Instruments and Solution for Iron & Steel Industry PDF

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Challenges in the iron & steel plant

To technology in iron & steel industry is continuously improved to obtain the best possible performance. The improved plant performance gives rise to the higher quality improvement and lower cost, and simultaneously environmental friendly plant operation.

The control systems and field instruments are working at the various processes of the iron and steel plant. The process of iron and steel plant is starting from Sinter plant, Coke oven etc, and the blast furnace, iron pre-treatment are following. The products are widely used at furnace control and utilities in important processes (such as continuous casting machine (CCM)) in down stream of iron / steel making process.

Improve combustion efficiency and product quality

The temperature of the hot blast used in blast furnace has been increasing every year and currently stands at around 1300°C. Under such circumstances efficient operation is achieved by such measures as increasing the calorie value of fuel gas and recovering waste heat from gas. To further improve combustion efficiency and save energy, measurement of the oxygen concentration in exhaust gases is required.

A furnaces for heating slabs needs to be operated under low-oxygen conditions at high temperatures of 1000°C and above to prevent oxidation of the steel. The measurement of oxygen concentration in the furnace is essential.

Why buy Yokogawa?

Blast furnace and it's peripherals such as hot stoves, PCI (Pulverized coal injection), TRT (Top pressure turbine), etc. is the most important area in steel factories where Yokogawa delivers best performance. We have much experience in the area of instrumentation of not only the area but also all iron and steel process. The reliable and high quality measurement & control with Yokogawa's field-proven sensors and controllers helps the process optimization, and efficient/ safe/ reliable plant operation at low cost, and supports to achieve the dual aims of quality production and environmental protection through the field proven technologies.

Furnace Body Cooling

Furnace Body Cooling

Overview and Problems

  • Drum pressure control and drum water level control
  • Monitoring of circulation water flow
  • Enlarge the maintenance period and save the maintenance cost

Solution

  • Field proven silicon resonant sensor guarantees long term stability
    EJA: 0.1 % of URL 5 years
    EJX: 0.1 % of URL 10 years
    Under all conditions (temperature, static and over pressures)

Benefits

  • Improvement of a maintenance period
  • High stability and High reliability
  • Reduction of a maintenance cost

 

Monitoring of Cooling Water

Monitoring of Cooling WaterOverview and Problems

  • Tuyere water leakage detection system (BF)
  • Secondary cooling water flow control (CCM)
    -Intermittent control
    -Mist spray control

Solution

  • Adhesion diagnosis function
    -Replaceable electrode structure
  • High quality and High performance
    -Accuracy: ±0.35 % of Rate (V = 0.15 ~ 10m /sec)
    (0.2 % of Rate is available as an option)
    -Repeatability: ±0.1 % of Rate (V ≥ 1m /sec)
  • High noise suppressor and Quick response

Benefits

  • Informs the timing of the maintenance of the electrode
  • Safety operation
  • High-quality steel producing

 

Monitoring and Controlling of Steam Flow and Temperature

Monitoring and Controlling of Steam Flow and TemperatureOverview and Problems

  • Renewal demand for obsolete instruments YS DXA
  • Need centralized data monitoring YS DXA

Solution

  • Colour LCD display with a wide variety of screen including meter display YS DXA
  • Expanded network function YS DXA
  • Control output backup function YS
  • Display and operation DXA
    -Custom display function
    -Display and prints report from a web browsing
    -Review historical data with calendar search function

Benefits

  • Perform safe and stable control at low cost YS
  • DCS backup application YS
  • Less engineering for replacement YS
  • Create more intuitive overview monitors by customized display YS

Manufacturing Processes of Steel

 

Zirconia Oxygen Analyzer

Zirconia Oxygen AnalyzerOverview and Problems

  • Energy loss from air leak in sintering furnace
  • Combustion control in coke oven, hot blast stove, blast furnace and heating furnace
  • Prevent oxidation of the steel in heating furnace

Solution

  • Air leakage detection
  • Measuring and adjusting oxygen concentration in the exhaust gas
  • Monitoring oxygen concentration in heating furnace

Benefits

  • Save energy and improve the efficiency of sintering furnace maintaining high quality
  • Improve combustion efficiency in coke oven, hot blast stove, blast furnace and heating furnace
  • Maintain high enough temperature and prevent hazardous condition in blast furnace
  • Maintain high product quality in heating furnace

 

Combustion Control

Combustion ControlOverview and Problems

  • Coke oven gas and blast furnace gas are utilized in various combustion process
  • Continuous and stable measuring is difficult because of dust, tar, naphthalene and so on
  • Pre-treatment to eliminate dust, tar and naphthalene is necessary

Solution

  • Stable measurement by combined YOKOGAWA reliable products and technically effective burner design
  • Sampling system matching process condition

Benefits

  • Accurate calorie measurement improves the heating process efficiency
  • Boost yield and maintain high quality

 

Process Gas Chromatograph

Process Gas ChromatographOverview and Problems

  • Guidance of the total furnace operation
  • Detect abnormal condition

Solution

  • Analyze blast furnace top gas, coke oven gas and mixed gas composition

Benefits

  • Improve the process efficiency and custody transfer

 

Inductive Conductivity Analyzer

Inductive Conductivity AnalyzerOverview and Problems

  • The pickling process removes the contaminants from the metal's surface by using acids without damaging the metal's surface

Solution

  • The acid concentration is monitored and controlled to remove scale and oxide sufficiently

Benefits

  • Maintain the customers' high product quality efficiently enough in the pickling process

     

Technologies Commit Users' Benefits

DPharp Silicone Resonant Sensor

Our Goal

Our shared goal is customer satisfaction through operational excellence.
Yokogawa has brought true innovations to industry. We are committed to ensuring accuracy, reliability, and safety of your production system throughout your business life cycle. Our comprehensive solutions and expertise help you achieve more results with less total costs of ownership. Below key technologies shall aim for your operational excellence.

Dual Frequency Coil Excitation

DPharp Silicone Resonant Sensor

DPharp Pressure Transmitters with digital silicon resonant sensor delivers the maximum benefits from the elasticity of the single crystal silicon material while enhancing sensitivity and repeatability. The properties of the resonators remain constant for a long team. This makes DPharp the ideal pressure sensor for harsh industrial automation environments. DPharp offers the highest stability, repeatability and reliability.

YS1000 Dual CPU

Dual Frequency Coil Excitation

Magnetic Flowmeters measure flow volume based on Faraday's law. The frequecy of excitation current given to coils affects in the measurement accuracy and response time.

Dual Frequency Coil Excitation is Yokogawa's original technology to ensure ± 0.35 % accurate measurement as well as 0.1 second fast response simultaneously. Our signal processing technique enables us to bring the benefits of an AC & DC magnetic flowmeter into a single magnetic flowmeter.

Burner Unit

YS1000 Dual CPU

With dual-CPU construction, manual control capability and display continues even if an abnormality occurs on one of the CPUs. If controller self-diagnostics detects a control circuit failure, the controller can suspend analog/digital output, switch to manual mode and allow manual control by operator. 

Gas Calorimeter Key Technology

Burner Unit

The sample gas burns inside the burner unit and a thermocouple detects the burning temperature increase. The air is introduced from the air inlet and divided to the primary, secondary and tertiary air. The primary and secondary ones are for burning the sample gas and the tertiary is for diluting and stirring the exhaust gas. The sample gas is mixed with the primary air (In case of the low calorie gas, the primary air is throttled), and burnt completely by the secondary air. Then, the combustion temperature generates, and burnt gas is promptly diluted and stirred by the tertiary air. Finally the gas is exhausted out from the top of the detector.

The increased temperature is measured with the difference of the electromotive force between the cold junction point (located at the air inlet) and the hot junction point (inside the mixed diluted exhaust gas). The heating wire wound the burner tip is used for both ignition and preheating (In case of low calorie gas).

 

업종

Related Products & Solutions

ADMAG AXF

The AXF magnetic flow meter is a sophisticated product with outstanding reliability and ease of operation, developed on the basis of decades of field experience. Based on FOUNDATION™ fieldbus specifications, AXF Fieldbus Magnetic Flow meter models offer more flexible instrumentation.

GC1000 Mark II

The ability to perform discrete separation and positive identification of components and measurement of the composition without interference is an advantage of the gas chromatograph. The process gas chromatograph is widely used in many industries.

Inductive (Torodial, Electrodeless) Conductivity Analyzer

유도식 전도도 방법은 특히 높은 전도도 측정에 적합합니다. 분석계는 2개의 Troidal 변압기가 내장된 센서와 함께 작동합니다. AC 전류는 공정 샘플에 전압을 유도하여 샘플에 전류를 발생 시킵니다. 이 전류의 세기는 옴의 범칙에 따른 샘플의 전도도에 비례합니다. 

Inductive (Torodial, Electrodeless) Conductivity Sensor ISC40

ISC40 센서는 EXA ISC 분석계와 함께 사용하도록 설계되어 있습니다. 이 조합은 신뢰성, 정확성, 범위성, 가격 성능 측면에서 전도도 측정에 대한 모든 기대를 초과합니다.

Single Channel Oxygen Analyzer System ZR22/ZR402

ZR 프로브의 In-situ 측정 방법은 공정 컨디셔닝이나 추출 샘플링을 필요로 하지 않습니다. 이는 유지 보수 비용을 줄이고 공정의 변화에도 보다 신속하게 대응할 수 있습니다.

YS1310

YS1310 지시 경보계는 2 입력의 지시 경보계입니다. 2 루프를 동시 표시에 표시할 수 있습니다. 2 입력 각각에 대해 상한 경보, 하한 경보, 위 상한 경보, 아래 하한 경보가 가능하며 총 6개의 접점에서 임의의 경보의 AND 접속 또는 OR 접속을 출력 할 수 있습니다.

YS1350/YS1360

YS1350은 수동으로 SP 신호를 컨트롤러 등에 출력 할 수있는 수동 설정기입니다. YS1360은 조작기에 MV 신호를 수동으로 출력 할 수있는 수동 설정기입니다.

YS1500

YS1500 조절계는 PID 제어에 필요한 기본적인 제어 기능을 미리 내장하고 있어 사용자의 목적에 따라 기능을 선택 설정할 수 있는 단일 루프 컨트롤러입니다.

YS1700

YS1700 프로그램 조절계는 사용자 프로그램을 통해 다양한 어플리케이션을 지원하는 단일 루프 컨트롤러입니다. Yokogawa 독점 기술의 높은 신뢰성과 사용의 용이성 및 확장성을 갖추고 있습니다.

디지털 레코더 DX1000/DX2000

FDA 21CFR Part 11을 준수한 확장 보안 기능 (옵션)을 탑재한 모델입니다.

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