The "No-Man-on-the-Floor"-Technology is a set of technologies that allows the EAF to be operated on a 24/7 basis from the control room, without leaving it.
The "No-Man-on-the-Floor"-Technology consists of some special Technologies like the Tenova Auto Tapping System (TAT), EAF Monitoring Camera System, Tenova Sampling Robot, PLT Physical Ladle Tracking and Automatic Scrap Yard Management and eliminates the risk of having operators on the floor.
Tenova Auto Tapping system permits to carry on the EAF tapping and turnaround operations without leaving the control room
Remote EAF tapping
The EAF operator starts the tapping operation with a pushbutton and the TAT™ takes control of the tapping operation: EAF tilts automatically based on ladle weight The operator supervises the operation thanks to the optical camera monitoring the ladle freeboard and the infrared camera, which checks the slag carryover.
Slag Carryover Detection
The TAT™ system detects if slag is pouring out of the EBT during tapping and integrates the slag signal to calculate the amount of slag that is tapped in the ladle: Easy visualization of the ladle weight: the TAT™ can automatically tilt back the furnace, but it can always be overruled by the EAF operator The TAT™ allows the operator to foresee and improve the secondary treatments required, based on the amount of slag carryover.
EBT Hole Auto-Sanding
The TAT™EBT hole auto-sanding allows the EAF operator to perform the sand filling without leaving the control room The pivoting arm can be installed on the sump area or on the fixed platform.
EBT Hole Inspection
The TAT™ system utilizes a video camera, installed on the pivoting arm of the auto-sanding equipment to provide the EAF operator with a clean view of the EBT hole Easy visualization of the EBT and the refractory around it to inspect possible hole obstruction by slag or residual scrap No need of any worker to walk on the sump panel to perform this inspection.
EBT Hole Cleaning
The TAT™ EBT cleaner, is a steel cylinder with a rounded head that is inserted from underneath the EBT and has a smaller diameter than the EBT hole The length of the EBT cleaner is longer than the one of the hole The cleaner reaches the top of the hole and moves any slag or scrap that is obstructing the hole so that the sand can be added The EBT cleaning operation is supervised by the EAF operator with the EBT inspection camera.
EAF Monitoring Camera System allows to inspect the interior of the EAF in power off using both fix and movable cameras
Panels inspection by remote position. The operator can see the inside of the EAF from the control cabin. Movable cameras are installed on articulated arm (as door manipulator, etc.) Fixed cameras are installed on the outside-top part of the panel, covered during EAF power on The water cooled cover on the panel's window protects the monitoring cameras For the fixed cameras the cover opens with a pneumatic cylinder Typically three cameras allow to cover all interior of EAF panels Refractory wear, hot heel level, panels condition, possible water leaks can be seen using the EAF Monitoring Camera System
- A combination of fixed and movable camera allows the full EAF interior view
- Infrared cameras can be installed to permit a better view of water leaks
- Vertical orientation of the camera allow the EAF roof inspection from below.
Tenova Sampling Robot is the new generation of sampling equipment for the EAF
- It can be used for all sampling purposes (temperature, O2 ppm, steel sample)
- Robot gets into the EAF door regardless of tilting angle
- Heavy-duty foundry-type commercial robot
- No need of need of manual intervention to change cartridge sample
- Electrically driven and heat protected to work in the EAF environment.
The Tenova Sampling Robot allows the plant to perform sampling operation without the need for the EAF operator to get out of the EAF control room
- The cartridge magazine can hold up to 72 cartridges of up to three different types
- Automatic removal of used cartridge and automatic leading on new cartridge
- Before every sampling operation, the robot checks the cartridge tip position
- Automatic knife to cut and collect the steel sample
- The steel sample is sent to the lab via belt and chutes without the need of touching the sample.
Fully compliant with OSHA regulations.
PLT Physical Ladle Tracking detect the early deterioration of refractory in a ladle
Maximize the life of the liquid steel ladles The system utilizes Radio Frequency Identification (RFID) technology
- A RFID tag is attached to the ladle, and protected by a special shield or armor
- RFID readers and antennas are strategically located throughout the Meltshop
- The RFID tags are detected by the antennas, and a unique ID number associated to a particular ladle, is sent by the readers to a central server.
Automatic Scrap Yard Management optimizes the scrap bucket preparation procedure The Automatic Scrap Yard Management provides the following features:
- Buckets recipe according to the production plan
- Crane operators automatically receive recipe for bucket preparation on crane Panel PC
- Scrap yard operators are constantly up to date with the actual furnace situation
- Additional information for crane operator such as scrap yard map, material position and stock quantity
- Bucket car movement and management.
- Cleaning and sanding are controlled from within the safety of the EAF control room
- The remote EAF tapping feature eliminates the risk of having an operator at the tapping pulpit
- The EBT cleaning and auto-sanding systems eliminate the risk of having an operator on top of the furnace
- Provides the operators with real-time information conditions on the inside of the furnace
- Aids in detecting water leaks
- Provides a better estimate on the amount of hot heel
- Able to take temperature
- Steel sample and slag sample eliminates the need of having operators on the floor
- The EAF Monitoring Camera System provides the operators with real-time information conditions on the inside of the furnace and provides a better estimate on the amount of hot heel
- The PLT Physical Ladle Tracking reduce heat losses and waiting time of a full ladle and Determine the best refractory for a certain steel grade
- The Automatic Scrap Yard Management reduce the variability on scrap layering procedures. It keeps track of material quantity on each bucket and scrap yard remaining material stock.
- Detect the early deterioration of refractory in a ladle
- Maximize the life of the liquid steel ladles
- Reduce heat losses and waiting time of a full ladle
- Improve maintenance and ladle turnaround
- Determine the best refractory for a certain steel grade
- Reduced the variability on scrap layering procedures
- Keeps track of material quantity on each bucket and scrap yard remaining material stock
AC and DC EAFA modern EAF is a concentrate of technology combining knowledge from different fields, Tenova offers the market some of the most advanced solutions for EAFs leveraging on a holistic approach to the steelmaking process.
Flexible Modular Furnace® (FMF®)The Flexible Modular Furnace® was born from Tenova experience on EAF and Hot Metal steelmaking practices in China. The combination of the two experiences guided Tenova toward a unique flexible steelmaking technology.