Refractory Engineering Furnace Optimisation by Mettop
TABLE OF CONTENT 1 EXECUTIVE SUMMARY... 3 2 METTOP AT A GLANCE... 4 3 3D REFRACTORY ENGINEERING... 5 4 ADD-ONS A SPECIAL SERVICE BY METTOP... 6 4.1 QUALITY CONCEPT... 6 4.2 LINING SEQUENCE... 6 4.3 HEAT TRANSFER CALCULATION AND EXPANSION CALCULATION... 6 4.4 START-UP PROCEDURES AND HEATING-UP INSTRUCTIONS... 7 4.5 SPECIAL SUPPORT AND TRAINING COURSES... 8 5 HOLISTIC APPROACH SCOPE OF SERVICES BY METTOP... 9 6 CONTACT... 10 Mettop GmbH Peter-Tunner-Str. 4 8700 Leoben Austria t +43 3842 81 7 87 f +43 3842 81 7 87-8 office@mettop.com www.mettop.com Court of Registration Leoben Civil Court Commercial Registration No. FN 26145k Bank Steiermaerkische Bank und Sparkassen AG Account No. 00001263219 Bank Identification Code 20815 IBAN AT192081500001263219 2 BIC STSPAT2G VAT No. ATU 61690637 DE 274789359 PL 5263148464
1 EXECUTIVE SUMMARY It is the rising demand for an economic and cost saving operation mode in all metallurgical plants that makes every aggregate unique and asks for tailor made solutions that are absolutely essential for an optimised process. A rethinking of the prevailing refractory concept, especially in terms of refractory lifetime and furnace availability, can lead to significant improvements. Upgrading of the existing furnace refractory design can lead to a wide range of improvements and benefits for the customer: Optimised visualisation of the refractory material by using exclusively 3D engineering Combined consideration of furnace geometry, steel construction, refractory material and arrangement of all additional components Prolonged refractory lifetime by contribution to optimised operation (heating-up specifications and expansion calculation) Speeding up the installation by providing lining sequences step by step Best furnace availability due to support before, during and after installation on-site Comparing different suppliers grades to guarantee the best available product Cost saving lining concepts by choosing price optimised material Best available concepts by implementation of most modern operational systems (purging systems, cooling solutions and tuyere arrangements) With these tools it is possible to achieve the following objectives: Increased time of furnace campaigns Optimisation of furnace availability Decrease of costs for refractory material 3
2 METTOP AT A GLANCE Mettop GmbH, founded in 2005, is an independent Austrian engineering company, specialised in the design, optimisation, and engineering of technologies for metallurgical processes. It is active in the field of pyro- as well as hydrometallurgy of non-ferrous metals and recently also started with innovative cooling systems for the iron and steel industry. Special topics can be highlighted: Feasibility studies on metallurgical processes Basic and detail engineering of metallurgical processes Technical and metallurgical process optimisation New tankhouse technology, i.e. the METTOP-BRX Technology Water-free and safe cooling technology, i.e. the Ionic Liquid Cooling Technology (ILTEC) Cooler design and integrated solutions for cooler, refractory and process conditions Gas purging systems Refractory management comprising of refractory engineering, delivery and supervision during lining on site Project management, monitoring and risk analysis Staff-training to implement the provided technical innovations The scope of services comprises optimisation solutions in the area of furnace integrity, combining refractory selection and layout, gas purging systems and cooling elements. In the field of hydrometallurgy, a new electrolysis technology - the METTOP-BRX Technology - was developed and is in operation to allow an acceleration of the electrolytic refining of up to 50 percent. For all metallurgical aggregates and equipment, Mettop developed the new and water-free cooling technology ILTEC, that uses an ionic liquid as cooling medium, for creating new pathways towards safe and efficient cooling for the entire metallurgical industry. In addition, Mettop is internationally active in terms of technical consulting (process optimisation) and operator training for customers in the non-ferrous metals industry, and also assists in the optimisation of risk management in metallurgical plants. v 4
3 3D REFRACTORY ENGINEERING In contrast to the state-of-the-art refractory engineering in two dimensions, Mettop uses 3D refractory engineering to optimise refractory linings and furnace concepts. 3D refractory engineering requires a full design of all lining details during the construction and drawing stage. This is a big advantage compared to 2D refractory engineering, as the cutting of bricks on site can be avoided with the detailed 3D design. As a consequence, time and costs during installation can be saved. Furthermore, the 3D refractory engineering allows a step-by-step visualisation of the installation procedure. This again facilitates the refractory installation on site. 3D engineering of the furnace allows the automatic generation of a complete part list of all bricks and additional fixtures (e.g. steel plates, hanging hooks, expansion inserts). These are named systematically and are saved in a comprehensive list. Each brick format and every additional part is only drawn once and then copied, so that the part list can be generated automatically and contains all the information required for the refractory lining installation, as for example the required amounts of brick formats and qualities, the number of expansion inserts, weight, volume and positioning of bricks in different furnace areas. In Figure 1 the difference between 2D and 3D can be seen. Figure 1 Comparison of a 2D refractory drawing of an off-gas opening of a drum type anode furnace and the same part drawn in 3D. The sophisticated steps, ledges and brick formats can hardly be distinguished in 2D whereas in 3D each brick is visualised 5
4 ADD-ONS A SPECIAL SERVICE BY METTOP With the finalisation of the drawings for refractory engineering, the service of Mettop is not yet complete. For the purpose of providing the best possible concept for a best possible operation of the entire process, refractory engineering comprises of more than drawings. 4.1 Quality Concept As an independent refractory supplier without a production site or contract to refractory producers, Mettop can select the best available material to provide an independent and process-orientated optimised concept. Since the scope of supply refers to refractory engineering but not refractory manufacturing, a totally neutral material list, without any relation to single manufacturers, can be offered. This allows the customer to independently order the refractory material according to the provided quality concept. In addition, Mettop provides full service in terms of ordering, shipping and delivery, including supervision on site if requested. Based on the metallurgical and process know-how, the decision about the best available refractory material has to be considered individually for each customer and application. This also means that for one single furnace different brick qualities and subsequently different suppliers can be used, just as desired by the customer. 4.2 Lining Sequence In order to make the installation and the lining work on site as fast and smooth as possible, a visualisation of the lining sequence can help immensely. With the 3D engineering tool, a brick by brick illustration of the entire lining can be provided, for example as a video or as single pictures. This helps to prevent cost, time and material consuming failures during the lining and will lead to a more economical and cost saving lining. In Figure 3 an installation instruction for a drum type anode furnace can be seen. Picture by picture the installation of each single brick can be visualized. 4.3 Heat transfer calculation and expansion calculation In order to provide not only the best material but the best lining result, an optimised furnace performance is also significantly influenced by the start-up procedure. Since expansion during heating-up is a topic of significance, a careful consideration of the expansion behavior during this start-up phase is inevitable. In Figure 3 an example of both, the steady state heat transfer calculation and the expansion calculation, is given. As a result of the heat transfer calculation, the expansion of the different materials at the different installation positions is known and instructions can be given on how to prevent damage of the refractory during the start-up phase. 6
Figure 2 Lining sequence including installation instruction for the entire lining process for a drum type anode furnace Steady state heat transfer calculation Calculation Of Expansion Allowance In Straight Linings Customer PNo.: CNo.: Vessel Range Rev. Name Date Example Furnace HTC-01: Bottom - str 18.08.2015 Ambient temperature (input) Surface temperature (calculated) Heat transition coefficient Calculation formula Wind velocity Emissivity Diamter Heat loss per m² Heat loss per m tube Inside 1,250.0 1,241.0 150.0-1,351.0 - Outside 30.0 169.7 9.7 ASTM680F 0.0 0.5-1,351.0 - Unit C C W/m²K mm W/m² W/m Wall layers from inside to outside Temperature [ C] Material mm W/mK mean border Quality 1 450 2.700 1,128.0 1,241.0 Quality 2 10 2.700 1,013.0 1,015.9 Quality 3 150 2.609 972.0 1,010.9 Quality 4 10 2.623 931.0 933.3 Quality 5 230 1.338 813 928.1 Quality 6 16 1.296 687 695.8 Quality 7 304 1.239 516 679.1 Quality 8 10 0.076 262 347.8 Quality 9 20 50.68 170 170.2 1200 169.7 m/s Figure 3 Detailed consideration and calculation of the steady state heat transfer through the different materials (right) and the expansion calculation including instructions for expansion joints (right) Customer: Vessel: Sector: PNo.: CNr.: Calculated by: Length: 1,600.00 mm [l] Brick: 100.00 mm [s] Brick inside temperature.: Brick outside temperature.: 1,267.00 C [Ti] 615.00 C [Ta] Extension at [T1]: 300.00 C 0.40 % [e1] Extension at [T2]: 1,400.00 C 1.50 % [e2] Mortar (Y/N): Y dry-laid: 0.15 mm/joint Spring: 0.00 mm wet-laid: 0.10 mm/joint Compression mass: 0.00 mm Fibre board: 10.00 mm Expansion of steel shell: Polystyrene: 0.00 mm Tensioning: 10.00 % 4.00 mm 3 mm 1/5 Temperature 1,136.60 C Ti-(Ti-Ta) 1/5 [T] Extension at [T] 1.24 % e1 + (e2 - e1) / (T2 - T1) (T - T1) [e] No. of jonits 15 pcs. l / s [n] Expansion 20 mm l e / 100 [ε] Expansion all-up 6 mm ε - Compensation [Ε] Theo. no. of. exp. inserts Exp. theo. allow after every Exp. allow after every Exp. covered by card boards Example Furnace EXPC01 - Bottom WL - Length Compensation Calculation 2.10 pcs. 7.13 brick 8 brick 19.29 mm Parameter Ε / Thicknes of exp. Insert n / N Jointfigure Thickness of expansion paper Expansion insert Card Board [N] 4.4 Start-up procedures and heating-up instructions Once the furnace is lined, the operation mode starts with a first heating-up of the furnace. Especially too rapid heating can cause irreversible cracking, but also too little heat at some areas of the furnace might result in condensation and subsequently in cracking due to hydration. In order to prevent any damage caused by inappropriate heating, a specific and detailed description of the heating-up procedure is proposed. 7
Figure 4 Specific heating up description 4.5 Special Support and Training Courses It is of superior interest to provide the best possible performance on applying a new refractory concept, but not only in terms of material performance. Therefore we take service seriously and assist in all sorts of issues. Installation on-site with precision, speed and efficiency The entire installation on-site will be supervised and guided by Mettop personal. After sales service Mettop provides after sales service and special support for planned maintenance as well as for the case of an unlikely event. Training courses For an optimised profit from the benefits, and using the entire metallurgical potential of refractory engineering, it is of interest to fully understand the metallurgical background of the processes. Therefore Mettop provides detailed and comprehensive training courses on-site to teach the operators metallurgical know-how combined with operational instructions. 8
5 HOLISTIC APPROACH SCOPE OF SERVICES BY METTOP The scope of services of Mettop is intended as a holistic concept to create an optimised process. The offered refractory engineering itself comprises of the following: 3D engineering Construction plans Complete list of parts Independent and process orientated optimised concept Technical documentation Since Mettop combines substantiated knowledge about refractories with profound metallurgical know-how, it makes sense to be part of the entire process concept. On letting Mettop be part of the process, the following tools are used for optimising processes: Thermodynamical modelling with HSC CFD modelling Optimised construction Optimised refractory design for less wear Most modern cooling systems Possibility of improvement of metallurgical processes via purging systems Finally, after having created a refractory concept, Mettop will support the customer in every possible way to achieve an optimised performance: Visualisation of the lining sequence, step-by-step installation procedure Heating-up description Considerations regarding possible problems on-site (hydration, ) Extension calculations and instructions On-site support, supervision during start-up After sales service and special support Training courses for operators 9
6 CONTACT Mettop GmbH Peter-Tunner-Strasse 4 8700 Leoben Austria www.mettop.com Dr. Iris Filzwieser: +43 664 88 60 45 41 iris.filzwieser@mettop.com Dr. Andreas Filzwieser: +43 664 88 60 45 40 andreas.filzwieser@mettop.com DI Stefan Wallner: +43 664 88 60 45 53 stefan.wallner@mettop.com Mettop GmbH Peter-Tunner-Str. 4 8700 Leoben Austria www.mettop.com Dr. Iris Filzwieser: +43 664 88 60 45 41 iris.filzwieser@mettop.com 10 Dr. Andreas Filzwieser: +43 664 88 60 45 40 andreas.filzwieser@mettop.com DI Stefan Wallner: +43 664 88 60 45 53 stefan.wallner@mettop.com