SIROLL Furnace Optimization. Provides optimally heated pieces to hot rolling operations while minimizing fuel consumption. Metals Technologies

Transcription

1 SIROLL Furnace Optimization Provides optimally heated pieces to hot rolling operations while minimizing fuel consumption Metals Technologies

2 SIROLL Furnace Optimization Provides optimally heated pieces to hot rolling operations while minimizing fuel consumption Your challenge: Hot rolling operations need high-quality reheated slabs, billets, or blooms at the lowest possible cost at the mill s optimal production rate. The heating strategy has a major influence on both the quality of reheated pieces and on the amount of fuel used for reheating. A traditional, non-optimized heating strategy may seem sufficient under steady state conditions but does not provide optimal quality and cost performance when there are interruptions in production, variations in product grades or dimensions, or variations in target dropout temperatures. In today s marketplace, a solution is needed to deliver the highest quality and lowest cost heating under all conditions with minimal impact on the environment. Our solution: SIROLL Furnace Optimization is a complete hardware and software solution that provides the latest technology in supervisory control of the reheat furnace. The system calculates and tracks the thermal condition of individual pieces inside the furnace, including hot-charged pieces. Based on this information, optimal zone temperature setpoints and furnace production rates are determined. The system takes into account both planned and unplanned delays in rolling production minimizing fuel consumption during idle times, and optimizing the ramp-up of setpoints in anticipation of continued production. The optimized heating strategy results in accurate discharge temperatures, minimal surface scale formation, minimal decarburization, minimal fuel consumption, and minimal environmental emissions all while respecting the desired piece-to-piece dropout rate and maximum temperature gradient within each piece. The system is well-proven in many applications for slab, billet and bloom reheating furnaces with various configurations, including walking beam, pusher, rotary hearth, etc. 2

3 Good reasons for SIROLL Furnace Optimization: J Reduced energy costs and emissions (CO, CO2, NOx, SOx) fuel consumption reduced by 6 to 15% J Consistent piece-to-piece discharge temperature performance average bulk temperature within 1% of target temperature J Temperature consistency within each piece variations within the heated piece as low as 1% of the target temperature J Reduced scale formation and decarburization surface quality is improved as a result of the optimized heating strategy J High productivity quality goals are achieved while respecting the desired production rate; tighter control of dropout temperature, so no need to overheat pieces to be safe J Improved rolling mill gauge performance temperature consistency from piece-to-piece and within each piece results in consistent hot rolling stock 3

4 System components and architecture Furnace control software that minimizes fuel consumption and saves on energy costs Charge tables Mill pacing Model profile Heat balance System components: The major components included in the SIROLL Furnace Optimization system are: An on-line, multi-dimensional thermal model calculates piece temperatures and gradients while accounting for changing product dimensions, varying initial temperatures (including hot charging), skid marks, and material grades. The model is used to predict the heating of every piece in the furnace. Furnace control software strategies provide zone temperature and production rate setpoints to consistently produce properly heated pieces. The setpoint control strategy: -Reduces fuel consumption -Decreases temperature gradients within the product 4 -Decreases temperature variations between pieces -Increases product surface quality by minimizing the amount of scale and decarburization Delay management adjusts zone temperatures to maintain the proper product temperature during delay conditions to permit resumption of production at the end of the delay while minimizing fuel consumption and achieving quality goals. Mill pacing software maximizes production while accounting for the requested discharge interval and the available heat input of the furnace. The system uses minimum piece-topiece discharge intervals to calculate residence profiles (location/time profiles) for all pieces in the furnace. Based on the residence profiles, an optimized heating strategy is determined. Modeled section of a round product Modeled section of a slab with fixed (F) and moveable (M) skids

5 SIROLL Furnace Optimization SIROLL Furnace Control Typical system architecture with SIROLL Furnace Optimization and SIROLL Furnace Control Heat transfer control path configuration - rounds Heat transfer control path configuration - slabs System components: Adaptive feedback software biases the aim discharge temperatures according to mill temperature feedback and typical rolling practice. Data acquisition software collects furnace and product information for accurate piece tracking, production and quality reports, operator interface screens, and any desired data transfer to higher-level computers. An off-line model, as a design and analysis tool, brings flexibility to a system that is expected to handle new product grades and sizes that might be added to production in the future. The off-line model uses the same heat transfer calculation subroutines as the on-line model. It allows the user to input different product data and furnace conditions in order to generate desired what if types of scenarios and calculates the results under those conditions. The off-line model proves to be a very useful design tool at all stages of system development, commissioning, tuning and on-going usage. System architecture: SIROLL Furnace Optimization is designed in a client-server configuration with ethernet communications between a single server computer and multiple Human- Machine Interface (HMI) client computers. The server is typically implemented on the Windows platform and is also available on other platforms. The client workstations are personal computers with a Windows-based graphical software package that can be distributed to additional client computers without the need for additional software licensing. The SIROLL Furnace Optimization system provides optimized setpoints to the SIROLL Furnace Control system which provides basic automation for the material handling and combustion control equipment. The system can also be integrated with existing basic automation systems as well as other existing computer systems. 5

6 Selected success stories with SIROLL Furnace Optimization Customer: ArcelorMittal, Vanderbijlpark, South Africa Furnace type: (1) Walking beam, (3) pusher type - upgrade The results: - 6.8% reduction in fuel usage Commissioning: 2007 Customer: Corus (British Steel), Scunthorpe, UK Furnace type: (1) Walking beam - new and upgrade Product type: Bloom The results: - Average deviation from target dropout temperature 1.09ºC - Standard deviation 2.20ºC Commissioning: Original 1997, upgrade 2007 Customer: Maanshan Iron & Steel, Maanshan, China Furnace type: (3) Walking beam - new The results: - Average deviation from target dropout temperature -2.72ºC - Standard deviation 13.88ºC Commissioning: 2006 Customer: Duferco Farrell Corporation, Farrell, PA, USA Furnace type: (3) Pusher type - upgrade The results: % reduction in fuel usage - Increased productivity at the HSM - Reduced target discharge temperatures attributable to tighter controls Commissioning: 2004 Customer: Nucor Steel, Hertford, NC, USA Furnace type: (1) Walking beam - upgrade The results: % reduction in fuel usage - Average discharge temperature gradient reduced from 342ºF to 187ºF - Guarantees proven over a sample set of 17,149 slabs Commissioning: 2004 Customer: US Steel Tubular Products (Lone Star Steel), Lone Star, TX, USA Furnace type: (2) Pusher type - upgrade The results: % reduction in fuel usage - Scale formation reduction 18.7% - Average deviation from target temperature 13ºF Commissioning:

7 World-class solutions for world-wide customers Our customers Customer/plant Country Furnace Product New or Year of type upgrade start-up Canadoil Plate Ltd. Thailand Walking Beam (2) Slab New 2010 Columbus Stainless South Africa Walking Beam (1) Slab Upgrade 2009 Jigang China Walking Beam (3) Slab New 2009 AHMSA Mexico Pusher Type (2) Slab New 2009 Evraz Regina Steel (IPSCO) Canada Walking Beam (1) Slab Upgrade 2008 ArcelorMittal South Africa Walking Beam (1) Slab Upgrade 2007 ArcelorMittal South Africa Pusher Type (3) Slab Upgrade 2007 Corus (British Steel) UK Walking Beam (1) Bloom Upgrade 2007 Maanshan Iron & Steel China Walking Beam (3) Slab New 2006 Voestalpine Stahl Austria Walking Beam (1) Slab Upgrade 2006 AHMSA Mexico Walking Beam (2) Slab Upgrade 2005 Shagang China Walking Beam (2) Slab Upgrade 2005 Duferco Farrell USA Pusher Type (3) Slab Upgrade 2004 Nucor Steel Hertford USA Walking Beam (1) Slab Upgrade 2004 Severstal Russia Pusher Type (4) Slab Upgrade 2004 JISCO China Walking Beam (1) Slab New 2004 US Steel Tubular Products (Lone Star Steel) USA Pusher Type (2) Slab Upgrade 2003 Voestalpine Stahl Austria Pusher Type (2) Slab Upgrade 2003 USS Mon Valley USA Pusher Type (5) Slab Upgrade 2002 Alfasid Algeria Pusher Type (2) Slab Upgrade 2002 Timken USA Walking Beam (1) Billet Upgrade 2002 ArcelorMittal (ISPAT-Inland) USA Walking Beam (1) Slab New 2001 ArcelorMittal (ISPAT-Inland) USA Walking Beam (2) Slab Upgrade 2001 BMZ Shlobin Belarus Walking Beam (2) Billet Upgrade 2000 Vitkovice Czech Republic Pusher Type (1) Slab Upgrade 1999 Laiwu Steel China Walking Beam (1) Billet New 1998 IPSCO, Inc. Canada Walking Beam (1) Slab Upgrade 1997 Newport Steel USA Walking Beam (1) Slab New 1997 British Steel UK Walking Beam (1) Bloom New 1997 Timken USA Walking Hearth (1) Billet Upgrade 1997 AHMSA Mexico Walking Beam (2) Slab New 1996 American Steel & Wire USA Walking Beam (1) Billet New 1996 China Steel Taiwan Walking Beam (2) Slab New 1996 J&L USA Walking Beam (1) Billet New

8 For further information, please contact: Siemens VAI Siemens Industry Sector Siemens Industry, Inc. Metals Technologies 501 Technology Drive Canonsburg, PA Phone: Headquarters: Siemens VAI Metals Technologies GmbH & Co P.O. Box 4, Turmstr. 44 A 4031 Linz, Austria contact.metals@siemens.com The information provided in this brochure contains merely general descriptions or characteristics of performance which in actual case of use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. Order No.: MTBR-SIIVI-0809 Printed in U.S.A. Dispo No.: K-No.: Subject to change without prior notice. Siemens AG All rights reserved. SIROLL is a trademark of Siemens AG.