FC Technik AG Oct 2016

G as C ontr o l Un i t s for the s tee l indus tr y | f l ox [o o n t r o l ] | FC Technik | 1

flox[control] Gas Control Units

for the Steel Industry

2 | FC Technik | f l ox [co n t r o l ] | G as C ontr o l Un i t s for the s tee l indus tr y G as C ontr o l Un i t s for the s tee l indus tr y | f l ox [o o n t r o l ] | FC Technik | 3

THE Company Flox[ConTrol] sHows iTs sTrEnGTH

FC Technik is a company with headquarters inWinterthur, Switzerland and activities all around the world. We offer our customers theadvantages which accrue from many years of experience in gas measuring and control technology. For over twentyseven years, we havespecialized in serving the me-tallurgic industry. FC Technik develops and produces the flox[on] mass flow controller. Our company’s collective pas-sion is the control of flowing gases.

All Gas Contol Units of the flox[control] series are taylor made for the requirements and ther the harsh conditions of the steel industry.

In all phases of modern steel production, gases are used for shielding, stirring or homogeni-zing. As an alternative to the use of singe mass flow controllers FC Techniks offers complete solu-

tions to handle gasflows easily, with high efficiency an economy. flox[control]units are successfully tested in actual practice. They are easy to install and maintanance free.

Heart of the flox[control] units are the mass flow controllers of the flox[on] series, developed by engineeres of FC Technik and well tested for years in the steel industry.

In the tradition of legendary Swiss perfectionism we guarantee the precision and robustness, as well as the long and dependable opera-ting lifetime of our machines.FC Technik has a wide range of know-how in steel production as well as secondary metallurgy. Our flox[on] series of mass flow controllers has a long history of successful application in these fields.

FC Technik offers quick andresponsive world-wide service to ensure that meeting the cus-tomers’ needs is always the first priority. Our qualified and compe-tent employees develop innovative solutions for innovative clients. And of course, we implementspecial client-specific wishes quickly and dependably.

Our product portfolio includes gas control units for direct or indirect injection of inert gases. In the steel industry, our mass flow controllers are used primarily in the areas of electric arc furnaces, converters, ladles and continoues casting.

flox[on] B

flox[on] S

flox[on] S500

flox[on] J

Robust despite extreme heat

Successfully tested in actual practice

High energy efficiency and economy

Simple operationin harsh environments

Long operating life

Constant flow regardless of

back-pressure

Changes gas medium without

switching surges

Robust despitefouling

Maintenance-free

Prompt reproduceability of processes


Furnaces

Continous casting To further process

EAFBOF

RHVOD/VO

Ladle

Gas ConTrol UniTs For THE sTEEl indUsTry

Steel

Prevents nitrogen aspiration from surrounding air

Prevents excesive clogging at the stopper tip

Gas Control System forLadle Purging

Compact Booster-Gas-Regulation-Unit

for Ladle Purging

RH Lift Gas TuyeresTest Unit

Combi Gas Regulation Unit for the Steel Industry

Purge Plug Test Unit TST

SAAC System for Ladle Shroud Shielding

Shroud argon-shielding Stopper

Secondary refining

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CompaCT BoosTEr Gas rEGlaTion UniT For ladlE pUrGinG

The FC Technik flox[control] booster is unique in the world and can be used for different applications in the ladle purging process. Our Gasregulation concept is desi-gned for high pressure applications for the purging ladle bottom system with a max. pressure of 34 bar.

The system consists in general of 3 main components: the Gas-Regulation Unit the Compressor Section and the Pressure Vessel (capacity 500 l (with available max. 34 bar pressure)

The system is independent from the application in the ladle refining process. It can be used as well as for soft-bubbling/alloying or temperature adjustment etc..Used gases are Argon or Nitrogen.

This new system enables the possibility of a continuous gas-flow. Our ther-mal Mass-Flow-Controller are nowadays state of the art and setting up the desired flows with the corresponding indicator. The quick transformation from Set- to Real-Values increase the treatment speed. The new generation of our MFC‘s is very stable in the gas flow at fluctuating back pressure. The reproducibility is an essential advantage for the treatment cycle in the refi-ning treatment.

Our electric, active working Booster-Unit characterizes particularly with re-gard to the comparatively high capacity and the end-pressure. This yields a very high availability of the purging elements and has a positiv effect to the refractory material.

The control of our Booster-Unit and the required additional equipment, star-ter, 3-phase connection, valves and pressure sensor are the component parts of the common controller.

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flox[control] booster

Compact Booster-Gas-Regulation-Unit for Ladle Purging 1 Gas Regulation Unit 2 Compressor Section 3 Pressure Vessel (capacity 500 l with available max. 34 bar pressure) 4 flox[on] S

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• available max. pressure of the gas during the start phase of the refining process• blocked purging plugs opening at full pressure• Snorkel quality indicators over time• improvement of the purging process (independent of back pressure variation)• different purging-profile options, easy input of the memory on the program- and parameter-screen• bonding of the measured datas for the documentation in existing systems

Advantages

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Gas ConTrol UniT For ladlE pUrGinG

The FC Technik flox[control] LP is in-dividualy and taylor-made designed for differnt purging plug systems. The pic-ture above show three different designs of flox[control] LP depending on customers requirements.

The specification and functions of the gas control stations are designed to fit for all ladle treatment applications:

• Purging at BOF tapping • Purging at EAF tapping • Ladle Furnace Purging • VD and VOD Purging • Purging at the RH Degaser

Functions and application can be combined in a single system to optimize in-vestment costs and space requirement. Auxiliary systems like high pressure booster and emergency gas supply systems can easily get connected to the systems and are also part of our supply.

The gas control station and the ladle purging plug define the Ladle Purging System. The gas control station provides all the required features and functions to design the purging process. For the process design, reproducibi-lity, functionality and dynamics are important aspects, the design of the gas control system has to unify all required aspects. Our product range of gas control systems is exactly what our customer want, because we design them according to their require-ments. The specification of the flox[on] mass flow controllers cover the full range of Ladle Pur-ging applications. flox[on] mass flow control-lers are specially designed to perform in the challenging environment of the steel indus-try.

flox[control] LP

Application

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rH liFT Gas TUyErEs TEsT UniT

Selective control and regulation of the lift gas in each individual tuyere of the snorkel guarantees an optimized process and a po-sitive effect on the durability of the refrac-tory material.

One of our newest developments is our test unit for lift gas, to proof the tightness and flow-rate of the tuyeres and piping of the snorkel assembly before it goes into operati-on. Gas consumption, flow and pressure can be measured and documented to guarantee 100 % availability and increased functionality of each snorkel.

The standard system is designed as a standalone and plug&play solution, the concept of snorkel testing before using could be implemented in any of our RH Lift Gas control systems.

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flox[control] RTU

flox[on] S

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• Numeric results (comparable indicators)• Standardized testing procedure, independent from operator• Snorkel quality indicators over time• Increase of process reliability• Increase of refractory performance• Low operation costs • Low investment costs

Advantages

Concept and Specification

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RH Lift Gas Tuyeres Test Unit 1 gas-inlet 2 gas-outlet 3 flox[on] S 4 pneumatic ball valve 5 filter pressure controller 6 pressure controller

Data Power supply 100...250 VAC Gas Supply 4....10 bar / ca. 1000Nl/min max. Working gases Nitrogen (Comp. Air), Argon Connections 1/2” FBSP, or any other


saaC sysTEm For ladlE sHroUd sHiEldind

The SAAC system provides shielding gas to the ladle shroud gasket.

The shielding effect is used to protect the steel from air contact. Oxygen from ambi-ent air may cause unwanted oxidic inclusi-ons. Ambient air may cause also nitrogen enrichment, which may have a negative in-fluence on some steel properties.To protect the steel stream inside the lad-le shroud the FC Technik AG SAAC system provides different functions. The adequate function can be selected by operator inter-action or by predefined system algorithm.

flox[control] SAAC

Functions

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Pressure Control Mode:

In the Pressure Control Mode the SAAC system will regulate the positive pressure at the gasket according to process parameter.The Pressure Control Mode will be activated as long as the flow is within its limits. This is the standard operation mode when conditions are normal at the gasket.

Flow Control Mode:

In the Flow Control Mode the SAAC System maintains a constant flow rate according to the parameters. This mode of operation should be activated when the conditions at the gasket are unstable and undefined as well as when the flow rate required to maintain the predefined pressure exeeds certain limitations.

Anti Splash Mode:

The Anti Splash Mode can be activated manual, if the bath agitation is too high.In the Anti Splash-Mode the SAAC system regulates the flow to a predefined safe state flow rate. If the back pressure returns within its between the limits, the Regulation Mode will automatic change back to Pressure Control Mode.3 lamps show the status indication:

The actual pressure is between a predefined upper and lower limit > the ladle shroud gasket is in good working condition! No interaction is required.

The actual pressure is below the predefined lower limit > there could be a leakage in the piping or the ladle shroud connection (gasket)!

The actual pressure is above the predefined upper limit > the ladle shroud connection is blocked! No shielding effect provided.

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Orange:

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ComBi Gas rEGUlaTion UniT

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The Combi Gas Control Unitflox[control] Combi comprised all relevant purging- shielding- and control-functions.Following processes can be determined:

• Controlled Ladle Purging (CLP) • Regulation of the gas amount during casting at the ingots• Shielding at the collector nozzle of the ladle• Testing of the purging plug (TST) at the ladle preparation area

flox[control] Combi

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flox[on] S

flox[on] B

Combi Gas Control Unit flox[control] Combi I flox[on] B II flox[on] S 1 Outlet CLP for Ar 2 Outlet Shielding 3 Outlet TST 4 Inlet Ar and compressed air

Ladle Purging (see flox[control] LP)

All the required datas and parameters for the purching process are stored in the Gas Control Unit. This programm regulates the wohle process. The process parameters can be considered by the customer and adjusted individually.The functional diversity and a reliable reproducibility of the process are the highlights of flox[control] Combi.

Casting

During the casting the empty ladle can be filled with argon. The gas amounts fit then to the bath level of the ladle. The required inputs could be transmitted to the Combi Gas control Unit by a down tilt sensor.

Shielding

The shielding unit prevents the contact of the liquid steel with air coming from the atmosphere. It protects against unwanted oxide inclusions. The risk of nit-rogen increase will be avoided to prevent a quality reduction of the steel grade.

Test Unit (TST) (see flox[control] TST)

The test unit TST is designed to test the purging plugs in the ladle preparationarea. This is to avoid purging failures in the following heat and to prevent thepurging plug from unnecessary excessive cleaning (burning, torching) with oxy-gen.Argon, Nitrogen or compressed air are used as test media. It‘s not allowed to use natural gas or any other inflammable gas.

Functions

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pUrGE plUG TEsT UniT TsT

The flox[control] TST test unit is designed to test the purging plugs in the ladle prepa-ration area.

This is to avoid purging failures in the follo-wing heat and to prevent the purging plug from unnecessary excessive cleaning (bur-ning, torching) with oxygen.

Nitrogen or compressed air is used as test media. It‘s not allowed to use natural gas or any other inflammable gas.

Plug Test:The plug test function generates an indication about the porous plug condi-tion. At a predefined pressure setting the actual flow rate is measured. The actual flow rate defines the condition of the plug. Three levels are defined:

To improve the cleaning procedure the TST Bypass function gives a continuous feedback on the porous plug condition during the cle-aning process. This may increase the porous plug life and reduce the costs of cleaning. To improve the overall effect even more a second test after the cleaning can give a comparable result about the porous plug condition.

flox[control] TST

Test Functions

Advantages

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The actual flow rate is between a predefined upper and lower limit > the porous plug is in good working condi-tion.

The actual flow rate is above the higher limit > there could be a leakage in the piping.

The actual flow rate is below the lower limit > the plug is blocked or partly blocked, oxygen washing could be required (depending on the plug type)

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Orange:

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Oxygen washing support (Bypass):During the washing procedure with an oxygen lance, a continuous pressure through the plug is produced. The flow rate is monitored continuously, as soon as the flow rate exceeds a predefined limitation an indication is genera-ted to stop further oxygen washing.

reproducibility and reliability, through numeric test result

reduction of porous plug consumption, through optimized oxygen washing

safety due to less burning/washing procedures time savings

The TST is independent from the volumetric capacity, corresponding metal level and the amount of plugs installed in the ladle bottom. It is essential for the purging process to know, if the porous plug is in wor-king condition or if oxygen cleaning is required. For this purpose the plug test function of the TST delivers a fast, reliable and numerical result. For the operators the system delivers a signal not requiring further interpreta-tion, only the three indications. For the records a number (the flow rate) is available, the number gives the opportunity for additional classification of the result.

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CUsTomErs - worldwidE

flox[control] Gas Control Units from FC Technik are already in use in almost all parts of the world. The following is an excerpt from our list of references. Obviously, this list will continue to expand in the future. The unique quality of our products will see to that.

Customer Country Place ProductThyssenKrupp Steel Europe AG Germany Bruckhausen Stopper Gas Control UnitSaarstahl AG Germany Völklingen Various Gas UnitsSalzgitter Flachstahl GmbH Germany Salzgitter Tundish Shielding UnitSalzgitter Flachstahl GmbH Germany Salzgitter Test Unit for Ladle Purging Plug (TST)Salzgitter Flachstahl GmbH Germany Salzgitter MFC’s for Converter MHPPeine Träger GmbH Germany Peine Ladle Purging (CLP)ArcelorMittal Germany Ruhrort Stopper Gas Control UnitArcelorMittal Germany Bremen Various Gas UnitsArcelorMittal Germany Eisenhüttenstadt Test Unit for Ladle Purging Plug (TST)ArcelorMittal Germany Eisenhüttenstadt Shroud Anti Aspiration Control (SAAC)ArcelorMittal Germany Hamburg Test Unit for Ladle Purging Plug (TST)ArcelorMittal Bosnia Zenica Converter Bottom PurgingArcelorMittal South Africa Newcastle Lift-Gas Control Unit RHArcelorMittal USA Indiana Habour Converter Bottom PurgingArcelorMittal Mexico Lazaro Cardenas Shroud Anti Aspiration Control (SAAC)Benteler Stahl/Rohr GmbH Germany Lingen Ladle Purging (CLP)BGH Edelstahlwerke GmbH Germany Freital Various Gas UnitsBGH Edelstahlwerke GmbH Germany Siegen Various Gas UnitsDEW Siegen Germany Siegen Sliding Gate Shielding/TSTElbe Edelstahlwerke Feralpi GmbH Germany Stade Test Unit for Ladle Purging Plug (TST)Brandenburger Elektrostahlwerke GmbH Germany Brandenburg EAF Bottom PurgingHennigsdorfer Elektrostahlwerke GmbH Germany Hennigsdorf Ladle Purging (CLP Booster)Kind & Co Germany Biehl/Weilstein Ladle Purging (CLP); TST; SAACBuderus Edelstahl GmbH Germany Buderus Ladle Purging (CLP)Hertwig GmbH Germany Hückeswagen RH-Test Unit Liftgas for Up-Snorkel Friederich Wilhelms-Hütte Germany Mülheim a. d. Ruhr Converter Bottom PurgingSMS Mevac GmbH Germany Essen Various Gas UnitsTreibacher Industrie AG Austria Althofen EAF Bottom PurgingTata Steel UK Scounthorpe Ladle Purging (CLP)Tata Steel UK Port Talbot Ladle Purging (CLP Booster)A.B.S. Acciairie Bertoli Safau s.p.a. Italy Udine Ladle Purging (CLP)Acciairie Venete Italy Sarezo Ladle Purging (CLP)Verona Steel Italy Verona Ladle Purging (CLP)Nunki Steel s.p.a. Italy San Giorgio Di Nogaro Ladle Purging (CLP)Yolbulan Bastug Turkey Osmaniye Ladle Purging (CLP)Isdemir Turkey Iskenderun Tundish Gas Control UnitIzmir Demir Celik Sanayi A.S. Turkey Izmir Ladle Purging (CLP)Kardemir A.S. Turkey Karabük Ladle Purging (CLP)Erdemir Turkey Iregli Tundish Gas Control UnitMetamin A. S. Turkey Istanbul Test Unit for Purg Plug Production (TST)Gerdasu Sidenor Spain Basauri Various Gas SystemsCMC Sisak Croatia Sisak Various Gas SystemsMechel Romania Otelu Rosu EAF Bottom PurgingMobarakeh Steel Company Iran Esfahan Tundish Gas Control UnitNovokurznezk Ukraine Donetsk EAF Bottom PurgingTaganrog Metallurgical Works Russia Tanrog Ladle Purging (CLP)TMK Seversky Tube Works Russia Sverdlovsk Ladle Purging (CLP)Saudi Basic Industries (Hadeed) Saudi Arabia Jubail EAF Bottom PurgingOvako Hofors AB Finland Hofors Tundish Gas Control UnitOutokumpu General Stainless Finland Tornio SAAC, Stopper Gas Control UnitNucor Corporation USA Memphis EAF TLS-SystemNucor Yamato Steel Company USA Blytheville EAF Bottom PurgingGerdau Ameristeel USA Wilton EAF Bottom PurgingCMC Steel Texas USA Seguin Ladle Purging (CLP)Essar Steel Algoma Canada Sault Ste Marie Ladle Purging (CLP)Gerdau Sidertul Mexico D.F. Mexico Ladle Purging (CLP)Ahmsa Mexico Monclova Converter Bottom PurgingAceros San Luis Potosi Mexico S.L. Potosi Tundish Gas Control UnitTernium Mexico Monterrey Various Gas SystemsBöhler Uddeholm Villares Metals Netherlands Dodrecht Ladle Purging (CLP)Posco China Zhangjiagang EAF Bottom PurgingSEAH Besteel Corporation South-Korea Goonsan Tundish Gas Control Unit

2 0 | FC Technik | f l ox [co n t r o l ] | G as C ontr o l Un i t s for the s tee l indus tr y

FC Technik AGSt. Gallerstrasse 340CH-8409 Winterthur

Tel. +41 (0) 52 238 01 75Fax +41 (0) 52 238 01 77

[email protected]

FC Technik AG Oct 2016

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