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Added-value original products for steelmaking plants thanks to Danieli design and manufacturing expertise.
DANIELI WATER COOLED ELEMENTS FOR STEELMAKING FURNACES AND EQUIPMENT
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Danieli FastArc® Long-Life Energy-Saving Panels and water-cooled elements for EAFs and secondary metallurgy equipment to compete with the market pricing and high quality standards established by our own manufacturing centers, and guaranteed with the fastest delivery times.
DANIELI SERVICE
In order to reach the high quality standards now expected from steel manufacturers, Danieli is committed to achieving those standards, designing and manufacturing water-cooled panels and equipment at our own facilities.Since the major causes of unscheduled downtimes in steel plant production are also water-cooled components failures, the plant's availability index is increased significantly when Danieli’s high-efficiency and high-reliability water-cooled components are installed. This performance is reached by continuous quality monitoring of our standard manufacturing procedures and materials (boiler type / low-carbon steel tubes, copper tubes), assembling and welding procedures, and pre-delivery tests. All this, together with the 100% on-time delivery company policy.
More than
21,000 water-cooled panels and elements for steelmaking plant furnaces, sold worldwide since 1985
Danieli Long-Life, Energy Saving panels:
– 25% of energy consumption
20,000 heats of service reached
Danieli specialists add valueto on-site services
Water-cooled equipment and service life
> Steel and copper panels> EAF shell sidewall panels> EAF/LF roof panels> VD/VOD water-cooled shield> Fume treatment plant water-cooled duct (primary water-cooling system).
Danieli water-cooled panels' lifetime average:> Standard EAF shell panels: 5,000 heats> Roof panels: 6,000 heats> Long-life energy saving panels: more than 20,000 heats
Danieli water-cooled panels advantages
> EAF panel houses optimized to reach full shell steel capacity.> Energy losses reduction.> Higher service life.> Quick panels replacement time with fastwater connections coupling.> Reduced operation downtimes.> Reduced maintenance requirements.> Increase operational safety.> Maximum 60 days delivery time or no-spares storage requirement for customers' with Long Term Service Agreement LTSA contract.
CE
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Registrations
Directive 97/23/CE - H Cert. No 009
No IT-3903ISO 9001 Cert. No 0218ISO 3834-2
ISO 14001 Cert. No 0237A/0 ASME Stamp Holder Certi�catesNo. 36612 and 36613
Danieli water-cooled panel quality
> All manufacturing process is carried out in accordance with the Danieli Quality Control Plan QCP. > The raw materials, such as tubes and return caps are supplied by Danieli-selected manufacturers worldwide in compliance with Danieli's specifications. > Welding process in accordance with Danieli Welding Procedure Specifications WPS qualified as per Standards ASME QW 200.1-sez. IX and EN ISO 15609-1:2004.> Welding steps: TIG-141/GTAW mode, with inert gas shield, to achieve a deep and uniform weld zone and MAG-135/GMAW mode, with active gas shield for a perfect weld finishing.> Intermediate pressure test between the two welding steps to leakages detect.> Visual and magnetic final weld tests.> Final trials with 12h-pressure tests and flow capacity test.> For complete furnace wall and roof water-cooled panel sets, a final test stage is carried out with all items on furnace/roof cooling cage assembled and connected.> 100% panels tested.
Danieli water-cooled panel services
> Water-cooled panels as spares to existing furnaces.> Specific design of new panels for all type of furnaces.> Engineering of new furnace water cooling system to enhance melting process efficiency through reduced maintenance stops and increased operational safety.> Technical support to enhance lifetime expectation.> Technical support to improve plant performances.
All phases of the design process are fully integrated. Design and manufacturing activities are fully computerized through integrated 3D CAD /CAE/ CAM tools.In-house manufacturing allows a constant and precise quality control throughout the whole process, from engineering to shipment of the equipment.
DANIELI WATER-COOLED PANELS
Danieli FastArc® Long-Life Energy-Saving panel (Danieli Patent)
The energy saving panels are made by two overlapped panels, with the inner layer (process environmental side) made with spaced tubes and outer layer made of standard panel. Between the two layers, slag accumulation provides thermal insulation, minimizing energy loss, resulting in some 25% of energy loss reduction and more than 20,000 heats per life time.
Main advantages:
> Increase of arc power.> Reduction in energy losses.> Increase in productivity.> Increase in service life. (up to four times compared to standard panels).> Higher operational reliability.> Reduced operating down-time in case of water leakage (10-15 min. required just to switch the water circuit, panel substitution not required).> Higher resistance to wear and scrap impact.> Improved slag-holding capacity.> Stable self-regeneration of slag protection, directly captured from the process. No gunning or refractory casting required. > Increased water velocity for improved cooling efficiency.
Design criteria
1
3
5
4
2
A A
Section A-A
A A
Section A-A
A A
Section A-A
A A
Section A-A
Heat flux(absorbed by H2O)
Energysaving
Standard
Average (kW/m2) 310 335
Maximal (kW/m2) 452 563
Protecting slag surface temperature
Energysaving
Standard
Average (°C) 822 234
Maximal (°C) 1111 640
Heat load on shell panels
DANIELI SERVICE
Hea
t loa
d (k
W/m
2 )
00
250500
7501000
1250
Distance from steel bath (mm)
15001750
20002250
2500
100
200
300
400
500
600
700
800
900
Head load diagram shows the major thermal insulation, thanks to slag protection, reachable by Danieli Long-Life Energy-Saving water cooled panels as compared to the standard one.
Conventional water-cooled panel
Danieli Long-Life Energy-Saving panel
Danieli experts provide customers with a deep plant equipment analysis to reach the full functionality of cooling system. Main criteria for a quality panel's design are linked to the operative working condition, including:
> Flow capacity and water quality.> EAF operation practices (i.e.: foamy slag formation).> Scrap characteristics. > Use of oxygen/carbon/limeinjectors.> Fume acidity and sulphur concentration (in particular for pig iron and hot metal EAF charging).
Careful panel engineering leads Danieli to develop tailored furnace cooling solutions that allow a reduction of heat losses, as well as the overall EAF energy consumption figures, and increasing panel service life.
1-2 Standard design and Long-Life Energy-Saving design (Danieli Patent) of EAF cooling panels.
3 Head load diagram shows the major thermal insulation, thanks to slag protection, reachable by Danieli Long-Life Energy-Saving water cooled panels as compared to the standard one.
4 Water-cooled panels performances comparison.
5 Thermal profile study of the Danieli Long-Life Energy-Saving panels (Danieli Patent) during engineering phase and in operation filled by slag.
Upgrades to FastArc® technology and technical support to improve plant performances
Further steelmaking plant performance improvements are achievable by performing, in addition to replacing the water-cooled panels, well focused and balanced upgrades to steelmaking equipment through technology packages, such as:
> FastArc® EAF cooled Modules for increased chemical energy input. > HiREG enhanced electrode regulation
system. > Advanced slag detection and slag foamy
control systems. > LF inert-roof with water-cooling system. > VD/VOD stirring and oxygen lances,
dust filtering systems.
Danieli Service engineers provide consulting for equipment repair, modification and upgrades to achieve plant-ready solutions, minimizing installation costs and plant shutdown expenses. Steel melting and refining processes are monitored and analyzed to develop appropriate strategies ranging from new operating procedures and minor equipment overhauling, up to major plant upgrades.
1 Danieli 2.6-Mtpy meltshop, designed to feed thin slabs to the HSM. It is equipped with two 160-t AC EAFs, two twin-ladle furnaces, one twin-tank / twincover VD-OB vacuum degasser, as well as two fume treatment plants.
2 Inside view of the Danieli 420-t DC EAF shell with in evidence the Long-Life Energy-Savings panels and the water-cooled U-shaped panel of the slag door.
3 Danieli chemical energy injection system during EAF startup testing stage.
4 Danieli EAF roof in operation featuring water-cooled panels optimized design to minimize energy losses, reduce fume velocity and fines' draught, and smaller weight compared with a conventional roof.
2 3 4
1
Danieli do Brasil, Brazil
Danieli Service Center, Argentina
Danieli CorporationCranberry Township, USA
Danieli Service Center, Mexico
DanielHeadquartersItaly
MorgårdshammarSmedjebackenSweden
Danieli Engineering PolskaPoland
Danieli Procome,Spain
Danieli Service Center, UK
Danieli Service Center, Egypt
Danieli Service Center, Saudi Arabia
Danieli Service Center, UAE
MorgårdshammarKrefeld, Germany
Danieli Engineeringand Service, Austria
Danieli Service Center,Vyksa, Russia
Danieli Service CenterMagnitogorsk, Russia
Danieli ChangshuMetallurgical Equipmentand Services, Changshu, China
Danieli EngineeringYokohama, Japan
Danieli Service Center Penang, Malaysia
Danieli Far East, Rayong Industrial Area, Thailand
Danieli India Ltd, Kolkata, India
Companies
Branch offices
Danieli do Brasil, Brazil
Danieli Service Center, Argentina
Danieli CorporationCranberry Township, USA
Danieli Service Center, Mexico
DanielHeadquartersItaly
MorgårdshammarSmedjebackenSweden
Danieli Engineering PolskaPoland
Danieli Procome,Spain
Danieli Service Center, UK
Danieli Service Center, Egypt
Danieli Service Center, Saudi Arabia
Danieli Service Center, UAE
MorgårdshammarKrefeld, Germany
Danieli Engineeringand Service, Austria
Danieli Service Center,Vyksa, Russia
Danieli Service CenterMagnitogorsk, Russia
Danieli ChangshuMetallurgical Equipmentand Services, Changshu, China
Danieli EngineeringYokohama, Japan
Danieli Service Center Penang, Malaysia
Danieli Far East, Rayong Industrial Area, Thailand
Danieli India Ltd, Kolkata, India
Companies
Branch offices
5 Danieli Service Centers worldwide: these regional companies, along with the global network, provide the same high-quality Danieli services near to the customer, so as to grant rapid response for all operational, maintenance and consultation requests.
THE RELIABLE INNOVATIVE PARTNER IN THE STEEL INDUSTRY
TECHNICAL SERVICE AND SPARE PARTSSINCE 1961
EUROPE
AUSTRIA Danieli Engineering and Services, VölkermarktTel (43) [email protected]
GERMANY Morgårdshammar, KrefeldTel (49) [email protected]
POLAND Danieli Engineering Polska, Wroclaw Tel (48) [email protected]
RUSSIADanieli Service Center, VyksaTel (7) [email protected]
Danieli Service Center, MagnitogorskTel (7) [email protected]
SPAINDanieli Procome, SpainTel (34) [email protected]
SWEDENMorgårdshammar, Smedjebacken Tel (46) [email protected]
UNITED KINGDOMDanieli Service Center, SheffieldTel (44) [email protected]
UKRAINEDanieli Service Center, DnepropetrovskTel (38) [email protected]
DANIELI SERVICE CENTERS
AMERICAS
ARGENTINADanieli Service CenterTel (54) [email protected]
BRAZILDanieli do Brasil, São PaoloTel (55) [email protected]
MEXICO Danieli Service Center, Garza GarciaTel (52) [email protected]
USA Danieli Corporation, Cranberry Township (PA)Tel (1) [email protected]
AFRICA AND MIDDLE EAST
EGYPTDanieli Service Center, CairoTel (20) [email protected]
SAUDI ARABIADanieli Service Center, Al-Khobar CityTel (966) [email protected]
UAEDanieli Service Center, Abu DhabiTel (971) [email protected]
FAR EAST
CHINADanieli Changshu Metallurgical Equipment and Service, ChangshuTel (86) [email protected]
INDIADanieli India, KolkataTel (91) 33.39847777 [email protected]
JAPANDanieli Engineering, YokohamaTel (81) [email protected]
MALAYSIADanieli Service Center, PenangTel (60) [email protected]
THAILANDDanieli Far East, Rayong Industrial AreaTel (66) [email protected]
HEADQUARTERS
Via Nazionale, 4133042 Buttrio (UD) ItalyTel (39) 0432.1958729Fax (39) [email protected]
