Steel Production - Flex Process LTD

Steel Production:

Air Blower Modelling to optimise production and improve safety.

The Problem

New demands on existing plant can be complex to understand. Blast furnaces work by blowing air into the bottom of a bed of molten iron, coke and coal. If the air flow stops, the bed collapses causing catastrophic damage. In this case, three new demands on the air blowers were requested in a short timescale:

1.
Increased back pressure to improve iron production.
2.
Temporary feeding of one blast furnace from a different blower during maintenance.
3.
Emergency feeding of two blast furnaces by a single blower to prevent bed collapse if one blower trips.

The Solution

The development of high fidelity dynamic models to within a few percent accuracy.
Compared to existing plant using static and dynamic trials to improve confidence.
Virtual simulation of all new scenarios with accurate results that can be presented to management.
Detailed reporting of the results and gained know how to retain in house.

The Benefits

Near capacity limits of equipment can be tested virtually and safely without risk of surge.
Equipment better understood revealing losses through relief valves due to actuator failure, eventually resulting in 5% increase in air flow.
High quality information can be obtained, making decision making easier.
Once in a lifetime scenarios can be tested, refined, and sometimes abandoned early, before committing further funds.

Services Provided

Plant Survey.
Compressor Surge Control.
Pressure Relief.
Reverse Engineer Control logic.
Dynamic Model.
Reveal Operating Deficiencies.
Detailed Reporting.

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