#181 - Alliance Formed for Ironmaking Technologies

Tenova HYL and Danieli & C have entered into an agreement with Nippon Steel & Sumikin Engineering Co. Ltd. (NSENGI) to combine and commercialize their Energiron Direct Reduction technology with an optimized blast-furnace and syngas technology (high-efficiency coal gasification and steelworks byproduct gas utilization technology) developed and owned by NSENGI.

The two key areas of combined know-how involve the integration of the Energiron Direct Reduction technology with the blast furnace as well as the areas of interface between existing and future syngas technologies with the Energiron process. This alliance will allow the three companies to combine research and development activities with the ultimate objective of developing a new ironmaking technology that will reduce CO2 emissions and operating costs while increasing productivity for integrated steelmaking facilities.

HYL actively develops projects for direct reduction plants worldwide under the Energiron brand name. They started up the world's first successful direct reduction plant in 1957. Over 40 DR modules have been supplied worldwide since then.

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

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#180 - Roads after Winter

A while back we posted a picture of a dangerous mountain road in Belize, South America. This year’s cold North American winter proved to be very damaging to asphalt road surfaces. Although the results are not as harrowing as the Belize example, the enormous post-winter potholes are really annoying. (In some places, it gives us a little idea of what the old corduroy roads must have been like.)

The winter/roads effects seem to be most pronounced in locales that see sustained temperatures below -20°C (-4°F). The weather around the Nova offices definitely fit this profile during this past winter. The folks at CBC put together a few pictures that explain the process of pothole development.

This poor chap has located a hidden pothole.
Picture credit Liu tao / Ananova

In a past life in the coatings industry, I was able to explore the effects of viscosity, rheology, and additive dispersion on stability and performance of film-forming substances. Even though I know very little about roadwork, I was thinking recently that asphalt seems to need an improved flexibility profile in cold climates. But not to the point where hot weather produces excessive softening.

One idea that might have some potential in this area is rubber. Using rubber waste in asphalt has probably been proposed many times before. But these folks here seem to be making progress in ironing out some of the bugs of using this additive. ‘Crumb rubber’ produced from shredding old car tires can be used to enhance the aging properties of asphalt. This approach also finds a better home for old tires than in landfills.

If it makes better roads, reduces potholes, and reduces waste, it is surely worth continued research.

pothole pic - http://www.bedfordma.gov/highway-division/pages/pothole-information

landfill tires - http://www.mymodernmet.com/photo/tires-1

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#179 - Battle Fought at Nova’s Canadian Site

Unknown to us, a battle was fought over the weekend at Nova’s Canadian Site. Not with cannons and muskets, but with brushes and easels.

The ART BATTLE DAY 2014! brings more than 250 artists together to compete in same-day events in 20 Canadian communities for the chance to advance to the 2014 Art Battle National Championship. Here’s the website - http://artbattle.ca/

Battle # AB126 was held in Hamilton, ON at the 270 Sherman Ave North facility.

Here’s a photo set of some of the action. Photo album pics by TV station Cable 14's Mike Cameron.

Never a dull moment here!

Pics from Art Battle website.

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#178 - Nova Analyzers from the Field – Episode 6

In the 'Analyzers from the Field' series, we normally post a couple of pictures and write a brief summary of an instrument that has turned up in our Service Department. The older instruments always seem to have some kind of story around them which can be informative and interesting.

In this episode, we feature some equipment that has just recently been installed into the field at a Direct Reduced Iron plant in the southern USA. The DRI process directly reduces iron ore to iron. The produced product is iron pellets that have flexible options for transport or direct use in steelmaking.

Mass spectroscopy is used by some steel makers to obtain analysis of the process gases in and around the DRI reactor. The main advantage of this technique is that it is versatile in terms of analytical capability. Numerous types of gases may be measured by a mass spectrometer. However, mass spec technology can be complex. The sample conditioning requirements are stringent. It is therefore sensible to have a back-up plan in case of unexpected interruptions in the gas analysis data.

These Nova analyzers were installed as a robust back-up to the mass spec for the key gases being analyzed in the DRI reaction. There were four points in the process considered important enough to have back-up analyzers on.

Continuous gas analysis on these units is as follows:

0-20.0 % CO2

0-40.0 % CH4

0-60.0 % H2

- Cabinet temperature management for installation out-doors in -5°C to 48°C.

- Hazardous Area Cabinet for installation in Class 1 Division 2 Group B rated area.

The sample gas contained metallic dust and was typically under pressure (6.2-10.8Barg / 90-160psig). This required filtration at the extraction point along with regulation down to usable pressures. A sample extraction assembly was provided at each sample point.

The plant is still under construction at this time. However, the analyzer installation was well-executed and we are confident that the systems will function as expected. Here is a link to these analyzers in our catalog.

Episode 1 - old portable flue gas with dual CO channel
Episode 2 - portable ppm H2 analyzer for university metallurgical lab
Episode 3 - ex-proof H2 analyzer in South Africa
Episode 4 - 14yr old continuous CO/H2 analyzer on heat treat furnace
Episode 5 - 3 channel CO2 analyzer for fire suppression apps

If a system like this is of interest to you, contact Nova for details.

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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#177 - Earth Day – Mars Day

Here is a very cool picture of a Mars landscape. The picture was taken on March 27, 2014 by the Curiosity rover currently exploring the planet as part of NASA’s Mars Science Laboratory mission. The picture credit is Nasa / JPL-Caltech/MSSS. The composite / editing was done by Jason Major.

"City on Mars" 
Frank R. Paul, 1940

In years past, the traditional mental image of Mars (and associated Martians) has been influenced by science fiction stories that conjure up strange landscapes and exotic cityscapes.

However, science non-fiction has provided us with real photos that often present a landscape that seems very earth-like in appearance. That is until we remember that the temperature on Mars can drop to minus 125 degrees C (-195F) in the winter. The thin atmosphere is a lethal blend of 95% CO2. For breathing, human safety generally requires monitoring in the 0-5,000ppm CO2 range.

Here is another picture in the Mars series.

From the Mars One website:

Mars One is a not-for-profit foundation that will establish a permanent human settlement on Mars. Human settlement on Mars is possible today with existing technologies. Mars One mission plan integrates components that are well tested and readily available from industry leaders worldwide. The first footprint on Mars and lives of the crew thereon will captivate and inspire generations; it is this public interest that will help finance this human mission to Mars.

The Mars One mission plan consists of cargo missions and unmanned preparation of a habitable settlement, followed by human landings. In the coming years, a demonstration mission, communication satellites, two rovers and several cargo missions will be sent to Mars. These missions will set up the outpost where the human crew will live and work.

Before a manned Mars mission happens, it probably makes sense to re-visit our heavy propulsion and lunar capabilities. All of the technology proven out for reusable rockets and a successful moon mission will have direct relevance to a Mars mission. And the moon is a lot closer. The people at SpaceX are working on these issues.

Maybe when we have people successfully living and working on Mars, we will have Mars Day as a follow-up to Earth Day. It is fascinating to think about a Mars mission and possible Mars habitation. However, it is equally fascinating to see the wonders all around us here on planet earth. Here are some beautiful photos inspired by Earth Day - https://mybeautifulearth.withgoogle.com/

#176 - Some beautiful photos inspired by Earth Day

Some beautiful photos inspired by Earth Day here - https://mybeautifulearth.withgoogle.com/

Here's another one of Norm's Mount Kilimanjaro pics from his recent climb.

http://nova-gas.blogspot.ca/2014/04/173-nova-tech-climbs-mount-kilimanjaro.html

#175 - Tenova Factories

Our area of the Tenova Group specializes in R&D, analysis instrumentation, and process optimization. However, Tenova also has heavy manufacturing facilities worldwide.

Tenova Pomini

The Tenova Pomini factory, based in Castellanza, Varese (Italy), is the pride of Tenova’s internal production and assembly capability. Equipped with the most advanced CNC machine tools, the workshop is mainly focused on the production of Tenova Pomini roll grinders. With over 25,000 sqm of covered area the production facility is able to meet the most demanding delivery schedules and quality requirements.

Tenova I2S

The Tenova I2S production facility is located in Yalesville, CT. USA and takes up an area of about 12,550 sqm. The factory is equipped with one of the largest indoor cranes in the USA (125 ton) and a full service machine shop focused on the design, manufacture and assembly of cold reduction mills and thickness gauging systems. By combining quality manufacturing capability, a strong engineering foundation, and the latest in controls technology, Tenova I2S excels in the support of its customer's needs.

Tenova Metals India

Tenova's Indian manufacturing plants are located in the Thane district of Maharashtra (India), in the industry park near Mumbai, on an area of 1600 sq.m. The full-service workshops handle fabrication, machining, and equipment assembly for strip processing lines and cold rolling mills.

Fabrication and machining are restricted to critical items, while final assemblies and testing of the majority of equipment are conducted internally, to ensure compliance with Tenova quality standards.

Tenova Timec

Tenova Timec is Tenova’s production facility in China. Based in the industrial area of Tanggu (Tianjin) Tenova Timec is located near the third largest Chinese port, just 2 hours’ drive from Beijing. The factory is 54,000 sqm, including 15,000 sqm that is covered. The excellent quality of production is guaranteed under Tenova’s worldwide quality assurance program carried out to the strictest required standards.

Tenova TAKRAF

Tenova TAKRAF factory, based in Lauchhammer (Germany) is 235,000 sqm including 17,900 sqm that is covered and is divided into four separate bays used for:

- Metal prefabrication

- Steel construction

- Assembly

- Wearing parts manufacture

Tenova TAKRAF factory was constructed in 1996 and is equipped with new and efficient machinery. The internal fabrication is used just for complicated parts with elevated technological content, and for huge size and non-standard parts that would be difficult and time consuming to produce them through external fabrication. Twelve radio-controlled cranes with lifting capacities of up to 80 tons are installed in the bays. Equipped with the latest standards, the factory produces the key components for Tenova’s product range as well as all related spares and wearing parts.

More than 100 highly specialized and experienced workers contribute daily to the successful and on time delivery of the parts and components internally fabricated. Tenova TAKRAF factory is a highly specialized workshop with a specific focus on the production of:

- Bucket wheel drives and their components

- Crawler links of all types and sizes

- Ball bearing slewing rims up to a diameter of 6m, with hardened or as-rolled bearing races

- Gear rims in all diameters between module 20 and module 40

- Support bearings with ball diameter up to 1500 mm.

Here is a previous post with some other very cool Takraf-related information.