HEADLINE LOREM IPSUM - METEC

HEADLINE LOREM IPSUM

32

MEFKON PRODUCT RANGE

· Ladle preheater/drier

· Tundish preheater/drier

· Scrap drier

· Snorkel preheater

· Two-stage recuperator

· COB lance

· Burner / multifuel burner /

oxygen burner / flameless burner

· Combined air/oxygen burner

COMPANY

Redundant control of burner

· Energy-saving motors· Frequency controller· Energy savings potential: 45 % – 65 %

Engineered vessel covering· Ultra light concrete reduces heat storage capacity

· Self-adapting heat shield

Redundant control of heating curve

Reduced number of wear parts lead to cost reductions

Modern burner technology· Reduction of gas usage: up to 75%· Reduction of CO

2: up to 75%· Reduction of NOx: up to 90%

EFFICIENCY

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 Tech-

nology (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.

Tundish drying station, TWIN blower system

54

PRODUCTS AND ENGINEERING PRINCIPLES

MEFKON PRODUCT RANGE

· 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

ENGINEERING PRINCIPLES

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 mainte-

nance requirements in advance

· Data exchange with MEFKON server for external trouble-

shooting

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 %)

76

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

1

2 Mobile preheating/drying station, secondary air, TWIN blower system, handling by overhead craneBurner power 3 x 350 kWSecondary Air approx. 1.500 Nm3/h


Max. temperature 1.000 °C

PRODUCTS

3 Vertical ladle preheating / drying station, secondary air, TWIN blower system

Hydraulic lid swivelling 90°

Burner power 2.500 kW

Secondary Air approx. 1.500 Nm3/h

Additional oxygen injection for tempering



1) Torpedo ladle

3) Pig Iron Ladle

2) Chute

98

Vertical converter preheating / drying

station with combined air / oxygen

burner


Burner power 600 kW in Air mode

Burner power 1.500 kW in Oxygen mode

Additional oxygen enrichment for tempering



4

Oxygen control line

for converter lance

Max. 10.000 Nm3/h

Water cooling lines inlet and outlet for converter lance

100 m3/h

5

PRODUCTS

Horizontal ladle preheater with

2-stage radiation recuperator

Pneumatic lid movement

Approx. 1.000 mm stroke


Fast heating of ladles being in circulation


Ar / N2 ladle stirring

control line for porous plug

High precision mass flow control system

6

7

5) O2 Control Line

7) Porous Plug

6) Ladle

4) Converter

1110

PRODUCTS

Flare stack burner DN400

Ignition burner power 2 x 100 kW

8

Combined Oxygen

burning / blowing lance


Oxygen blowing rate 2.000 Nm3/h @ 10 bar


9

Ar / N2 RH lift gas control line

High precision mass flow control system

flow and pressure indication per line

11

Vertical RH-vessel

preheating / drying station



Heating times between 24 h up to 100 h


10

9) O2 Lance

10) RH Vessel

11) Lift Gas Control Line

8) Waste Gas Line to Flare Stack Burner

1312

PRODUCTS

Vertical ladle preheating station

with 2-stage radiation recuperator



Fast heating for ladles right before tapping


12

Ladle shroud heater / drier

Automatic ignition and flame monitoring

Burner power 70 kW

Heating times between 45 min up to 120 min

Max. temperature 800°C

13

Tundish preheating / drying

station, secondary air


Burner power 4 x 350 kW

Secondary air approx. 1.000 Nm3/h

Heating times between 90min up to 240 min


14

SEN heater

Automatic ignition and flame monitoring

Burner power 100 kW

Heating times between 45 min up to 120 min


15

14) Tundish

15) SEN

12) Ladle

13) Ladle Shroud

1514

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.

Tundish preheating station

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.

MEFKON GmbH & Co. KG

Industriepark 70 –74 | 56593 Krunkel | GERMANY

Phone: +49 2687 92627 0 | Fax: +49 2687 92627 20

[email protected] | www.mefkon.com

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HEADLINE LOREM IPSUM - METEC