Innovations
FalconTM
Manless, on-demand oxygen measurements for process optimization for modern EAF
Falcon is an automated measuring system capable of delivering accurate temperature, oxygen and carbon readings of liquid steel during the operation of electric furnaces. It is the fastest oxygen and temperature combined measurement on the market, developed to withstand the harsh environment around the electric arc furnace.
With a thermocouple and oxygen sensor, an oxygen level is quickly detected and sent to the PLC to be displayed on the user interface. An oxygen level helps the operator to accurately define if the endpoint of oxygen blowing is met.
Benefits
- Increase safety : Operated from the control room, the fully automated oxygen measurement system fits the current safety standard of no man on the floor.
- Increase Yield: Early and multiple possible oxygen measurements allows to a controlled and tuned carbon and oxygen injection minimizing iron overoxidation and decreasing iron losses.
- Energy Efficiency: The Falcon solution conducts “Closed Slag-door” measurements, ensuring optimal operation with a maximum foamy slag state, thereby enhancing the system's energy efficiency.
- A lower electrical consumption
- More efficient utilization and consumption of graphite electrodes
- Lower refractory consumption due to improved thermal transfer from the electrodes to the steel bath
- Improved quality
- Gives insight in dephosphorization conditions
- Substitution of complex, unreliable and expensive robots
System Information
The Falcon system consists of different components:
- The manipulator, which is a pneumatic based system that supplies Falcon probes using a drum mechanism. It ensures precise and efficient placement of the probes in the liquid steel.
- The Pneumatic unit powers the manipulator, providing the necessary pneumatic force to operate the system smoothly and reliably.
- The PLC control unit allows the system to be operated from the control room. It manages the data collected by the probes and ensures accurate and timely measurements.
- Designed to hold and supply 20 Falcon probes
- The drum's capacity allows for extended operation periods, reducing the need for constant reloading.
- Quick reloading capability: A new drum with probes can be reloaded in just one minute, ensuring minimal downtime and continuous operation.
Technical Data
|
|
Description |
|---|---|
| Application | Temperature, oxygen and carbon measurement in EAF |
| Measurement input | Two analog inputs |
| Measurement range | |
| Temperature | 1500…1850°C (2732 to 3362°F), type C |
| Oxygen | 150…2000ppm |
| Measurement accuracy | |
| Temperature | ± 10 °C |
| Oxygen | ± 5 mV |
| Calculated values | carbon, aluminum in kg to kill steel, slag %FeO, amount of O2 to reach aO target, steel bath homogeneity (in combination with Chameleon) |
| Different hardware components: | |
| Falcon launcher | |
| Dimensions | 701x1400x422 mm (HxWxD), 140 kg |
| Operating ambient temperature range | -20°C (-4°F) to 60°C (140°F) |
| Air flow: continuously for cooling | 200 l/min |
| Air flow: during the probe launch | 3200 l/min (2900…5000 l/min) |
| Falcon Pneumatic Unit | |
| Dimensions | 1400x800x300 mm (HxWxD), 110 kg |
| Compressed air | 3 to 6 bar |
| Power supply | 24 V DC (from control unit) |
| Falcon Control Unit | |
| Dimensions | 1200x800x400 mm (HxWxD), 120 kg |
| Power supply | 3x400VAC+PE / 50-60Hz / 16 A / max. 4 KW |
| Dust/moisture protection class | IP 54 |
| Level2 communication protocols | Profibus, Profinet, Ethernet IP, Modbus TCP |
