NON- FERROUS METALS Measurement Solutions for Process Optimisation

Transcription

1 NON- FERROUS METALS Measurement Solutions for Process Optimisation

2 AGELLIS TAKE CONTROL OF YOUR PROCESS Agellis Group develops, manufactures and markets measurement solutions, facilitating process optimisation for the global molten metals industry. We have a strong commitment to enhance our customer s productivity, safety and long-term profitability. OUR SOLUTIONS ENABLE increased automation, improved process efficiency and enhanced safety for personnel within metal production. Our solutions are based on two platforms, EMLI (Electromagnetic Level Indication) and VISIR (Vision and Infrared), developed from our unique expertise in both electromagnetic and vision technologies, extensive knowledge of industrial processes and close customer cooperation. More than 30 years experience of global metal industry along with continuous investment in research and develop ment has enabled us to achieve a worldleading position in molten metal level measurement, detection and monitoring. A state of the art electromagnetic platform for molten metal measurement systems. VISIR A vision and thermographic camera platform for critical process monitoring. CONTENTS EMLI... 4 EMLI-FurnaceProfile... 5 EMLI-SmelterLevel... 6 EMLI-MetalSlag... 7 EMLI-TundishLevel... 8 EMLI-MouldLevel Suspended... 9 VISIR...10 VISIR-LadleDeslag...11 VISIR-LadleSafe VISIR-FurnaceSafe VISIR-MetalDetect...14 FROM FURNACE TO CASTER Agellis solutions assist metal producers in stabilising their process, reducing production costs while improving safety from furnace to caster. Whether you need to control slag carryover, precisely measure metal levels or avoid costly breakouts, Agellis has the optimal solution for your process. 2 3

3 ELECTROMAGNETIC ELECTROMAGNETIC MEASUREMENT OF METAL AND SLAG LEVELS FOR FURNACES EMLI-FurnaceProfile THE EMLI-FURNACEPROFILE SYSTEM allows process improvement through objective and consistent metal level measurement. By knowing the levels in your furnace at all times, variations in the process can be eliminated. Temperatures inside the furnaces can be measured in order to control heat loss. EMLI-FurnaceProfile system improves safety as no manual dip pin measurement is needed. Lance mechanisms, speed and immersion times are all customised to fit the specific requirements. The system measures the difference in electrical conductivity between the different layers in the furnace. From these changes in electrical conductivity metal levels are calculated with high accuracy. EMLI-FurnaceProfile ELECTROMAGNETIC Fully automatic EMLI-FurnaceProfile system installed on a 6-in line furnace. EMLI-FurnaceProfile EMLI-SmelterLevel EMLI-MetalSlag EMLI-TundishLevel EMLI-MouldLevel Suspended Objective and consistent level measurements. Increase safety for operators. Measurement of slag level, matte level, blister&alloy level and transition zones. Temperature measurement is possible in chosen layer of the furnace. Cross check mass balance calculations. Improve the process control by knowing your levels at all times. emli-furnaceprofile/ 5

4 ELECTROMAGNETIC ELECTROMAGNETIC CONTINUOUS ELECTROMAGNETIC MEASUREMENT OF METAL LEVEL FOR SMELTERS EMLI-SmelterLevel METAL DETECTION DURING SLAG TAPPING EMLI-MetalSlag THE EMLI-SMELTERLEVEL UNIT continuously measures and monitors the true metal level in smelters or furnaces in real-time. The system measures the metal level irrespective of metal type, amounts of slag on top of the metal or temperature. Tracking the metal level inside the furnace is crucial for process efficiency, shortening tap-to-tap times and controlling energy consumptions. THE EMLI-METALSLAG SYSTEM continuously monitors slag flow during furnace tapping and provides early alarm outputs when metal is detected in the slag stream. These outputs can be used to immediately end slag tapping by giving visual and audible alarms. The EMLI-MetalSlag system can be used on blast furnaces as well as SAF, Flash, Pierce Smith, Reverberatory, Teniente and Slag Cleaning Furnaces and others. With sensors mounted behind the refractory bricks the system provides information to track metal levels during melting and tapping. Typical raw signal from system showing metal bath during difference smelting phase in an ISA furnace. Avoid dangerous situations by monitoring the slag stream for the presence of metal. Agellis EMLI-MetalSlag sensors Agellis EMLI- SmelterLevel Sensors emli-smelterlevel/ Measure the metal level continuously. Improve the process stability by following the correct signal signature. Save smelting time by knowing when to tap. Save smelting time by minimising dip bar measurements. Typically used with ISA and Aussmelt furnaces. Control bath agitation. Detect metal in slag runner/tap hole. Avoid dangerous situations in following processes. Simple installation and low maintenance. emli-metalslag/ 6 7

5 ELECTROMAGNETIC ELECTROMAGNETIC CONTINOUS TUNDISH AND RUNNER METAL LEVEL MEASUREMENT EMLI-TundishLevel ELECTROMAGNETIC MOULD LEVEL MEASUREMENT EMLI-MouldLevel Suspended The tundish is connected at the caster to precisely monitor the metal levels without being affected by slag amounts or powder. THE EMLI-TUNDISHLEVEL SYSTEM continuously monitors the true metal levels in the tundish or runner and provides outputs to control the flow to main tain desired operating levels without being affected by the presence of slag or protection powder. This allows a precise metal level control ensuring a constant pressure head, minimised intermix areas and accurate draining pro cedures. Typical benefits are more constant casting speeds, avoid slag in the moulds, higher production output and substantial yield increase due to proper and consistent draining control. THE EMLI-MOULDLEVEL SUSPENDED SYSTEM constantly monitors metal level in the mould or runner during casting and provides outputs to control the flow to maintain desired operating levels. To position the sensor in the mould, an automatic manipulator or a manual arm can be used. The electromagnetic technology means that the EMLI-MouldLevel Suspended system measures true metal level irrespectively of the amount of powder or slag on the metal surface. The sensor is placed in the mould either by an automatic manipulator or a manual arm. Agellis EMLI-sensors Agellis EMLI-TundishLevel Tundish mounted sensors Continuous true metal level measurement. Enable reduction in manpower. Minimised intermixed area. Allow consistent ferrostatic pressure in tundish. Electromagnetic technology, measures true metal level. Fast true response time. Automatic and fast calibration. emli-tundishlevel/ solutions-and-products-sub/smelters /emli-mouldlevel-suspended/ 8 9

6 VISION AND LADLE SKIMMING MONITORING VISIR-LadleDeslag THE VISIR-LADLEDESLAG SYSTEM is designed to monitor ladle deslagging operations in order to quantify the percentage of slag covered area. Thus, skimming operators using the VISIR-LadleDeslag system can produce slag free ladles consistently. The system monitors the deslagging operations in real time. By limiting process variations and ensuring that the deslagging process is more consistent the variations in quality in the final product are minimised. The VISIR-LadleDeslag system automatically tracks and stores vital information for each heat and makes sure your quality assurance program is met. The system allows a clear view of the skimming operations and an objective rating of the results. VISION AND VISIR-LadleDeslag VISIR-LadleSafe VISIR-FurnaceSafe VISIR-MetalDetect Consistent and objective monitoring of deslagging process. Historical data stored in open and searchable database. Metal loss warning. Yield increase. visir-ladledeslag/ 11

7 VISION AND VISION AND LADLE HOT SPOT DETECTION SYSTEM VISIR-LadleSafe FURNACE BREAKOUT PREVENTION VISIR-FurnaceSafe THE RISK OF A LADLE BREAKOUT will always be present when handling liquid metals with equipment damage, personnel injuries and loss of production as a consequence. Eliminate dangerous and costly situations by scanning and evaluating the condition of each ladle in your fleet. Using the historical database, refractory performances can be objectively evaluated and average ladle refractory lifetime can be increased in a safe way. THE RISK OF BREAKOUTS will always be present when handling liquid metals with equip ment damage, personnel injuries and loss of production as a consequence. VISIR-FurnaceSafe system continuously monitors the furnace shell thermal status and trends temperatures for over measuring points. The monitoring system automatically alerts you when detecting early signs of dangerous hot spots, helping you to handle the situation before it becomes a hazard. VISIR-FurnaceSafe stores data in a measurement database, letting you create weekly reports and evaluate refractory performance. Detect dangerous ladles before a breakout occurs. Make sure only safe ladles are taken to the caster. Continuously check the furnace shell for signs of weakness and detect potential breakouts before they happen. Hot spot detection and warning. Hot spot detection and warning. Maximise ladle refractory lifetime. Used with LF, RH, EAF, AOD, LD/BOF. Integrated with plant PLC and network. Maximising safety in furnace areas. Maximising safety in ladle handling areas. Capability of handling up to five cameras. visir-ladlesafe/ Historical database open to process metallurgist. Historical database open to process metallurgist. visir-furnacesafe/ 12 13

8 VISION AND METAL DETECTION DURING DESLAGGING VISIR-MetalDetect THE VISIR-METALDETECT SYSTEM is designed to monitor the ladle or furnace deslagging operations in real time to detect when metal is also being poured within the slag stream. Thus, a minimal amount of metal is lost and yield improved. VISIR-MetalDetect system enables you to assist operators to control their metal losses in a safe and secure manner. By monitoring the deslagging stream and informing the operator when metal is detected the process can be modified quickly and safely. By controlling the skimming process variations and ensuring that the metal losses are significantly reduced, yield improvements and quality consistency can be achieved. Avoid metal losses during deslagging operations. All historical data is stored in an open and searchable metallurgical database. visir-metaldetect/ Consistent and objective monitoring of metal losses during skimming. Historical data stored in open and searchable database. Helps operator avoid metal losses, resulting in yield increase. Increase lifetime of your slag pots. 14

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