ESSAR STEEL (HAZIRA) LTD

As a regular supplier to a superior Indian steel producer, Northern Combustion Systems Ltd supplied a number of plant as part of a major contract for a 3.9 million Tonne expansion.

• 4 off      200T Vertical Dryer / Preheater
• 2 off      200T Horizontal Preheater
• 4 off      Launder Preheater
• 2 off      Launder Dryer

The 4 off Vertical ladle heaters designed on the cantilever principle, comprised of a pivoted, refractory lined cover with a centrally positioned, down firing duel fuel gas burner. The burner equipped with separate valve control systems to enable the burner to operate on corex gas with rapid change over to natural gas operation. The burner and ladle cover raised and lowered through 90°C using an integral hydraulic lifting system. The duty of the vertical ladle stations ranged from 450°C to 1200°C to preheat ladles in accordance with customer heating cycles.

The 2 off horizontal ladle heaters comprised of a vertical heat shield lined cover with a centrally positioned, down firing duel fuel gas burner. The burner equipped with separate valve control systems to enable the burner to operate on corex gas with rapid change over to natural gas operation. The vertical heat shield lined cover mounted on a two-axle carriage. The carriage mounted on rails and capable of 500mm forward and reverse motion using a hydraulic cylinder and close coupled power pack. The duty of the preheating station to preheat ladles in the range 450°C to 1200°C to preheat ladles in accordance with customer heating cycles.

The 6 off launder stations designed on the cantilever principle, comprised of a pivoted, refractory lined cover equipped with 4 off down firing duel fuel gas burner. 2 off large burners fired into the main body and 2 off smaller burners firing into the runoff spout. The burners equipped with separate valve control systems to enable the burner to operate on corex gas with rapid change over to natural gas operation. The burner and cover raised and lowered using a hydraulic cylinder and close coupled power pack with transmission chain and sprockets in rails guided with diablo rollers. The duty of the Launder stations ranged from up to 800°C preheat lauders in accordance with customer pre-programmed heating profiles.

The ladle and launder stations were fully assembled and tested in our UK facility before disassembled into major sub-assemblies for container loading. The equipment to be shipped was delivered with 14 off 40’-0” Open Top Containers destined to the customer site in Hazira, Gujerat, India. The full turnkey supply included 2 years spares, supervised assembly and engineer to fully commission the onsite equipment to completion.

Ladle Preheater William Cook

We were asked to design a ladle preheater for the heating of ladles before filling with molten steel.

On a site visit we noticed there was an unused jib crane, we incorporated this as part of the design to suspend the preheater lid allowing it so be to raise , spun and lowered on to three ladles positioned on stands within the jib arm radius.

The result proved to be very efficient and safe for our client’s employees use.

Launder Pre-Heater

A number of Launder pre-heaters have been manufactured for ALD Vacuum Technologies GmbH including installations at third party sites in France and Russia.

The launder accepts molten metal from a vacuum furnace, and the launders must be virtually dust free, as well as uniformly heated.

The lauders are custom designed and built by Northern Combustion Systems and employed a series of premix burners and controls fixed to the lid/launder cover.

The lid, itself, raised and lowered via a hydraulic system.

Vessel Preheater – Oxygen / Gas vessel preheating unit

This preheating station shown here installed at a large steel producer in India is used to preheat vessels used in a steel de-gassing process. The twin burner system has been designed to run on Corex gas for the low temperature part of the heating cycle and then to automatically switch to the second burner which uses a mix of pure oxygen and gas capable of taking the vessel to a temperature of 1550ºC. The main vessel cover is water cooled and a smaller cover is provided for the vessel spout. This PLC controlled system utilises full electronic flame safeguards to shut the burners down should there be a loss of gas, oxygen or combustion air pressure, operating limits or over temperature alarm.

The cover is raised and lowered by means of a hydraulic cylinder, with the cover pivoting on substantial Plummer block bearing housings. The mounting frame was designed to fit the customers’ existing steel mezzanine floor structure.