HEADLINE LOREM IPSUM COMPANY EFFICIENCY MEFKON PRODUCT RANGE Ladle preheater/drier Tundish preheater/drier Scrap drier Snorkel preheater Redundant control of burner Modern burner technology Reduction of gas usage: up to 75% Reduction of CO 2 : up to 75% Reduction of NO x : up to 90% MEFKON designs and manufactures systems for the drying and heating of all types of vessels with refractory materials during the production of hot metal and steel. Our products are based on the Emission Optimised Heating Technology (EOHT) we have developed. This technology enables our customers to dry and heat with unparalleled efficiency in terms of emissions and energy consumption. As MEFKON is not associated to a refractory materials producer or producer of components we are therefore able to integrate highest-quality products from burner, control and refractory technologies into our systems. MEFKON EOH Technology was developed by a team of industry experts with extensive, long-standing experience in the refractories industry. Each team member has on-site experience in steelworks. Combined, we have commissioned, maintained and repaired more than 1000 heating and drying systems. This experience and the holistic technical understanding of all relevant processes and influencing factors form the basis for our engineering services. Two-stage recuperator COB lance Burner / multifuel burner / oxygen burner / flameless burner Combined air/oxygen burner Redundant control of heating curve Energy-saving motors Frequency controller Energy savings potential: 45 % 65 % Engineered vessel covering Ultra light concrete reduces heat storage capacity Self-adapting heat shield Reduced number of wear parts lead to cost reductions Tundish drying station, TWIN blower system 2 3
PRODUCTS AND ENGINEERING PRINCIPLES MEFKON PRODUCT RANGE ENGINEERING PRINCIPLES Ladle preheater as horizontal or vertical type as well as special constructions Vertical ladle drier for drying processes of monolithic-lined ladles as well as tempering process of brick-lined ladles such as dolomite-lined ladles, with secondary air and /or oxygen injection, a rim suction system and post combustion Zero-emissions drying station (in addition to the post combustion inside the ladle, an external combustion chamber is used) Ladle housings (part of the Zero-emissions drying station) Tundish preheater multi-burner system Tundish drier for drying processes of monolithic-lined tundish, or drying of other materials Mobile burner systems SEN and ladle shroud oven and preheating systems Special burner constructions and multifuel burner Air burner with continuous oxygen enrichment Oxygen burner systems with or without water cooling Flameless oxygen burner systems Two-stage radiation recuperator COB lance Flares for waste gas burners Torpedo ladle heaters Launder heater and drier Valve racks for burner media Optimised operation (at the touch of a button) PLC controlled via touch panel and TCP/IP communication Web access to all recorded heater data for the best possible maintenance support Easy maintenance (clear and logical design of heating system) Reduced number and increased lifetime of wear parts Safe and easy access to all heater components Monitoring of control pressures in order to determine maintenance requirements in advance Data exchange with MEFKON server for external troubleshooting Highest safety standards according EN746-2:2010 Only DIN DVGW certified components are used Safety analyses according to machinery directive 2006 / 95 / EC performed by external experts Flame monitoring of the main burner for continuous flame monitoring (heating processes > 24h) Tightness check of gas valves after every burner off Continuous temperature control High-temperature monitoring via double thermocouple Continuous power regulation Gas /air or Gas /oxygen ratio monitoring Only SIL certified components used Highest efficiency through A self-adapting heat shield suspension such as a cardanic suspension Gapless covering of the vessel due to a special hydraulic control and a lid mounting similar to a cardanic suspension Ultra low-weight concrete lining of the heat shield for a reduction of the thermal power input Stoichiometric gas/air ratio control over the whole power regulating range with continuous temperature control Two-stage exhaust gas radiation recuperator Energy recuperation caused by a special flame shape Combined air/oxygen burner Very high burner power regulating range (approx. 1 : 11 between max. and min. load) Additional savings due to frequency-controlled blowers (savings in electricity of up to 65 %) Recommendation for the use of oxygen burner systems (savings in gas of approx. 70 %) 4 5
3) Pig Iron Ladle 1) Torpedo ladle 2) Chute PRODUCTS 1 Torpedo ladle preheating / drying station with 2-stage radiation recuperator Hydraulic lid swivelling approx. 30 Burner power 2 x 1.200 kw Heating times between 8,0 h up to 100 h Max. temperature 1.200 C 3 Vertical ladle preheating / drying station, secondary air, TWIN blower system 2 Mobile preheating/drying station, secondary air, TWIN blower system, handling by overhead crane Burner power 2.500 kw Secondary Air approx. 1.500 Nm 3 /h Additional oxygen injection for tempering Heating times between 8,0 h up to 100 h Max. temperature 1.200 C Burner power 3 x 350 kw Secondary Air approx. 1.500 Nm 3 /h Heating times between 8,0 h up to 100 h Max. temperature 1.000 C 6 7
5) O 2 Control Line 4) Converter 6) Ladle 7) Porous Plug PRODUCTS 4 Vertical converter preheating / drying 6 Horizontal ladle preheater with station with combined air / oxygen 2-stage radiation recuperator burner Burner power 600 kw in Air mode Burner power 1.500 kw in Oxygen mode Additional oxygen enrichment for tempering Heating times between 24,0 h up to 100 h Max. temperature 1.300 C Pneumatic lid movement Approx. 1.000 mm stroke Burner power 2.000 kw Fast heating of ladles being in circulation Max. temperature 1.200 C 5 Oxygen control line 7 Ar / N2 ladle stirring for converter lance control line for porous plug Max. 10.000 Nm 3 /h Water cooling lines inlet and outlet for converter lance 100 m 3 /h High precision mass flow control system 8 9
8) Waste Gas Line to Flare Stack Burner 9) O 2 Lance 10) RH Vessel 11) Lift Gas Control Line PRODUCTS 8 Flare stack burner DN400 10 Vertical RH-vessel Ignition burner power 2 x 100 kw preheating / drying station Burner power 1.200 kw Heating times between 24 h up to 100 h Max. temperature 1.200 C 9 Combined Oxygen burning / blowing lance Burner power 2.400 kw Oxygen blowing rate 2.000 Nm 3 /h @ 10 bar Max. temperature 1.400 C 11 Ar / N2 RH lift gas control line High precision mass flow control system flow and pressure indication per line 10 11
13) Ladle Shroud 14) Tundish 12) Ladle 15) SEN PRODUCTS 12 Vertical ladle preheating station 14 Tundish preheating / drying with 2-stage radiation recuperator station, secondary air Burner power 2.500 kw Fast heating for ladles right before tapping Max. temperature 1.200 C Burner power 4 x 350 kw Secondary air approx. 1.000 Nm 3 /h Heating times between 90min up to 240 min Max. temperature 1.200 C 13 Ladle shroud heater / drier 15 SEN heater Automatic ignition and flame monitoring Burner power 70 kw Heating times between 45 min up to 120 min Max. temperature 800 C Automatic ignition and flame monitoring Burner power 100 kw Heating times between 45 min up to 120 min Max. temperature 1.200 C 12 13
MANUFACTURING PRINCIPLES, SERVICES AND SOLUTIONS MANUFACTURING PRINCIPLES MEFKON heating systems are designed and manufactured using state-of-the-art technology. Every MEFKON heater is based on the fundamental demands of highest efficiency, lowest emissions and highest reliability. Every single heating system is completely assembled, wired and checked according to inhouse quality standards and final functionality tests. After recording the quality and functionality tests, the heating system is dismantled into a few main components and prepared for shipment. Due to these extensive test procedures and the complete assembly, MEFKON has minimised the time needed to construct our products and put them into operation. SERVICE RANGE Spare parts provision for existing preheating / drying systems Heat shield repair and training for heat shield repair Maintenance /repair services for ladle and tundish preheater / drier Commissioning service for ladle and tundish preheater / drier Commissioning service for COB lances Efficiency analysis of existing preheating / drying systems Our main task is to find an optimal solution, especially when it comes to key issues such as a uniform temperature distribution, shortened heating times and less stress / strain tolerance of the refractory material and the efficiency increase of the whole system. The precise, smooth adjustment of the temperature control range to the existing infrastructure parameters is the first step in systems optimisation. Significant success factors include the reduction of mass and the sealing of the burner lid. We have developed a new and very robust burner lid, which contains up to 1 2 tonnes less refractory material than conventional lids. This is possible without making any compromises with respect to its sealing ability. In addition it also achieves improved insulation efficiency. The heated mass is reduced by 5 6 %, which leads to a significant reduction in energy consumption. One further characteristic of MEFKON technology is its construction aimed at low wear and tear and thus reduced maintenance. All our products have a modular design which uses moving parts as little as possible. Moreover, our products are constructed based on preventive maintenance principles, allowing for remote monitoring and early warning systems. Burner technology is also key to achieving optimal system configuration. We place very specific requirements on burner manufacturers in order to integrate them into our systems. Tundish preheating station 14 15
MEFKON GmbH & Co. KG Industriepark 70 74 56593 Krunkel GERMANY Phone: +49 2687 92627 0 Fax: +49 2687 92627 20 info@mefkon.com www.mefkon.com