steelmaking technologies eaf-lf … technologies eaf-lf injection systems design & engineering...

100% IN-HOUSE TECHNOLOGIES

STEELMAKING TECHNOLOGIES

EAF-LF INJECTION SYSTEMS

DESIGN & ENGINEERING

TAILOR MADE SOLUTIONS

STEELMAKING TECHNOLOGIES

MORE designs, manufactures, installs and commissions advanced process technology packages related to chemical energy, auxiliary equipment and water cooled elements for the Electric Arc Furnace steel-making mini mills.

Continuous research & development, top-class manufacturing quality, highly skilled specialists, reliable equipment and process know-how are the basis for our indisputable leadership in the steel-making industry with more than 1000 successful installations worldwide.

MORE designs, manufactures, installs and commissions advanced process technology packages related to chemical energy, auxiliary equipment and water cooled elements for the Electric Arc Furnace steel-making mini mills.

Continuous research & development, top-class manufacturing quality, highly skilled specialists, reliable equipment and process know-how are the basis for our indisputable leadership in the steel-making industry with more than 1000 successful installations worldwide.

COMPANY PROFILE

Side wall injection system for supersonic oxygen, carbon and lime injection

The information provided in this document is the property of MORE and they may be not reproduced. © 2015-2016 MORE. All rights reserved.

MODULETECHNOLOGY

4

8 10 12 18COMPANY PROFILE HISTORY KEY TO SUCCES

12 DESIGN & ENGINEERING14 RESEARCH & DEVELOPMENT16 WORKSHOP

PRODUCT LINE

INDEX

Wall operated oxygen and carbon water cooled lance manipulator.

PALMUR

6

20 66 72 76EAF 20 LINDARC26 MODULE TECHNOLOGY34 MOCA36 MOLI38 AUTOSLAG40 PARPI42 PALMUR44 ROBOX46 NANO ROBOX48 TEMP50 CATFIS52 MOTANK54 EBT SAND56 STROP58 STAP60 SMARTEC62 VALVE STANDS64 COPPER NOZZLES

LF 66 CATDRET68 PALTET70 STIRBOX

SERVICES QUALITY

7

MORE is a worldwide leading manufacturer of process technology packages related to chemical energy and auxiliary equipment for the steel making industry.

MORE has developed an international reputation for quality products since the company was established in 1984. Special equipment and manufacturing techniques are employed to ensure that maximum strength and durability are built into every item we produce.

The wide range of products we offer, make MORE suitable for all kinds of EAF applications. The in-house manufacturing facility gives us the flexibility to supply our products quickly, custom work can be manufactured to your particular requirements by our specialists.

All products are buildt and tested in our modern workshop using specially designed heavy duty, automated equipment, made to our own demanding specifications. Uniformity of quality control is achieved through an integral automatic checking system supplemented by our quality control program. MORE is ISO 9001:2000 certified ensuring all products are manufactured according to strict international standards.

COMPANY PROFILE

INNOVATION IN STEELMAKING

Capacity of 150t (165 st) with 100% DRI charging, system equipped with MORE sidewall injection system.

EAF

6

MORE is a worldwide leading manufacturer of process technology packages related to chemical energy and auxiliary equipment for the steel making industry.

MORE has developed an international reputation for quality products since the company was established in 1984. Special equipment and manufacturing techniques are employed to ensure that maximum strength and durability are built into every item we produce.

The wide range of products we offer, make MORE suitable for all kinds of EAF applications. The in-house manufacturing facility gives us the flexibility to supply our products quickly, custom work can be manufactured to your particular requirements by our specialists.

All products are built and tested in our modern workshop using specially designed heavy duty, automated equipment, made to our own demanding specifications. Uniformity of quality control is achieved through an integral automatic checking system supplemented by our quality control program. MORE is ISO 9001:2000 certified ensuring all products are manufactured according to strict international standards.

INNOVATION IN STEELMAKING

COMPANY PROFILE

Capacity of 150t (165st) with 100% DRI charging system equipped with MORE sidewall injection system.

EAF

8

HISTORY

MORE starts as an engineering company in Gemona del Friuli (UD) by supplying water cooled elements and fume systems for EAF

1984

1985 1994 2001

1988 1998 2007

The first side wall supersonic oxygen lance with carbon lance is supplied

The first EAF complete side wall injection system is supplied

The 100th EAF side wall injection system is supplied

MORE provides complete EAF shells including self-made side wall oxy-fuel burners

MORE opens its own production facility in Buja (UD) - The first temperature and sampling manipulator is supplied

MORE relocates the offices to a new building in Gemona del Friuli (UD)

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2009 2011 2013

2008 2010 2012 2014

The 150th temperature and sampling manipulator is supplied - The first LINDARC EAF off-gas analysis system is supplied

MORE expands the production facility in Buja (UD)

The new M-ONE combined oxygen and carbon injector is successfully installed

The first MOTANK slag door cleaner that works sideways from the slag door is supplied

MORE expands its workshop to install a new set of CNC machineries

The first CATDRET temperature and sampling manipulator for a ladle furnace is delivered

The first NANO ROBOX consumable lance manipulator for a 25t/ 28st EAF is supplied

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We are recognized for our unique capability in understanding customers’needs and transferring them into practical solutions; feasible in both technical and economic terms.

Mechanical, electrical and automation design activities are performed by internal specialists with extensive experience in the electric arc melting furnace technology.

Highly skilled engineers are constantly working to study new products. This makes us forerunners in the exploration and industrial application of new technological solutions.

A project management team coordinates mechanical, electrical and system automation activities related to a project, from the feasibility study up to the final performance and acceptance test.


TAILOR MADE PRODUCTS FOR STEELMAKING APPLICATION

Engineering team at work

MORE HEADQUARTERS

10

We are recognized for our unique capability in understanding customers’ needs and transferring them into practical solutions, feasible in both technical and economic terms. Mechanical, electrical and automation design activities are performed by internal specialists with extensive experience in the electric arc melting furnace technology. Highly skilled engineers are constantly working to study new products. This makes us forerunners in the exploration and industrial application of new technological solutions. A project management team coordinates mechanical, electrical and system automation activities related to a project, from the feasibility study up to the final performance and acceptance test.

TAILOR MADE PRODUCTS FOR STEELMAKING APPLICATION


Engineering team at work

MOREHEADQUARTERS

12

Our leadership in this field is the result of constant research for innovation and improvement, making us the ideal partner for the most important international steelmakers.

Since 1984, technological research & development are intended as a mission, to be accomplished by way of innovative equipment that must be continuously improved.

The technical department makes use of up-to-date software such as CAD/CAE/CAM, Finite Element Method and Computational Fluids Dynamic (CFD) to perform its tasks without compromise.

In order to ensure that our customers get the best solutions, we continuously work to improve our processes and invest in research and development. Many of our projects include developing tailor made installations that meet the exact requirements of our customers.

RESEARCH & DEVELOPMENT

SOARING AHEAD OF OUR COMPETITORS

CFD analysis and HMI software development.

MORE HEADQUARTERS

12

Our leadership in this field is the result of constant research for innovation and improvement, making us the ideal partner for the most important international steelmakers.

Since 1984, technological research & development are intended as a mission, to be accomplished by way of innovative equipment that must be continuously improved.

The technical department makes use of up-to-date software such as CAD/CAE/CAM, Finite Element Method and Computational Fluids Dynamic (CFD) to perform its tasks without compromise.

In order to ensure that our customers get the best solutions, we continuously work to improve our processes and invest in research and development. Many of our projects include developing tailor made installations that meet the exact requirements of our customers.

SOARING AHEAD OF OUR COMPETITORS

RESEARCH & DEVELOPMENT

CFD analysis and HMI software development.

MOREHEADQUARTERS

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To ensure the quality, the reliability and the safety of our products, equipment manufacturing and assembly is carried out completely in MORE’s workshop.

The warehouse, manufacturing and assembly building cover over 5.000 sqm / 6,000 sqy and are equipped with the most modern facilities for welding, manufacturing, assembly such as:

• CNC machineries • Turning centers• MIG-TIG welding positions• Welding robots• Mechanical assembly and testing lines• Electric assembly and testing lines• Hydraulic/pneumatic/gas test bench• Sand-blasting machine• Surface treatment machines• Spray painting tunnel

WORKSHOP


All activities are performed by MORE’s workforce

MORE WORKSHOP

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To ensure the quality, the reliability and the safety of our products; equipment manufacturing and assembly is carried out completely in MORE’s workshop.

The warehouse, manufacturing and assembly building cover over 5.000 m2 / 6,000 yd2 and are equipped with the most modern facilities for welding, manufacturing, assembly such as:

• CNC machineries• Turning centers• MIG-TIG welding positions• Welding robots• Mechanical assembly and testing lines• Electric assembly and testing lines• Hydraulic/pneumatic/gas test skids• Sand-blasting machines• Surface treatment machines• Spray painting tunnel


WORKSHOP

All activities are performed by MORE’s workforce.

MOREWORKSHOP

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PRODUCT LINE

CNC copper bulged blockproduced in MORE workshop.

MORE OFFERS A COMPLETE LINE OF TAILOR MADE DESIGNS AND SOLUTIONS FOR MELT SHOPS RELATED TO INJECTION SYSTEMS AND AUXILIARY EQUIPMENT

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CONCEPT

The modern electric arc furnace operation calls for top performances, optimized use of chemical energy, improved safety, reduction in conversion costs and lower emission levels. To achieve and improve these requirements, a highly accurate and reliable off-gas monitoring system has been developed in collaboration with LINDE AG. The innovative in-situ laser system allows for real time off-gas emissions measurements enabling a closed-loop operation with dynamic control of the chemical energy practice during the EAF cycle.

Electric Arc Furnace technologies

REAL TIME LASER BASED ELECTRIC ARC FURNACE OFF-GAS ANALYSIS SYSTEM

LINDARCTM

CO 0÷100%CO2 0÷100%O2 0÷25%H2O 0÷100%Temperature 400 – 1600°C (752 – 2,912°F)

ABSORPTION SPECTROSCOPY TECHNIQUE

LINDARCTM off-gas analysis system uses the technique of “Tunable Diode Laser Absorption Spectroscopy” (TDLAS). This single-line absorption spectroscopy measuring technique is based on the selection of one single absorption line nearby the infrared spectral range for the specific gas. The concentration of the selected element is determined by the quantity of light absorbed at its specific spectral range.This measurement technique guarantees precise results even with very high dust contents.

MEASURED ELEMENTS

Trasmission

Wavelength

Absorption line

λ

EAF INJECTORS

EAF

LINDARCTM

TECHNOLOGY

GASEOUS FUEL VALVES STAND

OXYGENVALVES STAND

CARBONDISPENSER

1818

Transmission

Electric Art Furnace technologies

LINDARCTM

REAL TIME LASER BASED ELECTRIC ARC FURNACE OFF-GAS ANALYSIS SYSTEM

CONCEPTThe modern electric arc furnace operation calls for top performances, optimized use of chemical energy, improved safety, reduction in conversion costs and lower emission levels. To achieve and improve these requirements, a highly accurate and reliable off-gas monitoring system has been developed in collaboration with LINDE AG. The innovative in-situ laser system allows for real time off-gas emissions measurements enabling a closed-loop operation with dynamic control of the chemical energy practice during the EAF cycle.

ABSORPTION SPECTROSCOPY TECHNIQUELINDARCTM off-gas analysis system uses the technique of “Tunable Diode Laser Absorption Spectroscopy” (TDLAS). This single-line absorption spectroscopy measuring technique is based on the selection of one single absorption line nearby the infrared spectral range for the specific gas. The concentration of the selected element is determined by the quantity of light absorbed at its specific spectral range. This measurement technique guarantees precise results even with very high dust contents.

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BENEFITSThe LINDARC is a reliable and accurate technology that provides:

• Safety improvements• Increased productivity• Reduction of power-on time• Reduction of electrical energy consumption• Oxygen, fuel and carbon consumption optimization• Fast pay back of the investment• A maintenance free system

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INSTALLATION

The laser system is installed just after the combustion gap on the fixed duct. Positioning is carefully evaluated with CFD analysis so false air entering from the gap is not going to alter the composition of gases coming from the furnace.Due to the typically harsh environment of an electric arc furnace, the sensitive transmitter and receiver units are mounted outside the ducts to prevent high heat load and even mechanical damage.

COMPARISON OF DIFFERENT OFF-GAS MEASUREMENT TECHNIQUES

Conventional measurement techniques are based on an extractive method where the gas to be measured is drawn off from the off-gas stream, cooled, filtered, dried and analyzed continuously. The LINDARC provides far more accurate results and the main differences are shown on the following table.

The main disadvantages of this technique are:• Long response time (not less than 30 sec)

influenced by the distance between probe sampling point and analysis instrumentation

• Direct measurement of the H2O is not possible due to the off-gas sample filtering and drying

• Significant maintenance requirements for valves, filters and condenser units

EXTRACTION SYSTEM

LINDARCTM SYSTEM

H2O, CO AND CO2 ANALYSIS YES YES

DIRECT H2O MEASUREMENT NO YES

DIRECT OFF-GAS TEMPERATURE MEASUREMENT NO YES

MEASUREMENT OF REAL VOLUME NO YES

REACTION TIME > 30 SEC. < 2 SEC.

FILTER UNITS FOR GAS SAMPLE NEEDED NOT NEEDED

MAINTENANCE WEEKLY EVERY 4 MONTHS

ANNUAL MAINTENANCE COSTS FOR SPARES > 100,000 USD 0

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INSTALLATIONThe laser system is installed just after the combustion gap on the fixed duct. Positioning is carefully evaluated with CFD analysis so false air entering from the gap is not going to alter the composition of gases coming from the furnace. Due to the typically harsh environment of an electric arc furnace, the sensitive transmitter and receiver units are mounted outside the ducts to prevent high heat load and even mechanical damage.

COMPARISON OF DIFFERENT OFF-GAS MEASUREMENT TECHNIQUES

The main disadvantages of this technique are:• Long response time (not less than 30 sec) influenced by the distance between probe sampling point and analysis instrumentation• Direct measurement of the H2O is not possible due to the off-gas sample filtering and drying• Significant maintenance requirements for valves, filters and condenser units

Conventional measurement techniques are based on an extractive method where the gas to be measured is drawn off from the off-gas stream, cooled, filtered, dried and analyzed continuously. The LINDARC provides far more accurate results and the main differences are shown on the following table.

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BENEFITSSAFETY ASPECTS• Real-time signal of H2O value in the off-gas will

prevent explosions generated by water leaks • Real-time signal of CO value in the off-gas will

prevent explosions in the dust settling chamber or bag house

• Possible set-up of gap / dumpers position• Real-time signal of CO value in the off-gas

will prevent excessive release of CO in the atmosphere

COMBUSTIONS OPTIMIZATION • High accuracy of CO, CO2 and O2 measured

values• Fine tuning of burners settings (best ratio

of CH4 and O2)• High yield of CO combustion due to precise O2

injection• High system functionality thanks to minimized

maintenance design• Fast response time with real-time availability

of measurement results (< 2 second)• All readings made on the real off-gas volume

(no sampling, drying or filtering needed) PROCESS OPTIMIZATION • Dynamic closed-loop control of burner

and injection system GENERATED SAVINGS• Maximum yield of oxygen requirements • Low maintenance cost (no filters, no driers

installed)• Reduced electric energy requirements as CO

is combusted in the EAF shell

SPECIFIC BENEFITS FOR DRI CHARGING PROCESSES

• The CO/CO2 ratio in the off-gas will be used to dynamically control the carbon injection because the CO value is directly linked to the carbon content in the DRI

• Because the carbon content in the DRI will be indirectly monitored, potential anomalies with DRI process can be detected

• By controlling the carbon content in the melt, the usage of injected carbon will be optimized and savings related to carbon and electrical energy consumption are expected

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BENEFITSSAFETY ASPECTS• Real-time signal of H2O value in the off-gas will prevent explosions generated by water leaks.• Real-time signal of CO value in the off-gas will prevent explosions in the dust settling chamber or bag house.• Possible set-up of gap / dumpers position.• Real-time signal of CO value in the off-gas will prevent excessive release of CO in the atmosphere.

COMBUSTION OPTIMIZATION• High accuracy of CO, CO2 and O2 measured values.• Fine tuning of burners settings (best ratio of CH4 and O2).• High yield of CO combustion due to precise O2 injection.• High system functionality thanks to minimized maintenance design.• Fast response time with real-time availability of measurement results (<2 sec.).• All readings made on the real off-gas volume (no sampling, drying or filtering needed).

PROCESS OPTIMIZATION• Dynamic closed-loop control of burner and injection system.

GENERATED SAVINGS• Maximum yield of oxygen requirements.• Low maintenance cost (no filters, no driers installed).• Reduced electric energy requirements as CO is combusted in the EAF shell.

SPECIFIC BENEFITS FOR DRI CHARGING PROCESSES• The CO/CO2 ratio in the off-gas will be used to dynamically control the carbon injection because the CO value is directly linked to the carbon content in the DRI.• Because the carbon content in the DRI will be indirectly monitored, potential anomalies with DRI process can be detected.• By controlling the carbon content in the melt, the usage of injected carbon will be optimized and savings related to carbon and electrical energy consumption are expected.

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Ethernet – Level 2

Plant Data Server

LINDARC DWLDEAF HMI www

EAF PLC

LINDARC CLC SERVER

LINDARC Control Cabinet

LINDARC

Chemical package PLC

Injectors

Post combustorsFuel valves standOxygen valves stand

Carbon Dispensers

Chemical package HMI

Ethernet PLC


CLOSED LOOP CONTROL SCHEME

DYNAMIC CLOSED LOOP CONTROL

Data taken from the lasers are transferred to the LINDARC PLC where a closed loop control software provides control and management of the entire process. Specific software has been developed to generate a Closed Loop Control (CLC) between the off-gas analysis technology and the injectors / post-combustors. Oxygen / Natural Gas ratio of burners is dynamically controlled by the CLC, based on the CO2 and CO readings from the off-gas analysis technology. Oxygen which flows through the post-combustors is also controlled by the CLC software with the aim of maximizing post combustion inside the furnace and saving electrical energy during scrap melting.

CO2 CO2

CO CH4

O2

CH4

O2

COCH4

O2

CH4

O2

PC ratio =CO2 + H2O

CO + CO2 + H2 + H2O

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Data taken from the lasers are transferred to the LINDARC PLC where a closed loop control software provides control and management of the entire process. Specific software has been developed to generate a Closed Loop Control (CLC) between the off-gas analysis technology and the injectors / post-combustors. Oxygen / Natural Gas ratio of burners is dynamically controlled by the CLC, based on the CO2 and CO readings from the off-gas analysis technology. Oxygen which flows through the post-combustors is also controlled by the CLC software with the aim of maximizing post combustion inside the furnace and saving electrical energy during scrap melting.

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A MAINTENANCE FREE SYSTEM

Due to the design and manufacturing details that MORE engineers have considered, maintenance operations can be summarized with a visual inspection of the cleanliness of laser lenses during any scheduled shut-down maintenance day. Different from extractive systems (where constant and expensive maintenance of the filters installed into the analyzer unit is required), the LINDARC system has no parts that need to be removed or replaced.

On existing installations, no main maintenance operations have been performed on the lasers equipment for more than 36 months.

DWLD - DYNAMIC WATER LEAKS DETECTION

The LINDARC™ includes a DWLD software to prevent any dangerous explosions generated by accidental water leaks that may occur during operations. Using a specific proprietary software algorithm, that considers several variables and environmental conditions, it is possible to calculate and plot an expected water baseline level for every on-going heat. Any accidental water leakage that may occur will increase the water content above the dynamically/self-calculating baseline water level and it will generate a warning message for the operators.

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CONCEPT

The MODULE TECHNOLOGY: state-of-the-art chemical energy package for electric arc furnaces, combines a variety of fixed injectors and related control devices (i.e.: valve stands, carbon/fluxes dispensers, automation system and Human Machine Interface). Injectors add chemical energy by exothermic reactions, post-combustion control and foaming slag optimization to improve the overall EAF performances and to reduce transformation costs.


OXYGEN, CARBON AND LIME SIDE WALL INJECTION TECHNOLOGY FOR ELECTRIC ARC FURNACES

MODULE TECHNOLOGY

CHARACTERISTICS

The equipment on board of the EAF shell can be made-up of four different injectors. Each has been developed to satisfy a very specific requirement of the melting/refining process:

• M-ONE for supersonic oxygen lancing and carbon injection into the slag

• OXYGENJET for supersonic oxygen lancing

• LIMEJET for lime/dololime injection into the slag

• HI_JET for deep injection of fines (carbon, aluminum, lime, DRI fines, bag house dust) into liquid steel/slag interface

M-ONE LIMEJETOXYGENJET HI_JET

EAF INJECTORS

AUTOMATION SYSTEM

OXYGENVALVES STAND

MOLI LIME DISPENSER

MOCA CARBON DISPENSER

GASEOUS FUEL VALVES STAND

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MODULE TECHNOLOGY OXYGEN, CARBON AND LIME SIDE WALL INJECTION TECHNOLOGY FOR ELECTRIC ARC FURNACES

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BENEFITS• Increased oxygen efficiency and carbon recovery• Injectors nozzles do not clog• Increased metallic yield• Increased productivity• Improved foaming slag conditioning• Improved metallurgical process control• Improved overall operating efficiency• Improved process gas emission• Reduced fuel usage• Reduced electrical energy usage• Reduced power-on time• Reduced conversion costs

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M-ONE

This multipurpose injector puts the EAF chemical energy utilization into a new dimension. This innovative injection tool allows extremely high recovery of injected carbonaceous fuel, melting process flexibility and consistency, metallurgical control and environmental improvements.Oxygen and carbon lances are embedded in the same body. This kind of design improves the injection efficiency, reduces the amount of injectors installed on the EAF shell and delivers a very light tool to handle (30 kg/ 66 lb) for easy maintenance operations.Because the carbon injection is placed so close to the oxygen supersonic stream, carbon fines are accelerated thus improving carbon recovery when compared with traditional carbon lances. M-ONE features the same supersonic oxygen nozzle design used in the OXYGENJET.

Burner mode

Supersonic oxygen injection

Soft carbon injection

Deep carbon injection

Lime /Dololime injection

Burner mode





OXYGENJET

This injector consists of a supersonic-coherent oxygen stream lance to guarantee the optimal penetration of oxygen in the liquid steel for C oxidation and other oxidizing reactions in the steel/slag interface.MORE has developed a “Method of Characteristics with Boundary Layer Correction Code” to design the Axisymmetric Supersonic Nozzle. Nozzles designed with this code are practically shock-free, with static pressure at the exit section that perfectly matches the ambient pressure (the maximum pressure difference between the supersonic stream of oxygen and the ambient is only 0.04 bar) and the streamlines parallel to the injector axis.With this design, the coherency of the oxygen stream is maintained over a long distance to guarantee the optimal deep bath penetration.

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Electric Art Furnace technologies28


Burner mode





Burner mode





HI_JET

This innovative injection tool allows for extremely high recovery of injected carbonaceous fuel, melting process flexibility and consistency, metallurgical control and environmental improvement.MORE has developed a specific nozzle whit which the carbon fines are shrouded by a coaxial stream of supersonic oxygen that accelerates the fines 10 times more than a traditional carbon lance. Fines are then able to penetrate the slag and reach the liquid steel.

LIMEJET

This injector consists of a lime/dolo-lime lance to inject the lime/dolo-lime fines into the slag for V ratio and temperature steady control. Lime/dololime fines can be shrouded by oxygen/gaseous fuel to avoid fines build up in front of the tip.

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All MORE injectors work as highly efficient oxy-fuel burners for heating and assisting melting of scrap after each scrap bucket charge.The flame makes use of the innovative Mixed Swirled Technology (MSF).

CONCEPT

The injectors can generate a flame of oxygen - fuel. A specific research project has been performed to improve combustion and heat transfer efficiency to the scrap surface. The result is a MSF (Mixed Swirled Flame) optimized for each type of injector. The particular burner tip design dramatically improves the mixing of reactants and prevents the generation of a cold flame. The adjacent images show the temperature field of a premixed and swirled oxy-fuel flame.When cold scrap lies in front of the injector, unmixed oxygen can flash back and damage the injector and/or adjacent furnace water cooled panels. To avoid this side effect, the reactants need to be ignited as close as possible to the injector tip. The MSF configuration develops a very hot flame close to the injector, improves flame stability and its heat transfer ability, especially to the scrap located in the injector area. The MSF significantly helps to minimize the risk of unburned fuel flowing through the scrap pile producing endothermic reactions by cracking.

MSF BURNER TECHNOLOGYMIXED SWIRLED FLAME

Traditional axial diffusion flame

Blue colored cold flame due to the poor mixing of oxygen and natural gas

Mixed Swirled Flame

Stable and hot flame close to the injector tip

BENEFITS • Extremely high flame temperature

• Optimum mixing of gasses and combustion

• Improved heat exchange with scrap pile

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The injectors can generate a flame of oxygen-fuel. A specific research project has been performed to improve combustion and heat transfer efficiency to the scrap surface. The result is a MSF (Mixed Swirled Flame) optimized for each type of injector. The particular burner tip design dramatically improves the mixing of reactants and prevent the generation of a cold flame. The adjacent images show the temperature field of a premixed and swirled oxy-fuel flame.

When cold scrap lies in front of the injector, unmixed oxygen can backfire and damage the injector and/or adjacent furnace water cooled panels. To avoid this side effect, the reactants need to be ignited as close as possible to the injector tip. The MSF configuration develops a very hot flame close to the injector, improves flame stability and its heat transfer ability, especially to the scrap located in the injector area. The MSF significantly helps to minimize the risk of unburned fuel flowing through the scrap pile producing endothermic reactions by cracking.


MIXED SWIRLED FLAMEMSF BURNER TECHNOLOGY

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CONCEPT

The FLASH STOP system has been developed to prevent accidental damages due to oxygen and fuel backfiring in the copper front face, injector tip and water cooled panels caused by the presence of a thick piece of heavy scrap in front of the injector tip.

The system is made up of two temperature sensors embedded directly into the copper element to continuously detect the variance of the copper temperature. In case of a backfiring, the temperature on the front panel will rapidly increase over the alarm threshold. Then, the automation system will automatically reduce the burner power or switch-off the injector. As soon as the temperature returns to its normal value, the system will turn on the injector again.

BACKFIRE PREVENTING SYSTEM FOR SIDE WALL BURNERS AND INJECTORS

FLASH STOP

BENEFITS • Increased life time of burners and copper blocks

• Higher burner efficiency

• Added safety by reducing water leakages inside the EAF

• Reduced maintenance man-hours

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FLASH STOPBACKFIRE PREVENTING SYSTEM FOR SIDE WALL BURNERS AND INJECTORS

The FLASH STOP system has been developed to prevent accidental damages due to oxygen and fuel backfiring in the copper front face, injector tip and water cooled panels caused by the presence of a thick piece of heavy scrap in front of the injector tip.

The system is made up of two temperature sensors embedded directly into the copper element to continuously detect the variance of the copper temperature. In case of backfiring, the temperature on the front panel will rapidly increase over the alarm threshold. Then, the automation system will automatically reduce the burner power or switch-off the injector. As soon as the temperature returns to its normal value, the system will turn on the injector again.



INSTALLATION

MORE designs, manufactures and supplies a wide range of solutions to find the best position of the injectors inside the EAF shell, avoiding damages from scrap falling and reaching a correct geometrical configuration.

CNC COPPER BULGED BLOCKS

The objective of MORE’s quality policy is to guarantee the best levels of customer satisfaction by providing products with an excellent quality/price ratio. To improve both the reliability of our products and reduce the production costs, MORE has invested in state of the art CNC machining and turning centers. With this vertical level integration, MORE produces 100% of its copper elements in-house, which guarantees a high level of production and precision and quick delivery of spare parts.

Extruded cooper slabs CNC machining

Welding Final product

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Extruded copper slabs CNC maching

Welding Final product

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TECHNOLOGY

MORE copper bulged blocks are made from extruded and drawn copper slabs that guarantee exceptionally high thermal conductivity avoiding all the usual problems related to cast copper parts (i.e embedded impurities or cavities).Copper and steel welding is done by MORE's highly qualified welders.

BENEFITS

• Increased lifetime compared to ordinary cast blocks

• Shorter lead times compared to traditional cast blocks

• Optimal heat transfer capacity and reduced heat overload

• Copper faces are designed for simple on-site replacement (steel to steel welding)

• Sturdily built to resist heavy mechanical impacts

• Tailor made design

FEATURES

• Optimized panel design to minimize cracking tendency

• Bulged block can be designed with different geometries according to customers’ requests

• Extruded copper slabs with high-density, high temperature resistance and strong resistance to fatigue and good thermal conductivity to fatigue and good thermal conductivity

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CONCEPT

The MOCA pneumatic injection system has been conceived to satisfy the carbon metallurgical demand for steelmaking processes with precise flow control and transport air optimization.

A precise and efficient carbon injection in the EAF is the cornerstone for improvement of metallurgical processes and reduction of conversion costs.


PNEUMATIC CARBON INJECTION SYSTEMMOCA

SYSTEM CAPACITY FLOW RATE FLOW RATE (UPON REQUEST)

MOCA 15 1.500 lt | 396 gal10 - 50 kg/min 22 -110 lb/min

30 - 80 kg/min 65 -176 lb/min


30 - 80 kg/min 65 -176 lb/min


30 - 80 kg/min 65 -176 lb/min


30 - 80 kg/min 65 -176 lb/min

Other sizes are avaialble upon request

3232


The MOCA pneumatic injection system has been conceived to satisfy the carbon metallurgical demand for steelmaking processes with precise flow control and transport air optimization.

A precise and efficient carbon injection in the EAF is the cornerstone for improvement of metallurgical processes and reduction of conversion costs.

MOCA PNEUMATIC CARBONINJECTION SYSTEM

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BENEFITS• Dispenser encased in a self-standing steel frame for easy handling• Automatic anti-clogging system• Independent pneumatic cabinet for transported air requirements• Optimized consumption of transported air• Low operating and maintenance costs• Accurate tolerance of set point (± 5%)• Fast carbon flow rate stabilization (‹ 30 sec)

MANUFACTURING STANDARDS• 97/23/CE pressure equipment directive (PED)• ATEX 94/9/CE II 2D - Zone 21 – 22• ASME code rules, section VIII, division I

Other standards are available upon request

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CONCEPT

The MOLI pneumatic injection system has been conceived to satisfy the flux metallurgical demand for steelmaking processes with precise flow control and transport air optimization. Lime injection is a valid well-proven improvement compared to lime charged through the roof or into the scrap bucket. Additionally, injection of powdered reactants generates a much cleaner shop environment. Therefore, dusty and maintenance demanding belt conveyor systems can be abandoned.


PNEUMATIC LIME/DOLOLIMEINJECTION SYSTEMMOLI

SYSTEM CAPACITY FLOW RATE

MOLI 15 1.500 lt | 396 gal Up to 250 kg/min | 550 lb/min



MOLI 50 5.000 lt | 1,320 gal Up to 250 kg/min | 550 lb/min

MOLI 80 8.000 lt | 2,113 gal Up to 250 kg/min | 550 lb/min

Other sizes are available upon request

3434


MOLI PNEUMATIC LIME/DOLOLIMEINJECTION SYSTEM

The MOLI pneumatic injection system has been conceived to satisfy the flux metallurgical demand for steelmaking processes with precise flow control and transport air optimization. Lime injection is a valid well-proven improvement compared to lime charged through the roof or into the scrap bucket. Additionally, injection of powdered reactants generates a much cleaner shop environment. Therefore, dusty and maintenance demanding belt conveyor systems can be abandoned.

36

BENEFITS• Dispenser encased in a self-standing steel frame for easy handling• Automatic anti-clogging system• Independent pneumatic cabinet for transported air requirements• Optimized consumption of transported air• Low operating and maintenance costs

MANUFACTURING STANDARDS• 97/23/CE pressure equipment directive (PED)• ASME code rules, section VIII, division I

Other standards are available upon request

37

/

%FeO + %MnO

C2S+L

Current Slag

L

MW+L

DOUBLESATURATIONPOINT

%M

gO

1

3

5

0/

7

01

03

05

07

4 0/ 04 1/ 14 2/ 24 3/ 34 4/ 44 5/

Ideal slag viscosity area

MgO saturation

CaO Saturation


AUTOSLAGFLUX OPTIMIZATION SOFTWARE

MORE has developed a specific software that automatically calculates the Isothermal Stability Diagram (ISD) for a particular slag composition, whereby the conditions for optimum foaming can be ascertained.

CONCEPT

Based on the slag chemical analysis and the target of slag basicity and % FeO, MORE AUTOSLAG recommends the right quantity of flux that should be added to the current melting process in order to keep the slag within the following:

B3 basicityFeO e MnO contentMgO saturation

SLAG FOAMING PRINCIPLES

In modern steelmaking practice, it is important to maintain good foaming of the slag throughout the entire melting period to reduce the heat losses in the EAF shell, to reduce electrode consumption and to protect the side wall panels and the roof from the arc. Maintaining predictable and constant foaming of the slag has always been a challenge for steelmakers due to the

many variables that are involved in the process such as: slag basicity, slag viscosity, slag surface tension, slag temperature and also the right amount of suspended second phase particles in the slag. Several researches have shown that the best slag with the best foaming properties must be saturated with CaO and MgO (which are also essential to reducing the chemical attack of the EAF refractory).The proper foaming of the slag will reduce the FeO content in the slag and will also avoid adding an excess of MgO in order to protect the refractory lining.

36


AUTOSLAGFLUX OPTIMIZATION SOFTWARE

38

INJECTION SYSTEM PLC

SLAG ANALYZERAUTOSLAG

LEVEL 2

LIME DOLOLIME

ISOTHERMAL STABILITY DIAGRAM (ISD)

To determine the CaO and MgO saturation levels, CaO-MgO-SiO2-FeO and CaO-MgO-FeO systems, together with the MgO solubility as a function of slag basicity data, have been used.In order to combine all these phase correlations, as a function of MgO and FeO+MnO content, Isothermal Stability Diagrams (ISD) have been implemented.

MORE AUTOSLAG OPTIMIZATION SOFTWARE

36 37

MORE AUTOSLAG OPTIMIZATION SOFTWARE

39

CONCEPT

The PARPI system consists of two water cooled lances; one is used to inject oxygen at supersonic velocity and one injects carbon fines. The lances are supported and moved by a manipulator installed on the rigid platform at a certain distance from the slag door on the right or left side.


DOOR OPERATED OXYGEN AND CARBON WATER COOLED LANCESPARPI

SYSTEM LANCE CONFIGURATION

OXYGEN FLOW RATE

CARBON FLOW RATE

PARPI 2" ½ 1 oxygen lance1 carbon lance

Up to 3.200 Nm3/h 2,000 scfm

Up to 100 kg/min 220 lb/min

PARPI 3" 1 oxygen lance1 carbon lance

Up to 7.000 Nm3/h 4,350 scfm


3838


PARPI DOOR OPERATED OXYGEN AND CARBON WATER COOLED LANCES

The PARPI system consists of two water cooled lances; one is used to inject oxygen at supersonic velocity and one injects carbon fines. The lances are supported and moved by a manipulator installed on the rigid platform at a certain distance from the slag door on the right or left side.

40

BENEFITS• Remote operation from furnace control room in a safe position• Increased oxygen efficiency and carbon fines recovery• Easy and fast lance removal by a quick connection system• The flow of oxygen obtainable with this system allows for high • decarburization speed• The carbon injection into the slag promotes FeO and MnO • reduction with consequent early slag foaming and better • control of the metallic yield

41

CONCEPT

The PALMUR system is particularly suitable for electric arc furnaces that operate with a continuous charging process (scrap, DRI, HBI). The oxygen/ carbon lances are housed on a carriage which is mechanically connected to the furnace movable platform; therefore, moving solidly with the furnace shell.

The optimum distance of the lance nozzle from the liquid steel is adjusted constantly while the oxygen/carbon impinging angle remains fixed as the steel level within the furnace shell rises.


WALL OPERATED OXYGEN AND CARBON WATER COOLED LANCESPALMUR

SYSTEM LANCE CONFIGURATION

OXYGEN FLOW RATE

CARBON FLOW RATE

PALMUR 2" ½ 1 oxygen lance1 carbon lance

Up to 3.200 Nm3/h 2,000 scfm


PALMUR 3" 1 oxygen lance1 carbon lance

Up to 7.000 Nm3/h 4,350 scfm


4040


PALMUR WALL OPERATED OXYGENAND CARBON WATER COOLED LANCES

The PALMUR system is particularly suitable for electric arc furnaces that operate with a continuous charging process (scrap, DRI, HBI). The oxygen/ carbon lances are housed on a carriage which is mechanically connected to the furnace movable platform; therefore, moving solidly with the furnace shell.

The optimum distance of the lance nozzle from the liquid steel is adjusted constantly while the oxygen/carbon impinging angle remains fixed as the steel level within the furnace shell rises.

42

BENEFITS• EAF operated with the slag door closed• Remote operation from furnace control room in a safe position• Increased oxygen efficiency and carbon fines recovery• Easy and fast lance removal by a quick connection system• Sturdy piece of equipment that needs minimum maintenance• The flow of oxygen obtainable with this system allows for high • decarburization speed• The carbon injection into the slag promotes FeO and MnO • reduction with consequent early slag foaming and better

control of the metallic yield

43

CONCEPT

The ROBOX consumable lance manipulator is designed for remote control of consumable calorized or ordinary pipes to inject oxygen, carbon or other fines into the furnace through the slag door with


OXYGEN, CARBON AND FINES CONSUMABLE LANCE MANIPULATORROBOX

SYSTEM LANCECONFIGURATION

MANIPULATORCONFIGURATION

OXYGEN FLOW RATE

CARBON FLOW RATE

ROBOX 1 1 oxygen lance 1 single lanceUp to 3000 Nm3/h [1,870 scfm] -

ROBOX 2 1 oxygen lance1 carbon lance 2 single lances Up to 3000 Nm3/h

[1,870 scfm]Up to 100 Kg/min [220 lb/min]

ROBOX 3 2 oxygen lances1 carbon lance 3 single lances Up to 6000 Nm3/h

[3,730 scfm]Up to 100 Kg/min [220 lb/min]

ROBOX 31 oxygen lance1 carbon lance1 lime lance

3 single lances Up to 3000 Nm3/h [1,870 scfm]

Up to 100 Kg/min [220 lb/min]

independent moving lances.The equipment is installed on the fixed platform either on the right or left side of the furnace slag door and it can be remotely controlled from the main operator room. Each head has a heavy duty chain drive lance feeding system that guarantees high lance insertion speed and high strength to penetrate the slag.

4242


ROBOX OXYGEN, CARBON AND FINES CONSUMABLE LANCE MANIPULATOR

The ROBOX consumable lance manipulator is designed for remote control of consumable calorized or ordinary pipes to inject oxygen, carbon or other fines into the furnace through the slag door with independent moving lances. The equipment is installed on the fixed platform either on the right or left side of the furnace slag door and it can be remotely controlled from the main operator room. Each head has a heavy duty chain drive lance feeding system that guarantees high lance insertion speed and high strength to penetrate the slag.

44

BENEFITS• Remote operation from furnace control room in a safe position• Increased oxygen efficiency and carbon fines recovery• Easy and fast lance replacement • Sturdy piece of equipment that needs minimum maintenance• The particular design of the pipe guides facilitates the passage • of the coupling that joins the lances together so that the entire • lance length can be utilized• The flow of oxygen obtainable with this system allows for high • decarburization speed• The carbon injection into the slag promotes FeO and MnO • reduction with consequent early slag foaming • and better control of the metallic yield

45

CONCEPT

The NANO ROBOX consumable lance manipulator is designed for remote control of consumable calorized or ordinary pipes to inject oxygen, carbon or other fines into the furnace through the slag door with independent moving lances.The equipment can


COMPACT OXYGEN, CARBON AND FINES CONSUMABLE LANCE MANIPULATOR

NANO ROBOX

be installed on the fixed platform either on the right or left side of the furnace slag door in shops where limited space is available and it can be remotely controlled form the main operator room. Each head has a heavy duty chain drive lance feeding system that guarantees high lance insertion speed and high strength to penetrate the slag.

SYSTEM LANCECONFIGURATION

MANIPULATORCONFIGURATION

OXYGEN FLOW RATE

CARBON FLOW RATE

NANO ROBOX 1 1 head | 1 lance 1 single lance Up to 2000 Nm3/h [ 1,250 scfm] -

NANO ROBOX 2 1 head | 2 lances 2 independent lances into one head

Up to 2000 Nm3/h [ 1,250 scfm]

Up to 50 kg/min [100 lbs/min]

4444


NANO ROBOXCOMPACT OXYGEN, CARBON AND FINES CONSUMABLE LANCE MANIPULATOR

The NANO ROBOX consumable lance manipulator is designed for remote control of consumable calorized or ordinary pipes to inject oxygen, carbon or other fines into the furnace through the slag door with independent moving lances. The equipment can be installed on the fixed platform either on the right or left side of the furnace slag door in shops where limited space is available and it can be remotely controlled form the main operator room. Each head has a heavy duty chain drive lance feeding system that guarantees high lance insertion speed and high strength to penetrate the slag.

46

BENEFITS• Remote operation from furnace control room in a safe position• Increased oxygen efficiency and carbon fines recovery• Easy and fast lance replacement• Sturdy piece of equipment that needs minimum maintenance• The particular design of the pipe guides facilitates the passage • of the coupling that joins the lances together so that the entire • lance length can be utilized• The flow of oxygen obtainable with this system allows for high • decarburization speed• The carbon injection into the slag promotes FeO and MnO • reduction with consequent early slag foaming and • a better control of the metallic yield

47

IMPULSIVE CONTACTLESS TEMPERATURE SENSORTEMP

CONCEPTTEMP provides continuous liquid steel temperature estimation through an impulsive contactless measurement system.

The change of the liquid steel temperature throughout the heat is a key factor in controlling the melting process. This guarantees correct tapping operations to determines the end point condition combining temperature and carbon values.

The jet nozzle is designed to produce a large hole through the slag where a bicolor pyrometer can detect the different surface emissivities giving the right measures.

It is possible to distinguish if the radiation spot is steel or slag because their emissivities are completely different. Identification of the target emissivity is not an issue because the bicolor pyrometer gives a measurement of this parameter.

Jet shot 0,001 sec Jet shot 0,200 sec Jet shot 0,350 sec

Detection of different emissivities between steel and slag


BENEFITS• Plug and play technology• Constant measurement and sampling quality• Uninterrupted slag foaming stability• Reduced thermocouples use• Feeding rate control on continuous charging processes

49

CONCEPT

The CATFIS manipulator is designed to measure temperature, carbon/oxygen contents and take samples for steel chemical analysis automatically without having to power-off the furnace. It can be easily installed on the fixed platform either on the right or left side of the furnace slag door.

Manual sampling of EAF heats places operations personnel in a hazardous location in close proximity to the EAF slag door. In addition, due to the difficulty in manipulating the manual sample lances, inaccurate or incomplete temperature/oxygen readings and poor quality chemistry samples can occur. Poor quality measurements can extend furnace power-on times and/or delay tapping, resulting in lost productivity.


SAMPLING AND MEASURING LANCE MANIPULATOR OPERATED THROUGH THE SLAG DOOR

CATFIS

4646


CATFISSAMPLING AND MEASURING LANCE MANIPULATOR OPERATED THROUGH THE SLAG DOOR

50

BENEFITS• Totally safe, no manual operation in front of the furnace slag door• Oxygen and other lancing practices can carry on as the work • of the manipulator does not interfere with them• Electrodes can remain powered-on as the work of the • manipulator does not interfere with them• The reliability of the measurements and samples is exceptionally• high as the sensors enter the steel bath at a constant • predetermined angle• No special cardboards are necessary. Standard cardboards • can be used and allow for substantial savings • (about 50÷60 % savings compared with special cardboards• COMBI cardboards (i.e. temperature + carbon) • can be used and allow for substantial savings• Sturdy piece of equipment that needs • minimum maintenance

51

CONCEPT

Safe operation by avoiding the use of a fork-lift manned unit. The machine (consisting of a remote controlled cart equipped with an horizontal ram) is intended to clear non melted scrap and excess of slag deposit, from the EAF slag tunnel prior to the temperature, or sample being taken by a sampling and measuring lance manipulator.

The ram can be installed facing the slag door. In case of limited space, it is possible to deliver a unit that moves sideways either from the left or right side of the slag door.


REMOTE CONTROLLED RAM FOR SLAG DOOR CLEANINGMOTANK

4848


MOTANK REMOTE CONTROLLED RAM FOR SLAG DOOR CLEANING

Safe operation by avoiding the use of a fork-lift manned unit. The machine (consisting of a remote controlled cart equipped with an horizontal ram) is intended to clear non melted scrap and excess of slag deposit, from the EAF slag tunnel prior to the temperature, or sample being taken by a sampling and measuring lance manipulator.

The ram can be installed facing the slag door. In case of limited space, it is possible to deliver a unit that moves sideways either from the left or right side of the slag door.

52

BENEFITS• Remote operation from furnace control room in a safe position• Totally safe, no manual operation in front of the furnace slag door• Oxygen and other lancing practices can carry on as the work • of the ram does not interfere with them• Electrodes can remain powered-on as the work of the ram • does not interfere with them• Safe and reliable temperature and sample being taken • with a sampling and lance manipulator• Sturdy piece of equipment that needs minimum maintenance

53

CONCEPT

The EBT AUTOSAND system has been developed to increase to operators’ safety, avoiding manual operations from the top of the sump panel of the EBT tap hole after tapping.

A high resolution camera is installed on the equipment to inspect the EBT tap hole directly from the control desk and manage the sand charging or cleaning operation remotely. The sand is dropped onto the EBT tap hole by gravity from a hopper installed on top of the EBT opening, without any manual operation taking place.


AUTOMATIC EBT INSPECTION AND SAND FILLING SYSTEMEBT AUTOSAND

EBT after tapping EBT post sanding

Scrap Zoom in-sand grains visible

5050


EBT SANDAUTOMATIC EBT INSPECTION AND SAND FILLING SYSTEM

Zoom-in sand grains visible

CONCEPTThe EBT SAND system has been developed to increase to operators’ safety, avoiding manual operations from the top of the sump panel of the EBT tap hole after tapping. A high resolution camera is installed on the equipment to inspect the EBT tap hole directly from the control desk and manage the sand charging or cleaning operation remotely. The sand is dropped onto the EBT tap hole by gravity from a hopper installed on top of the EBT opening, without any manual operation taking place.

54

BENEFITS• Remote operations from the furnace control room• Automatic and remote sand charging operations• Improved operators health and safety• Direct productivity improvements• Reduced operating costs

55

CONCEPT

The ESTROP is an electric-actuated swiveling and hydraulic-actuated lifting device that performs the cleaning of the EBT hole, enabling a fast and reliable operation below the furnace without any manual operation taking place. The manipulator is a “stand alone” piece of equipment that can be installed on the bottom shell either on the left or on the right side of the EBT tap hole.

The cleaning operation is performed either from the main control room or from a local control box installed in a safe position, close to the EBT area. In this way, the operator will perform this operation either in manual or automatic mode, with maximum safety.


EBT TAP HOLE CLEANING SYSTEMESTROP

5252


STROP EBT TAP HOLE CLEANING SYSTEMEBT TAP HOLECLEANING SYSTEMSTROP

CONCEPTThe STROP is an electric-actuated swiveling and hydraulic-actuated lifting device that performs the cleaning of the EBT hole, enabling a fast and reliable operation below the furnace without any manual operation taking place.

The manipulator is a “stand alone” piece of equipment that can be installed on the bottom shell either on the left or on the right side of the EBT tap hole. The cleaning operation is performed either from the main control room or from a local control box installed in a safe position, close to the EBT area. In this way, the operator will perform this operation either in manual or automatic mode, with maximum safety.

56

BENEFITS• Remote operation from furnace control room in a safe position• Sturdy piece of equipment that needs minimum maintenance• Improved operators health and safety• Direct productivity improvements• Reduced operating costs

57

EMERGENCY EBT OPENING SYSTEMSTAP

CONCEPTThe STAP is an electric-actuated swiveling and lifting device that performs the emergency opening of the EBT tap hole avoiding the use of manned oxygen lance.

The manipulator is a “stand alone” piece of equipment that can be installed on a lower level nearby the EBT area. It is made of a rotating arm which holds at its end a lance for blowing oxygen inside the tapping channel.

The tapping channel cleaning operation is performed either from the main control room or from a local control box installed in a safe position, close to the EBT area. In this way, the operator will perform this operation either in manual or automatic mode, with maximum safety.


59

BENEFITS• Remote operation from furnace control room in a safe position• Sturdy piece of equipment that needs minimum maintenance• Improved operators health and safety • Faster EBT emergency opening procedure• Direct productivity improvements• Reduced operating costs

59

SMARTECCOOLING ELECTRODE SYSTEM

CONCEPTThe SmarTEC is an advanced cooling electrode system to regulate air/water flow through the electrode cooling rings dynamically. It consists of a valve stand, an optimized electrode cooling ring controlled by a dedicated proprietary automation software during every phase of the melting process.

This dynamic control significantly increases the efficiency and effectiveness of electrode cooling, thereby reducing electrode and electrical energy consumption without affecting the arc stability.

The right combination of water speed and flow rate allows for optimal electrode cooling. The wrong speed risks water dripping or splashing.

Controlled Water Flow Rate

LeidenfrostTemperature

SmarTEC

Valve Stand

Water Supply Line

Air Supply Line

SmarTECautomation

Process dropsin Cooling Rings

Pressure ofsupply lines

Water andAir flow rate

WaterConductivity


SPLASHING

DRIPPING

OPTIMAL JET VELOCITY

✘

✘

✔︎

SMARTEC COOLING SYSTEM

60

61

BENEFITS• Plug and play technology • Automatic air purging to avoid cooling rings from clogging • Reduced electrode consumption • Reduced operating costs

61

CONCEPT Dedicated valve stands are provided to measure, regulate and control the oxygen/gaseous fuel requirements of injectors installed in the EAF shell.

The stands can be designed to cope with new injection systems or to feed existing injectors, burners or lances.


FOR OXYGEN AND GASEOUS FUEL CONTROLVALVE STANDS

5454


Dedicated valve stands are provided to measure, regulate and control the oxygen/gaseous fuel requirements of injectors installed in the EAF shell.

The stands can be designed to cope with new injection systems or to feed existing injectors, burners or lances.

FOR OXYGEN AND GASEOUS FUEL CONTROLVALVE STANDS

62

BENEFITS• Measure and flow control for each oxygen/gaseous fuel line• ‘Plug and work’ manufacturing concept to minimize the installation and connection time• Oxygen/gaseous fuel independent skids allow for the installation into separate rooms to provide absolute safety standards• Oxygen piping made of stainless steel• Gaseous fuel lines with a double shut-off valves• Valve stands are manufactured and certified to comply with: • PED 97/23/CE-pressure equipment directive, • ATEX Ex II 2G Zone 1, ATEX Ex II 3G Zone 2, • EIGA-IGC Doc.13/12/E or other requested standards

63

CONCEPT MORE designs, manufactures and supplies a wide range of water cooled oxygen and carbon lance tips for supersonic oxygen and carbon injection into the Electric Arc Furnace.The objective of MORE’s quality policy is to guarantee the best levels of customer satisfaction by providing products with an excellent quality/price ratio. To improve both the reliability of our products and reduce the production costs, MORE has invested in state of the art CNC machining and turning centers. With this vertical level integration MORE produces 100% of the tips in-house, which guarantees a high level of production and precision, as well as quick delivery of spare parts

TECHNOLOGY Tips are made from extruded and drawn copper bars that guarantee exceptionally high thermal conductivity avoiding all the usual problems related to cast copper tips (i.e embedded impurities or cavities). Copper and steel welding is done automatically with a particular in-house developed welding process.

TECHNICAL DATA


FOR SUPERSONIC OXYGEN AND CARBON INJECTION THROUGH WATER COOLED LANCES

COPPER NOZZLES

TIPS RANGE

OXYGEN 2” ½ and 3”up to 7000 Nm3/h [4,350 scfm]

CARBON 1” ½ and 1” ¼up to 100 kg/min [220 lb/min]

5656


COPPER NOZZLESFOR SUPERSONIC OXYGEN AND CARBON INJECTION THROUGH WATER COOLED LANCES

MORE designs, manufactures and supplies a wide range of water cooled oxygen and carbon lance tips for supersonic oxygen and carbon injection into the Electric Arc Furnace-The objective of MORE’s quality policy is to guarantee the best levels of customer satisfaction by providing products with an excellent quality/price ratio. To improve both the reliability of our products and reduce the production costs, MORE has invested in state of the art CNC machining and turning centers. With this vertical level integration MORE produces 100% of the tips in-house, which guarantees a high level of production and precision, as well as quick delivery of spare parts.

64

BENEFITS• Increased lifetime compared to ordinary cast nozzles• Shorter lead times compared to traditional cast nozzles• Optimal heat transfer capacity and reduced heat overload• Tips are designed for quick and safe lance on-site • replacement (steel to steel welding)• Sturdily built to resist heavy mechanical impacts• Tailor made design

65

CONCEPT The CATDRET manipulator is designed to measure temperature, carbon/oxygen contents and take samples for steel chemical analysis automatically without having to power-off the ladle furnace.

In order to drive the lances back and forth independently, each electrical motor drive is equipped with an absolute resolver so that the depth of the cardboard insertion can be easily adjusted.

The CATDRET manipulator is a “stand alone” equipment that can be easily installed on the fixed platform of the ladle furnace.

SAMPLING AND MEASURING LANCE MANIPULATOR FOR LF, VD AND VOD

CATDRET

Ladle Furnace technologies5858

Ladle Furnace technologies

CATDRETSAMPLING AND MEASURING LANCE MANIPULATOR FOR LF, VD AND VOD

The CATDRET manipulator is designed to measure temperature, carbon/oxygen contents and take samples for steel chemical analysis automatically without having to power-off the ladle furnace.

In order to drive the lances back and forth independently, each electrical motor drive is equipped with an absolute resolver so that the depth of the cardboard insertion can be easily adjusted.

The CATDRET manipulator is a “stand alone” equipment that can be easily installed on the fixed platform of the ladle furnace.

66

BENEFITS• It is totally safe; no need for an operator to be near the ladle furnace• The reliability of the measurements and samples are • exceptionally high as the sensors enter the steel bath • at a constant predetermined angle and depth• With two lances, the overall cycle time • (sampling + measuring) is reduced

67

CONCEPT The PALTET manipulator is designed to inject carbon into the ladle furnace via a consumable lance.

This compact unit can be supplied with a custom made design to be easily installed on the platform near the LF roof.

CONSUMABLE LANCE MANIPULATOR FOR CARBON INJECTION INTO THE LADLE FURNACE

PALTET

Ladle Furnace technologies6060


PALTETCONSUMABLE LANCE MANIPULATOR FOR CARBON INJECTION INTO THE LADLE FURNACE

The PALTET manipulator is designed to inject carbon into the ladle furnace via a consumable lance.

This compact unit can be supplied with a custom made design to be easily installed on the platform near the LF roof.

68

BENEFITS• It is totally safe as there is no need for the operator to be near the furnace• The reliability of carbon injection is exceptionally high as the lance enters the steel bath at a constant and predetermined angle and depth• Its compact design guarantees quick and simple on-site installation• Sturdy piece of equipment that requires minimum maintenance

69

Argon

NitrogenSTIRBOX

AUTOMATION PROCESSCONTROL


INERT GAS STIRRING SYSTEM FOR EAF, LF, VD AND VODSTIRBOX

CONCEPT

The inert gas stirring equipment is one of the most important units in the secondary treatment station and the EAF process making.

The main purpose of using bubbling gas through the porous plugs is to homogenize the chemical steel composition and remove temperature stratification. Stirring also has a major impact on the inclusion population and is useful in the steel cleaning technique. Inert gas stirring helps to create a slag free area on top of the ladle to

which additions can be made. The stirring action of the inert gas helps to rapidly dissolve the additions.

MORE has developed a new compact valve stand cabinet that allows for fine regulation and control of the process gases for EAF, LF, VD/VOD, ladle stirring and other ladle intermediate treatment stations.

6262

STIRBOX INERT GAS STIRRING SYSTEM FOR EAF, LF, VD AND VOD


The inert gas stirring equipment is one of the most important units in the secondary treatment station and the EAF process making.

The main purpose of using bubbling gas through the porous plugs is to homogenize the chemical steel composition and remove temperature stratification. Stirring also has a major impact on the inclusion population and is useful in the steel cleaning technique. Inert gas stirring helps to create a slag free area on top of the ladle to

which additions can be made. The stirring action of the inert gas helps to rapidly dissolve the additions.

MORE has developed a new compact valve stand cabinet that allows for fine regulation and control of the process gases for EAF, LF, VD/VOD, ladle stirring and other ladle intermediate treatment stations.

70

BENEFITS• Individual flow gas line regulation and measuring in continuous mode• Process control & automation system• High pressure purging lines• Emergency stirring lance line• Manual lines for emergency/maintenance• Black-out safety system• Sealed compact steel cabinet installation• Fast installation and operation control

71

MORE’s qualified customer support team, together with manufacturing flexibility, can guarantee fast on-time delivery of ordered components for the benefit of the customer’s activity. By using genuine spare parts, you will be able to maintain excellent operational capability of your equipment and at the same time reduce your maintenance costs.Thanks to the continual adjustment of our stocks, we are able to guarantee fast delivery of all standard parts.

Your advantages:• Express service for short downtimes of your system• Individual customer support (languages DE, EN, FR, ES, IT)• Repair, service and component replacements• Customized spare part packages

Professional maintenance of your plant at regular intervals ensures long-term durability and reliability in your production process.

As precautionary measures, we offer various services:• Maintenance• Repair recommendations• Production consulting• Inspections

SERVICES

SPARE PARTS:

ON-SITE SURVEYS

64

MORE’s qualified customer support team, together with manufacturing flexibility, can guarantee fast on-time delivery of ordered components for the benefit of the customer’s activity.By using genuine spare parts, you will be able to maintain excellent operational capability of your equipment and at the same time reduce your maintenance costs.Thanks to the continual adjustment of our stocks, we are able to guarantee fast delivery of all standard parts.

Your advantages:• Express service for short downtimes of your system• Individual customer support (languages DE, EN, FR, ES, IT)• Repair, service and component replacements• Customized spare part packages

Professional maintenance of your plant at regular intervals ensures long-term durability and reliability in your production process.

As precautionary measures, we offer various services:• Maintenance• Repair recommendations• Production consulting• Inspections

SPARE PARTS

ON-SITE SURVEYS

SERVICES72

To run a high-performance, cost-effective EAF, you need customized technical solutions. Our engineering consulting services are available to assess your requirements and specify exactly what you need to optimize your investment.

Our team includes experienced automation and mechanical engineers as well as highly skilled process specialists supporting our customers along the entire chain from erection to start-up and final acceptance of the supplied equipment.

The team focuses on installing equipment that facilitates production and monitoring operations, giving theoretical and practical training to your staff while complying with the most stringent safety codes.

CONSULTING

COMMISSIONING

PROCESS ANALYSIS

SERVICES

Technical and process engineers are available for improvements, problem solving, training and technical advice.

MORE offers the service of experienced steel making and process specialists that can meet clients’ needs related to:

• Process evaluation & analysis• Operational improvements and process optimization• Reduction of transformation costs• Chemical package assistance • Production assistance• On-site training

74

QUALITY

GUARANTEED TOP QUALITY

Aiming at guaranteeing the best operational standards in all the stages of its organization (from designing, to construction, to sales), since 1997 the company has been certified to satisfy quality assurance requirements of ISO 9001. In 2003 MORE, obtained UNI EN ISO 9001:2000 Certification n. 2788/0 issued from ICIM.

MORE products meet our rigorous internal standards as well as the internationally recognized certifications you’ve come to expect from the line of products we build such as ASME, PED, ATEX and others.

All welding processes in MORE are made by certified welders from IIS (Italian Institute of Welding) and according to UNI EN ISO 3834-2 in order to keep track of all welding processes used during MORE manufacturing stages.

All equipment is designed, manufactured and tested in-house prior to delivery to check the working sequences and functionality.

68

Aiming at guaranteeing the best operational standards in all the stages of its organization (from designing, to construction, to sales, to occupational health and safety), since 1997 the company has been certified to satisfy quality assurance requirements of ISO 9001. In 2003 MORE obtained the UNI EN ISO 9001:2000 (Certification n. 2788/0) and in 2015 the BS OHSAS 18001:2007 (Certification n. IT-94143) from the ICIM Institute.

MORE products meet our rigorous internal standards as well as the internationally recognized certifications you’ve come to expect from the line of products we build such as ASME, PED, ATEX and others.

All welding processes in MORE are made by certified welders from IIS (Italian Institute of Welding) and according to UNI EN ISO 3834-2 in order to keep track of all welding processes used during MORE manufacturing stages.

All equipment is designed, manufactured and tested in-house prior to delivery to check the working sequences and functionality.

GUARANTEED TOP QUALITY

QUALITY76

CUSTOMERS

North / Central AmericaGerdau Jacksonville Jacksonville, Florida, USA

Gerdau Knoxville Tennessee, USA

Gerdau Midlothian Midlothian, Texas, USA

Gerdau Saint Paul Saint Paul, Minnesota, USA

Gerdau GallatinGhent, Kentucky, USA

Gerdau CharlotteCharlotte, North Carolina, USA

Gerdau CartersvilleCartersville, Georgia, USA

Gerdau SayervilleSayreville, New Jersey, USA

Gerdau WiltonWilton, Iowa, USA

Gerdau BeaumontBeaumont, Texas, USA

Gerdau JacksonJackson, Tennessee, USA

Gerdau Macsteel MonroeMonroe, Michigan, USA

Nucor JacksonFlowood, Missisipi, USA

Nucor MemphisMemphis, Tennessee, USA

Nucor MarionMarion, Ohio, USA

Nucor KankakeeBourbonnais, Illiniois, USA

Nucor JewettJewett, Texas, USA

Nucor HertfordAhoskie, North Carolina, USA

Nucor DecaturDecatur, Alabama, USA

Nucor BirminghamBirmingham, Alabama, USA

Nucor ToscaloosaTuscaloosa, Alabama, USA

Nucor NebraskaNorfolk, Nebraska, USA

Nucor YamatoBlytheville, Arizona, USA

Nucor UthaPlymouth, Utha, USA

Nucor DarlingtonDarlington, South Carolina, USA

Nucor CrawfordsvilleWaynetown, Indiana, USA

Nucor AuburnAuburn, New York, USA

Nucor BerkleyHuger, South Carolina, USA

CMC AlabamaBirmingham, Alabama USA

CMC TexasSeguin, Texas, USA

CMC South CarolinaCayce, South Carolina, USA

CMC ArizonaMesa, Arizona, USA

Charter Steel OhioCleveland, Ohio, USA

Charter Steel WiskonsinSaukville, Wiskonsin, USA

AK Steel ButlerButler, Pennsylvania, USA

Ak Steel MansfieldMansfield, Ohio, USA

North Star BluescopeDelta, Ohio, USA

Keystone Steel & WirePeoria, Illinois, USA

Evraz Rocky MountainPueblo, Colorado, USA

SSAB AlabamaAxis, Alabama, USA

The Timken CompanyCanton, Ohio, USA

NLMK IndianaPortage, Indiana, USA

Severstal ColumbusColumbus, Missisippi, USA

ArcelorMittal SteelEast Chicago, Indiana, USA

Ellwood Quality SteelsNew Castle, Pennsylvania, USA

North American StainlessGhent, Kentucky, USA

Sterling SteelSterling, Illinois, USA

ArcelorMittal SteeltonSteelton, Pennsylvania, USA

ArcelorMittal LaPlaceLaPlace, Louisiana, USA

Republic IndustriesLouisville, Kentuky, USA

AP Gallatin HoeganaesGallatin, Tennessee, USA

Gerdau ManitobaSelkirk, Manitoba, Canada

AltasteelEdmonton, Alberta, Canada

Hamilton Speciality BarHamilton, Ontario, Canada

ArcelorMittal DofascoHamilton, Ontario, Canada

ArcelorMittal Montreal OuestContrecoeur, Quebec, Canada

ArcelorMittal Montreal EastContrecoeur, Quebec, Canada

EvrazRegina, Saskatchewan, Canada

Gerdau Sidertul (Siderurgica tultitlan)Tultitlan, Mexico

Simec International San Cosme Xalostoc, Mexico

Talleres y AcerosOrizaba, Mexico

DeAcero SaltilloSaltillo, Mexico

DeAcero CelayaCelaya, Mexico

Ternium Hylsa Planta NorteSan Nicolás de los Garza, Mexico

Ternium Hylsa Division Aceros PlanosSan Nicolas de los Garza, Mexico

Aceros de Guatemala Ciudad de Guatemala, Guatemala

Aceros Dominicanos (Metal Dom C.)Santo Domingo, Dominica Republica

South AmericaGerdau Acominas (Usiba)Simões Filho, Brazil

Gerdau Aços Villares Pindamonhangaba S/APindamonhangaba, Brazil

CSN Companhia Siderurgica NacionalVolta Redonda, Brazil

ArcelorMittal PiracicabaPiracicaba, Brazil

ArcelorMittal Juiz de ForaJuiz de Fora, Brazil

ArcelorMittal TimoteoTimóteo, Brazil

ArcelorMittal CariacicaCariacica, Brazil

Votorantim Barra MansaBarra Mansa, Brazil

Votorantim ResendeResende, Brazil

EuropeCMC Zawiercie Zawiercie, Poland

ArcelorMittal WarszawaWarszawa, Poland

ISD Huta Częstochowa Częstochowa, Poland

HSW-Huta Stali JakościowychStalowa Wola, Poland

Industeel loireRive-de-Gier, France

Vallourec & Mannesmann TubesSaint-Saulve, France

AlpaGargenville, France

ArcelorMittal SollacFlorange, FranceSAM Neuves-MaisonsNeuves-Maisons, France

SAM MontereauMontereau, France

WinoaLe Cheylas, France

78

CUSTOMERS

Iton SeineBonniers Sur Seine, France

Ellwood Steel BelgiumSeraing, Belgium

Industeel BelgiumMarchienne Au Pont, Belgium

THY MarcinelleCharleroi, Belgium

Duferco La LouvièreLa Louvière, Belgium

Železiarne PodbrezováPodbrezova, Slovak Rep.

BGH Edelstahl FreitalFreital, Germany

BGH Edelstahl SiegenSiegen, Germany

ArcelorMittal Hamburg Hamburg, Germany

B.E.S. Brandenburger ElektrostahlwerkeBrandenburg, Germany

H.E.S. Hennigsdorfer ElektrostahlwerkeHenningsdorf, Germany

Stahlwerk ThüringenUnterwellenborn, Germany

Stadtwerke GeorgsmarienhütteGeorgsmarienhutte, Germany

Tenaris SilcotubZalău, Romania

ArcelorMittal HunedoaraHunedoara, Romania

Acciaierie Di SiciliaCatania, Italy

Acciaierie Bertoli Safau Pozzuolo del Friuli, Udine, Italy

Acciaierie Valbruna VicenzaVicenza, Italy

Afv Acciaierie BeltrameVicenza, Italy

Ferriera ValsabbiaOdolo, Brescia, Italy

Tenaris DalmineDalmine, Bergamo, Italy

Nunki SteelSan Giogrio di Nogaro, Udine, Italy

Acciaieria Di Rubiera Modena, Italy

Stefana Nave, Brescia, italy

Cogne Acciai Speciali Aosta, Italy

Thyssenkrupp Acciai Speciali TerniTerni, Italy

San Zeno Acciai DufercoSan Zeno, Brescia, Italy

Acciaieria ValsuganaBorgo Valsugana, Trento, Italy

Acciaierie ValbrunaBolzano, Italy

Celsa AmeringsstalMo i Rana, Norway

Sovel Athens, Grece

Corus Engineering SteelsStocksbridge, United Kingdom

Celsa ManufacturingCardif, United Kingdom

Böhler EdelstahlKapfenberg, Austria

SN Seixal Siderurgica NacionalPaio Pires, Portugal

AcerinoxLos Barrios, Spain

SidenordBasauri, Spain

ArcelorMittal SestaoSestao, Spain

ArcelorMittal ZaragozaZaragoza, Spain

Corrugados AzpeitiaAzpeita, Spain

Corrugados GetafeGetafe, Spain

A.g. Siderurgica BalboaJerez de los Caballeros,Spain

Siderurgica SevillanaAlcalá de Guadaíra, Spain

Africa / Middle EastSuez SteelAttaka, Egypt

ArcosteelSadat City, Egypt

Egyptian American Rolling MillSadat City, Egypt

Al Ezz Flat SteelSuez, Egypt

Al Ezz DekheilaAlexandria, Egypt

Al Ezz RebarsGiza, Egypt

Rajhi SteelJeddah, Saudi Arabia

HADEED - Saudi Iron & Steel Co.Al-Jubail Ind. City, Saudi Arabia

ArcelorMittal VanderbijlparkVanderbijlpark, South Africa

ArcelorMittal SaldanhaSaldanha, South Africa

Acierie Electrique de SonasidSonasid, Morocco

Qatar SteelMesaieed, Qatar

Emirates Steel Company L.L.CAbu Dhabi, UAE

Emirates Steel IndustryAbu Dhabi, UAE

United Steel Industry (Unisteel)Shuaiba Port, Kuwait

Kroman CelikCayirova-Gebze, Turkey

MMK AtakasDörtyol, Turkey

Asil CelikOrhangazi, Turkey

Yolbulan BastugOsmanie, Turkey

AsiaKorean Iron & Steel (KISCO)Changwon, South Korea

Korean Steel Shapes (KOSCO)Haman-gun, South Korea

Dongbu SteelGangnam-gu, South Korea

N.T.S. Steel GroupChatuchak, Thailand

Siam Yamato SteelBangkok, Thailand

Millicon BurapaSuriyawong, Thailand

M- METALLopburi, Thailand

Thep VietTân Thành, phưưng 12, District 5 Ho Chi Minh, Vietnam

OceaniaOnesteelWaratah, Australia

OnesteelLaverton North, Australia

OnesteelSydney, Australia

CUSTOMERS79

Rev 0_31/3/2015

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