Siemens receives final acceptance certificate from SDI Roanoke for holistic process model with Lomas offgas monitoring which is reducing conversion costs in its electric steel plant

In April, the U.S. steelmaker, Steel Dynamics Inc. (SDI) of Roanoke, Virginia, USA, issued the final acceptance certificate for the Simetal EAF Heatopt system installed by Siemens. The newly developed holistic process model combines modern measurement technologies like the Lomas off-gas analyzer with an intelligent control strategy. The system is used to monitor the offgases from an electric arc furnace, and makes an important contribution toward optimizing the process. It has reduced conversion costs by more than 1.5 USD per ton. This was the first time that a Lomas system had been installed in an electric arc furnace. Siemens is already the market leader for installing this technology in LD steelmaking converters.

Paul Schuler, Melt Shop Manager at SDI Roanoke, said: "The Simetal EAF Heatopt system (Holistic Energy And Transparency Optimizing-System) with the Lomas measurement tool has completely fulfilled our expectations, and in some areas exceeded them. The real-time monitoring and control of the melting process in our 100-ton electric arc furnace has significantly reduced the specific conversion costs. We have also been able to raise productivity and increase operational safety."

 
The Lomas system and an integrated offgas flow speed meter continuously monitor and analyze the flow of offgas from a furnace. The measured values are fed into the holistic process model and evaluated. This gives the operator's personnel continual, up-to-date information about the progress of the process in the furnace. The system also generates recommendations for adapting and optimizing the process control. Output deficits arising in the process can be corrected by closedloop control of the injection of natural gas, oxygen and carbon injection by means of burners and lances. In this way, the consumption of energy and electrodes can be reduced, and the use of oxygen, coal and combustion gas optimized for the process. This increases the efficiency and productivity of the electric arc furnace as well as the output of liquid steel. The Lomas system also increases operational safety by quickly detecting hazardous gas compositions forming during the melting and decarburization processes.  

The Roanoke Bar Division of Steel Dynamics runs a minimill meltshop in Roanoke, Virginia, in which scrap steel is melted in electric arc furnaces, and the molten steel is continuously cast into billets. Steel Dynamics, Inc. is the fifth-largest producer of carbon steel products in the United States. It produced 5.3 million tons of steel in 2011. Siemens received the order to install the Lomas system in the spring of 2011.

Further information about solutions for steel works, rolling mills and processing lines is available at: http://www.siemens.com/metals

A photo supplements this press release. Please see: http://www.siemens.com/mt-picture/IMT201207193

(The gas analysis system and holistic process model installed by Siemens in the electric arc furnace of Steel Dynamics Inc. (SDI) in Roanoke, Virginia, USA, are making a significant contribution toward reducing costs and increasing operational safety)

The Siemens Industry Sector (Erlangen, Germany) is the world’s leading supplier of innovative and environmentally friendly products and solutions for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the Sector enhances its customers’ productivity, efficiency, and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Divisions Industry Automation, Drive Technologies and Customer Services as well as the Business Unit Metals Technologies. For more information, visit www.siemens.com/industry

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Based on Siemens (Industry Sector, Metals Technologies) information