SIMETAL CIS Gimbal Top. An Automated Blast Furnace Charging System for Infinite Flexibility in Burden Profiles. Metals Technologies

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1 SIMETAL CIS Gimbal Top An Automated Blast Furnace Charging System for Infinite Flexibility in Burden Profiles Metals Technologies

2 Maximising Charging Flexibility at Minimal Investment Cost The challenge Regarding modern blast furnace charging technology, for the last thirty years customers have been presented with a limited number of solutions as a means of distributing burden materials to the furnace stock line to enhance furnace operation and minimise maintenance costs. Siemens VAI believes that the market is now ready for a new exciting technology that is highly competitive, has infinite flexibility and is simple, robust, easy to maintain and offers much greater operational flexibility than other market alternatives. Our solution The Gimbal Top charging system provides customers with the opportunity to generate any burden profile, irrespective of the type of material, by directing the charge to any point on the furnace stock line. The means of providing this distribution is with an innovative design of concentric gimbal rings, through a system that is directly driven by hydraulic cylinders. This arrangement allows the chute angle and position to be adjusted during the material discharge period. The innovative flexibility of chute movement and the simplicity of the drive unit will provide maximum charging flexibility at minimal investment cost generating significant improvement in blast furnace operation. This innovative new design has been designed as a mechatronic package in order to unite the merits of the equipment with our wealth of knowledge in blast furnace process control specifically through the VAiron optimisation models. 2

3 Reasons for choosing SIMETAL CIS Gimbal Top Operational: K Optimised furnace operation in terms of fuel rates K Increased fuel injection rates K Reduction in coke usage K Cheaper maintenance by avoiding long shutdowns K Long component life Engineering: K Simple, robust lever mechanism with drive cylinders mounted outside the pressure envelope K Even chute wear, prolonging the life of the ceramic lining K Avoids the use of expensive high-precision gears K Unique conical chute suitable for ceramic or hard faced linings K A closed-circuit water cooling system K Sealed-for-life bearings eliminates need for periodic lubrication 3

4 Robust and simply elegant: The Gimbal Top design (L to R) Rugged mechanism, simple tilting motion, cylinders outside pressure envelope Views of blast furnace distributor Connecting rod of Gimbal ring drive Siemens VAI Metals Technologies Ltd has within its iron-making group, possession of the necessary experience, expertise and knowledge to provide customers with state of the art solutions for all areas of blast furnace technology. Mechanical Design K Mounted directly to blast furnace top cone K Gas-tight housing K Distributor housing material carbon steel K Fixed and tilting chute lined with ceramic wear tiles K Gimbal bearings spherical roller (sealed-for-life) K Closed-circuit water cooling K Actuation two hydraulic cylinders Simple key principles K Simple tilting motion producing 360 distribution K Rugged level mechanism, driven by hydraulic cylinders K Drive cylinders mounted outside pressure envelope Hydraulic Design K Hydraulic power supply unit and piping K High-response directional hydraulic valves for cylinder control K Two double-acting cylinders, fitted with high-precision linear position transducers K Instrumentation to monitor actual location of the tilting chute K Control software for motion based on the defined parameters 4

5 Upper Lock Valve. 2 Material Flow Gate. 3 Expansion Bellows. 4 Gimbal Top TM Distributor. 5 Upper Receiving Chute. 6 Holding Hopper. 7 Lower Lock Valve. 8 Goggle Valve. 9 Distributor Tilting Chute. Gimbal Top Control Based on a unique blend of manufacturing and engineering excellence, Siemens VAI software and process engineering specialists can produce successful solutions for all aspects of furnace operation. Control of the tilting distribution chute is by means of a proprietary control and feedback system, fully integrated into the overall furnace charging software. The system provides a high level of accuracy and control for the gimbal movements and hence the positioning of the distribution chute designed to: K Receive charges of burden materials, independently of the distribution system. K Release those discharges, as required, to a dynamic distribution chute located below the holding hopper. K Distribute material in prescribed patterns to the furnace stock line in accordance with a pre-determined charging matrix. The SIMETAL CIS Gimbal Top Blast Furnace Charging System Control and Automation Modes Automatic Gimbal Control K MAC8 logic controller translates basic Level 1 commands into chute movement via software and hydraulics K Pre-programmed operating modes Local Gimbal Control K Motions independent of Level 1 control system K Allows manual positioning of the tilting chute during maintenance functions. 5

6 Maximum reliability Tested by reality FAQs 1. Can the distributor be used on a range of blast furnaces? Yes, the Gimbal Top is designed to provide a full range of charging alternatives for small, mid and large volume furnaces. Solutions available include: Parallel feed two or more hoppers for large and medium blast furnaces Central feed receiving hopper for skip and belt charge 2. Can the Gimbal Top be fitted to existing blast furnaces? Fundamentally yes, the distributor is designed to replace both bell and BLT market alternatives. 3. If the Gimbal Top fails, does furnace production stop? In the event of a control failure the gimbal is designed to return to a fail-safe position with the tilting chute vertical in the centre of the furnace. This allows the furnace to continue under limited production in centre-charge mode. Our intent here is that in the event of such a failure, operators have time to plan an unscheduled downtime, rather than having to pull wind immediately. 4. What is cooled by the closed circuit water cooling system? The cooling system incorporates two separate circuits. The first circuit for the gimbal pivot bearings, and lower half of the universal joints on the outer gimbal ring. The second circuit cools the main shafts, and then via the internal passages of the connecting rods to cool the upper bearing assembly of the universal joints on the gimbal outer ring. The use of fixed pipe work in the design minimizes the risk for potential leakage. Assuming that the suggested maintenance regime has been followed and pipes are correctly fitted the risk of leakage is minimal. 5. What are the operating parameters of the tilting chute? The chute moves from a vertical position 0 to 38, with an infinitely variable speed from 0 8 rpm. 6. What is the discharge performance from hopper into furnace? The discharge performance of the charging system is comparable with other hopper based distribution systems, typically designed for throughputs in the range of m 3 /sec. Gas tight housing of distributor 6

7 Proven experience In April 2003, Mittal Saldanha Steel contracted the Siemens VAI organisation to provide a means of distributing coal over the top surface of the Corex Melter Gasifier vessel, providing long term benefits of improving the efficiency and operation of the Corex system. Now successfully proven in the arduous high-temperature and high-pressure environment of Corex, Siemens VAI add this elegant and rugged design to it s portfolio of world class blast furnace technology. This core equipment development within our portfolio of blast furnace equipment was unveiled to the world at the IS 06 conference in October From the significant interest generated, an order has now been received for the blast furnace unit at Tata Steel in Jamshedpur, India. Blast furnace burden control History of Gimbal Top Technologies 2003 Concept Introduction 2004 Mittal Saldanha Coal 2007 Posco Finex 1.5M Coal Baosteel C3000 Coal Baosteel C3000 Oxide Tata Steel C Blast Furnace 2005 Posco Finex F2000 Coal 2006 World launch of Blast Furnace Gimbal Top at IS 06 Mittal Saldanha Oxide 7

8 For further information contact: Siemens VAI Metals Techologies Ltd. Ashmore House, 7 Fudan Way, Thornaby, Stockton-on-Tees, TS17 6ER, UK Tel: +44(0) Fax: +44(0) blastfurnace.metals@siemens.com Headquarters: Siemens VAI Metals Technologies GmbH & Co. P.O. Box 4, Turmstr. 44 A 4031 Linz, Austria Tel: (+43/70) Fax: (+43/70) contact.metals@siemens.com The information provided in this brochure contains merely general descriptions or characteristics of performance which in actual case of use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. Order No.: E10001-M3-A31-V Printed in the UK Dispo No.: K-No.: HOT PA Subject to change without prior notice Siemens AG All rights reserved. SIMETAL is a trademark of Siemens AG. CIS = Completely Integrated Solutions