Vortex flowmeters help optimize efficiency and energy usage for arc furnaces

Rosemount vortex flowmeters help MORE s.r.l. optimize steel quality, minimize oxygen and fuel consumption in its arc furnaces.

03/05/2013


MORE s.r.l. has reduced energy consumption and optimized the quality of steel produced from its electric arc furnaces by using Rosemount 8800 Vortex flowmeters from Emerson Process Management. MORE s.r.l. has reduced energy consumption and optimized the quality of steel produced from its electric arc furnaces by using Rosemount 8800 Vortex flowmeters from Emerson Process Management. The flowmeters are being used to measure and optimize oxygen used in the steel making processes more accurately than earlier technologies the company had tried. Optimization of the oxygen-fuel ratio is critical to minimizing conversion costs, reducing oxygen and fuel consumption, and avoiding rework. In addition, accurate control of oxygen improves furnace safety and reduces environmental impact.

Based in Gemona del Friuli (UD), Italy, MORE supplies a wide range of technologies and auxiliary equipment for electric arc furnaces used in the steel-making industry. These include sidewall injector systems used with chemical energy packages such as oxygen, carbonaceous fuels, lime, and other fines. These chemicals are injected into the furnace during the melting process to improve steel quality and provide additional energy from exothermic reactions, helping to reduce overall energy consumption.

MORE had been using differential pressure (DP) flowmeters to measure the oxygen flow in its electric arc furnaces. However, the capabilities of the existing meters made it difficult to meet customer demand for more accurate control, as well as changing process requirements. More accurate instruments with a broader measurement range were required.

Always eager to use the best available technology for its furnace installations, MORE decided to evaluate vortex flowmeters since this technology is recognized as being both accurate and suitable for challenging applications.

"We tried vortex meters from various other manufacturers but found that their products were not sturdy enough, or they were too sensitive to vibrations that resulted in an unreliable measurement and consequently, poor control of the oxygen-fuel ratio," said Roberto Urbani, purchasing manager, MORE s.r.l. "Using Rosemount vortex flowmeters eliminated these problems, delivering the accurate and reliable measurements we required."

In addition, to meet customer demands for greater flexibility in their furnace installations, the 25:1 turn-down range of the 8800 helps optimize gas heaters, providing greater opportunities to vary the characteristics of the steel for different applications. And while DP flow meters can have up to 30 leakage points, the gasket-free sensor design of the 8800 means there are no potential leak points, reducing maintenance requirements and enhancing safety. The meter body design eliminates all ports and crevices that can affect the ability of the sensor to measure flow, and the isolated sensor design eliminates the need to break process seals for sensor replacement.

Accurate oxygen control is critical for steelmaking. Too much oxygen causes over-oxidation (decarburization), which requires expensive re-work to obtain steel of suitable quality. It also creates over-heating, which can damage the furnace. Too little oxygen, on the other hand, slows production. The application therefore demands measurement devices that enable accurate control of the injector feed oxygen-fuel ratio.

MORE s.r.l.

www.more-oxy.com

Emerson Process Management

www.EmersonProcess.com

Edited by Peter Welander, pwelander@cfemedia.com



No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
Hannover Messe 2016: Taking hold of the future - Partner Country status spotlights U.S. manufacturing; Honoring manufacturing excellence: The 2015 Product of the Year Winners
Inside IIoT: How technology, strategy can improve your operation; Dry media or web scrubber?; Six steps to design a PM program
World-class manufacturing: A recipe for success: Finding the right mix for a salad dressing line; 2015 Salary Survey: Manufacturing slump dims enthusiasm
Getting to the bottom of subsea repairs: Older pipelines need more attention, and operators need a repair strategy; OTC preview; Offshore production difficult - and crucial
Digital oilfields: Integrated HMI/SCADA systems enable smarter data acquisition; Real-world impact of simulation; Electric actuator technology prospers in production fields
Special report: U.S. natural gas; LNG transport technologies evolve to meet market demand; Understanding new methane regulations; Predictive maintenance for gas pipeline compressors
Warehouse winter comfort: The HTHV solution; Cooling with natural gas; Plastics industry booming
Managing automation upgrades, retrofits; Making technical, business sense; Ensuring network cyber security
Designing generator systems; Using online commissioning tools; Selective coordination best practices

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
This article collection contains several articles on the vital role that compressed air plays in manufacturing plants.
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.
click me