/Steel Sector
Steel Sector 2017-05-26T07:16:28+00:00

Steel sector

Preheating Mould Furnace

Nº energy sources

1

Type of fuel

NG + Syngas from biomass – VULKANO

Type of process

Batch process

Operating Temperature

From 100ºC to 400ºC

Number and type of burners

3 (option 5) x 450 kW

Energy Consumption

135 Nm3/hour (Natural Gas)

Refractory materials

Ceramic fibbers on walls, doors and roof

Estimation of process efficiency

70%

Heat recovery equipments

None

Description

The load is placed in the oven where it is heated for 2 hours arising to 70 ºC. Then the mould is taken from the oven and placed in a pit for the molding of the final cores. Mould is brushed and formed. The whole process takes from 2 to 4 more hours, depending on the size of the mould. When this procedure is completed the mould is returned to the furnace. The temperature of the mould in this moment drops to approx.20ºC.

Following the mould is heated up to 120ºC during at least 3 hours. The mould is taken again out of the furnace to coat the final core from 3 to 5 times depending on the quality of the cylinder. Coating takes from thirty minutes to one hour, during this time the temperature falls about 10ºC.

After this, the mould is loaded again into the furnace turned by 180º around the horizontal axis and in this position is heated to 220ºC during 3 more hours. After this preheating process the mould remains for one hour with the furnace switched off and closed in order to achieve the equalization of the temperature throughout the mould.

Retrofitting measures implemented

Improved Refractory Materials

Improved Refractory Materials

Development and implementation of new alternative materials for high-temperature, high-alkali environments capable to operate at higher temperatures or/and for longer periods of time.
Read more

PCM-Based Energy Recovery

PCM-Based Energy Recovery

PCM has a double purpose acting as a physical filter which is able to recover energy at the same time that smooths fluctuations in the temperature profile working similar to a low-pass filter.
Read more

Co-firing Second Energy Source

Co-firing Second Energy Source

Second energy source from renewable/alternative feedstocks with the aim to substitute the high percentage of natural gas in industrial furnaces.
Read more

Integrated Control System

Integrated Control System

The new and improved control system will directly contribute to achieve a more efficient furnace and consequently important fossil fuel savings.
Read more

Holistic In-House Predictive Tool

Holistic In-House Predictive Tool

Decision support tool to optimize the furnace design and its energy and environmental performance, considering the interaction furnace-retrofitting solutions and upstream/downstream processes.
Read more