CPT International 02/2015

More documents

Info

K MELTING SHOP the furnace operation. The conveying system, developed by Dako, today operates with an accuracy of < 5 % petcoke. There is a direct relationship between the Boudouard reaction and the amount of petcoke added (Figure 3). The basis: TDI-PET technology Figure 4 shows the TDI-PET installation at the penstock above the water seal trough and below the hot blast duct and the expansion joint. Directly above the inspection flap, a steel pipe feeds the petcoke to the oxygen system. The TDI blowing nozzle injection system has been arranged to the right of the penstock. Runner iron temp. in °C 1515 1510 1505 1500 1495 Runner iron-temp. with HIGHJET TDI PET As shown in Figure 5, this design allows the fuel – in this case, pulverized petcoke – to be guided to the respective TDI-PET burner lances and carried along by the HighJet stream. This stream is characterized by a high impulse and a high oxygen content. Consequently, a mixture of pulverized petcoke, pneumatic air and oxygen can be injected into the cupola by a high impulse, facilitating a very deep penetration into the shaft furnace, whilst optimally exploiting the energy contained in the fuel. Thus, the energy required to melt the charge is not only provided by the foundry coke but also by the solids injected by the TDI-PET burner lances. This allows the furnace operation to be optimized and the coke rate further reduced. It is deemed realistic that up to 22 % of foundry coke can be saved, depending on the amount of initially charged coke. Of course, each furnace must be considered separately. Figure 6 shows the arrangement of the TDI-PET lance inside the water-cooled cooper nozzle. An advantage is that the injection speed of the PET 1.25 % 1490 Runner iron-temp. without HIGHJET TDI PET 1485 08:24 09:36 10:48 12:00 13:12 14:24 15:36 16:48 18:00 Time Figure 10: Effect on the runner iron temperature (idealized time line) CO in % 12 11 10 9 8 Burner on Burner on CO % with HIGHJET TDI PET Burner on Burner on Burner on CO % without HIGHJET TDI PET 08:24 09:36 10:48 12:00 13:12 14:24 15:36 16:48 18:00 time Figure 11: Effect on CO content in the top gas (idealized time line) pulverized petcoke is much higher than the hot blast speed in the copper nozzle. At the relining intervals, no significant wear was observed at the injection system. Figure 7 illustrates and describes the principle of using pulverized petcoke as fuel. Results of the TDI-PET technology – sulfur analysis Due to the fact that pulverized petcoke contains up to 2.5 % of sulfur, special attention was placed on the sulfur analysis. It turned out that the sulfur has no effect whatsoever. During the long-time operation of the furnace, it could be proved without doubt that the higher sulfur contents posed no problem. During five months of grey cast iron production, an increase by not more than 0.0063 % was determined. In case of ductile iron, the value was 0.005 over the same period. Any variations are the result of variations in the coke quality. Obviously, a slightly higher part of the metallurgical sulfur is discharged via the slag and the top gas. However, the quantities are below the respective limits of detection. Petcoke – effect on efficiency and carburization A key factor for the proper application of the petcoke technology is to understand the furnace-specific processes going on when petcoke is charged, especially in cases where the furnaces are operated with reduced rates of foundry coke. Continuous measurements of the CO and CO 2 concentrations in the top gas between the below-charge take-off and the combustion chamber helped to optimize the furnace operation and made any negative influences immediately obvious. While Figure 7 illustrates how petcoke can influence the iron chemistry, Figure 8 shows that the operation with petcoke does actually have a decisive effect. Analyses of the runner iron typically reveal fluctuating carbon contents, which cannot be avoided due to the specifics of the furnace operation. However, by the objective use of petcoke, these analysis fluctuations can be kept within closer tolerances ( Figure 9). 36 Casting Plant & Technology 2/<strong>2015</strong>
Intelligent process materials for the global steel-making and foundry industries. We supply the steel-making and foundry industries with individually matched covering materials and additives that meet the increasingly high demands on steel quality and environmental compatibility, and simultaneously stand for significant energy savings. Typical examples are our slag conditioner REPROMAT for fast formation of an optimum MgO-saturated foamed slag, our environmentally compatible REFRAFLUX® for highly reactive slag formation, and our NERMAT® covering material with its outstanding insulation properties. Düsseldorf, Germany 16-20 June, <strong>2015</strong> Meet us: Hall 5 / F 03 Refratechnik Casting GmbH Schiessstrasse 58 40549 Düsseldorf Germany Phone +49 211 5858 0 casting@refra.com www.refra.com
Page 1: www.giesserei-verlag.de 10. June 20
Page 4 and 5: K FEATURES INTERVIEW Kehrer, Friedr
Page 6 and 7: K INTERVIEW GIFA - the internationa
Page 8: K MATERIALS Rotor hub for a wind po
Page 11 and 12: Discover Bühler: Visit us at the G
Page 13 and 14: machine supports weighing in excess
Page 15 and 16: versus EN-GJS-400-18-LT, the materi
Page 17 and 18: Figure 1: Factors that can have a m
Page 19 and 20: Core disintegration - shakeout In t
Page 21 and 22: Figure 10: Test casting of step cor
Page 23 and 24: EXTRUSION + DIECASTING + FOUNDRY +
Page 25 and 26: Figure 1: Process of inorganic core
Page 27 and 28: AlSi10Mg(Cu) from melting plant KSM
Page 29 and 30: Figure 15: Detailed view of gripper
Page 31 and 32: www.sinto.com 16 th - 20 th June 20
Page 33 and 34: Figure 1: Flow diagram of the petco
Page 35: tem, the following specifications c
Page 39 and 40: X:\00-Küttner-Image\00_CDR-Dateien
Page 41 and 42: Steel grade Alloying contents in %
Page 43 and 44: overcome limits VISIT US HAll 10/A4
Page 45 and 46: al components which have to comply
Page 47 and 48: quenched component in advance, prov
Page 49 and 50: tional downstream heat treatment an
Page 51 and 52: ight next to the football stadium o
Page 53 and 54: ing the quality of the melt. One ar
Page 55: Visit us on GIFA in Düsseldorf / G
Page 58 and 59: K RESEARCH & DEVELOPMENT change of
Page 60 and 61: K INDUSTRIAL COOPERATION Author: Ch
Page 62 and 63: K INDUSTRIAL COOPERATION » Optimiz
Page 64 and 65: K INDUSTRIAL COOPERATION Author: Ma
Page 66 and 67: K INDUSTRIAL COOPERATION power requ
Page 68 and 69: K NEWS The premises of the Kurtz Er
Page 70 and 71: K NEWS Award ceremony with managers
Page 72 and 73: 30.09.2008 8:08:15 Uhr ly ge ld u-
Page 74 and 75: Approximately 50 % of cast products
Page 76 and 77: The situation in the NAFTA area, wh
Page 78: WFO-Technical-Forum Thursday, 18.06
Page 81 and 82: Optical Particle Analyzers ELECTRON
Page 83 and 84: WALTHER-PRÄZISION Flexibility and
Page 85 and 86: FOSECO New Inorganic Binder System
Page 87 and 88:
Energy-Efficient Exhaust Air Filter
Page 89 and 90:
SCHLAGER INDUSTRIEOFENBAU Industria
Page 91 and 92:
ELEMENTAR ANALYSENSYSTEME Elemental
Page 93 and 94:
EIRICH Molding sand preparation for
Page 95 and 96:
LAEMPE World market leader for core
Page 97 and 98:
DRACHE UMWELTTECHNIK Transport cruc
Page 99 and 100:
Installed thermal reclamation plant
Page 101 and 102:
KMA UMWELTTECHNIK Energetic air pur
Page 103 and 104:
FAGUS-GRECON Fire protection in the
Page 105 and 106:
OPTRIS Infrared camera for temperat
Page 107 and 108:
CLARIANT Eco-friendly Geko LE and E
Page 109 and 110:
COLD JET Aero foundry edition - rec
Page 111 and 112:
RÖSLER Gamma 400 G - improved blas
Page 113 and 114:
HÜTTENES ALBERTUS The HA Group - i
Page 115 and 116:
Vibrating and conveying solutions 2
Page 117 and 118:
PREVIEW / IMPRINT K Preview of the
show all

CPT International 02/2015

Create successful ePaper yourself

Delete template?

Save as template?