Reheating Furnaces

Presenter:

Eduardo Richter

Maio 2012

Ttulo da Apresentao 1
 Macroprocess Industrial Rolling Mill
MACROPROCESS

Reheating

Rolling process

Pass Design
COMUUNITIES

Reheating Rolling Mill Pass Design

193 Members 412 Members 158 Members

S&OP Communities 2
Hot Themes REHEATING COMMUNITY

KPIs

Best Practices

Energy Reduction

Refractory Projects

Survey Plan

Instrumentation

New Technologies

Furnace Control System

Reheating Strategies

S&OP Communities 3
Oxifuel Burners

Presenter:
Eduardo Richter

Ttulo da Apresentao 4
 Opening / Introduction

KM: 12 members from 3 different countries (Brazil, Spain, United

States) contributing to the discussion.

The aim of this study is to present the oxifuel technology as an

alternative to Reheating Furnaces

Technology applied in Melting Furnaces and adapted to Reheating

Furnaces
Discussion among specialists and members in the Reheating
Community of Practice
Technical Reports

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 Concept

The concept of this technology is the elimination of the inert part of

atmospheric air, i.e., the parcel that don't react and don't generate
energy for the system. In other words, the O2+N2+Ar supplied for the
Combustion Fan (Air) would be changed for pure O2.
The advantage of this process is the elimination of ~79% in volume of
inert parts.

The left image shows the convetional flame , the The left image shows a ceramic oxifuel burner self
right image shows the same burner in flameless cooled (2MW ULTRA LOW NOx). The right image
oxifuel mode (ULTRA LOW NOx). shows an oxifel burner water colled (0,5-5MW ULTRA
LOW NOx). Both have flame pilot and UV cells

Ttulo da Apresentao 6
Technical Analysis

Flame Temperature
Very high flame temperature and rigid control of the process
Scale formation
Billet residence time
Reheating Furnace Efficiency
Fuel economy and increase of the Furnace burn process

Ttulo da Apresentao 7
 Flame temperature comparison between Billet residence time comparison and scale lost
conventional air fuel burners (a) and oxifuel burners between conventional air fuel burners and
ULTRA LOW NOx (flameless) (b) oxifuel burners

Reheating Furnace Efficiency among types of

burners.

Ttulo da Apresentao 8
Environmental Analysis

Nitrous Complexes (NOx)

Compliance with existing international standards and regulations
Air-fuel burners generate higher levels of NOx than Flameless oxyfuel.
Generation of NO2 has a global warming potential 296 times better then
CO2.
Sulfur Dioxide (SOx)
There is a possibility of formation of hydrogen sulfide (H2S) and SOx
emissions. The hydrogen sulfide is lethal even at low concentrations.
Carbon Monoxide (CO)
with oxygen enrichment, the emission of CO in the atmosphere is
almost zero.
Carbon Dioxide (CO2)
Reduction of CO2 emissions by 45%.
Volume of exhaust gas 70-80% lower and with CO2 content of 95% (dry
basis). Potential for generating other fuels to the process.

Ttulo da Apresentao 9
 Comparison of combustions produsts Nitrous complexes emissions versus % of O2
beteween airfuel anda oxifuel tecnology present in exhausted gases

Ttulo da Apresentao 10
Conclusion
ADVANTAGES
Estimated fuel economy of 14%.
Increased thermal efficiency to 75-90% (CSG current air-fuel technology are
around 70%).
Less formation of scale, particularly special steels (up to -20% for special steels).
Increased heating capacity (higher productivity) by 50%.

DISADVANTAGES
High consumption of oxygen (higher cost).
Need to adapt the current installation of all Furnaces: Release of oxygen lines,
new valves and control, suitability of burners, etc.
Localized overheating of the load, causing surface melting (billet stick together,
mainly in Pusher Furnace).
Decarburization (for AC).
Reduction of Refractory and Heat Recuperator lifetime.

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Recommendation

The consensus is that there are technical details that need to be

further developed:
Localized overheating and billet stick together due surface welding
Lifetime of Furnace Refractory and Isolation
Automation and Control
Maintenance
Safety and Operation
Performance Assurance
Technical visits to other Furnaces having this technology
The technical reports in the Reheating Furnace Community have
several references using this technology.
Further discussion between the experts of the Reheating Furnace
Community.

Ttulo da Apresentao 12
Control and Shut-off valves replacement
Reheating Furnace
UVG Rolling Mill

Presenter:
Eduardo Richter

Ttulo da Apresentao 13
 Opening / Introduction

24/02/2012
Question:
We want to acquire a valve (item 04 of slide 05) to replace the existing 2 valves
(control and shut-off) and install manometer according standard in entry and
delivery side.
Someone knows this kind of valve? Do you recommend?
Regards,
Adrialdo Wisozcoski

Current Situation: Proposed Situation:

Pressure control
and Shut-off valve.

Model:
BRISE+SSV DA GASCAT,
Diameter 3

Control and Shut-off valves replacement - Reheating Furnace 14

KM answer
27/02/2012 3 days after posting the question
Answered by KM specialist Carlos Catunda
We have this kind of self-piloted valve, here in CSG. We recommend.

Attached is our supplier:-PIETRO FIORENTINI (below, the national representative).

There is also the NORTH AMERICA valves, that are very good (I do not have their
contact).

Cosme Henry
Dept. commercial Technical

(55) (21) 7819 - 3116/2201 8896/3435 6089 comercial@huberg.com.br

Cosme.Teixeira @ huberg.com.br

Skype: Cosme.Henrique

Any additional questions, please contact us.

Greetings

Carlos Catunda
COSIGUA

Control and Shut-off valves replacement - Reheating Furnace 15

Conclusion

The question was answered in 3 days.

The supplier contact was provided.
The valve was bought and now they are preparing for installation.

Proposals Price

Replace the current valves by 2 similar valves. R$ 8.255,00

Replace the current valves by 1 valve (Control

R$ 4.900,00
and Shut-off valve)

Economy R$ 3.355,00 (1700,00 $)

Control and Shut-off valves replacement - Reheating Furnace 16

Questions and Answers?

Eduardo Richter KM Moderator

Engineering Consultant

Contact:
Telephone: (51) 3323-8531
e-mail: eduardo.richter@gerdau.com.br

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