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Nearly maintenance free wireless instruments

Better leak detection equipment and methods

Keeping people away from hazardous operations

Reduced energy consumption and more efficient processing

Challenges

Steelmakers are aiming to enhance safety, drive down production costs and increase plant reliability.

  • Some plants are aiming to squeeze the last bit of incremental tonnage from their plants to match consumer demands and maximize efficiency.
  • Water leaks on electric arc or basic oxygen furnaces put workers at risk, cause equipment damage and lead to reduced operating hours.

Steelmakers are driving down energy costs and run their processes more efficiently.

Solutions

SPLC for electric arc furnaces

Hatch’s SPLC is the only arc stabilization technology that controls the arc on each of the three furnace electrodes at the speed that the arc changes, to provide consistently stable furnace operation throughout all stages of power-on time. Benefits include higher furnace productivity, reduced tap to tap time , reduced electrode consumption, reduced refractory consumption, and increased campaign life.

Hinged ladle lids

Steelmakers are squeezing the last bit of efficiency out of the process – hinged ladles lids are an easy way to help. The hinged ladle lid is a passive device that attaches or remove lids from steelmaking ladles during ladle movement on transfer cars. The hinged lid allows dumping of slag with no extra crane moves required. Productivity improvements, energy savings, reduction in crane utilization and enhanced ladle life are the main benefits of the hinged ladle lid.

Energy Harvesting Instruments

Electric arc furnaces with an AC transformer generate electric fields that can charge wireless instrument batteries. Hatch has implemented wireless, self-charging instruments for industrial metals furnaces. The main advantage is reduced maintenance with no wiring required and ease of installation due to wireless connections to plant control systems.

Water Leak Detection

Early detection of possible water leaks is critical to ensure stable furnace operation and safety of plant personnel. Hatch has developed two separate technologies: a pressure leak detection system (PLDS) and a soft sensor system. The PLDS uses supply/return valves and pressure meters installed on individual circuits to identify leaks. The system is automated to rapidly test circuits (~1 minute tests) and store historical data. Hatch’s soft sensor uses installed flowmeters in tandem with statistical methods to calculated deviations in differential flow. Both leak detection methods result in much faster and more predictable leak detection.

Dry Slag Granulation

Steelmaking slags are typically dumped to ground and used as low-value road aggregate. Hatch’s dry slag granulation process uses air to directly granulate slag. The dry slag granulation advantages include improved safety, reduced noise and pollution and ability to access higher value-added slag markets.

Custom Robotics Solutions

Steelmakers are adopting newer, safer working methodologies to improve process consistency and keep people away from hazardous molten slag and steel. Hatch’s robotics group custom-designs solutions for the metals industries toughest applications.

PyroLIBS (real-time chemical analysis)

Laser-induced breakdown spectroscopy (LIBS) provides direct real-time measurements of molten material composition (any elements of interest) without having to sample and test the material. The real-time data would provide feedback control to improve the process. While LIBS for solid materials is readily available (multiple companies), LIBS for molten material is a new frontier. Hatch is working with the National Research Council (NRC) of Canada to commercialize this technology for high-temperature, molten metal applications.

Blogs

Janice Bolen

Steel and sustainability: new ideas, better solutions

Janice Bolen
The whole world is working to reduce carbon emissions and fight climate change. The steel industry is stepping up too, finding new ways to curb energy consumption and become more environmentally sustainable.
All Blogs
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