even underwater. As shown in the picture link above, TAKRAF's BCEs travel on rails rather than on crawlers.

Agencies or companies that are in the market for one of these machines, should contact:

TAKRAF GmbH

Torgauer Straße 336

04347 Leipzig

Germany

phone +49 341 2423 500

fax +49 341 2423 510

sales@takraf.com

Tenova TAKRAF

Tenova SpA

Via Albareto 31

16153 Genoa

Italy

phone +39 010 6054067

fax +39 010 6054710

bulkhandling@it.tenovagroup.com

NOVA Analytical Systems

1-800-295-3771

sales at nova-gas dot com

websales at nova-gas dot com

http://www.nova-gas.com/

https://twitter.com/NOVAGAS

http://www.linkedin.com/company/nova-analytical-systems-inc-

http://www.tenovagroup.com/


* Open pit mining has declined somewhat in recent years for environmental reasons. However, many lignite mines remain in operation. Open pit mines and the land around them require a fair amount of rehabilitation after mining operations have ceased. See http://en.wikipedia.org/wiki/Open-pit_mining

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